METHOD FOR MANUFACTURING A CUSHION AND CUSHION

Abstract

The invention relates to a method for producing a cushion for an orthopedic device, the cushion having a first component, which comprises a first film layer and a second film layer, and a second component that are joined with each other in such a way that there is at least one fluid-filled volume between the first component and the second component, the method comprising the following steps: inserting the first film layer, which has at least one opening, and the second film layer into a tool, which has an upper mold and a lower mold; applying a differential pressure to at least one of the film layers, so that the at least one film layer moves at least in sections towards the upper mold or the lower mold, thereby creating a distance between the two films; joining the two film layers along at least one connection line.

Claims

1. A method for producing a cushion for an orthopedic device, the cushion having a first component comprising a first film layer and a second film layer, wherein the first film layer comprises at least on opening, and at least a second component, wherein the first component and the at least a second component are joined such that there is at least one fluid-filled volume between the first component and the at least a second component, comprising: inserting the first film layer and the second film layer into a tool which has an upper mold and a lower mold; applying a differential pressure to at least one of the first film layer or the second film layer, so that the first film layer or the second film layer to which the differential pressure is applied moves at least in sections towards the upper mold or the lower mold thereby creating a distance between the first film layer and the second film layer; and joining the first film layer and the second film layer along at least one connection line.

2. The method according to claim 1, wherein when the differential pressure is applied, the first film layer and the second film layer are deformed and are then joined with each other along the at least one connection line such that they do not lie against each other over an entire surface in an area of the at least opening of the first film layer.

3. The method according to claim 1 wherein the at least one connection line is designed in a form of a ring that is interrupted at at least one point.

4. The method according to claim 3, wherein the at least one opening of the first film layer lies at least partially within the ring.

5. The method according to claim 1 wherein the cushion is produced with at least two connection lines forming at least one channel between the first film layer and the second film layer, wherein the at least on channel is configured to permit fluid from outside of the cushion to enter or leave the at least one fluid-filled volume.

6. The method according to claim 5, wherein the first film layer and the second film layer lie against each other over an entire surface along at least one section of the at least one channel.

7. The method according to claim 1 wherein the at least one fluid filled volume comprises at least two fluid-filled volumes between the first component and the second component, and wherein the at least one connection line comprises at least two connection lines wherein the at least two connection lines form a connection between the first film layer and the second film layer, wherein a fluid is moveable from one of the at least two fluid-filled volumes into another of the at least two fluid-filled volumes.

8. The method according to claim 7, wherein the at least two connection lines are designed in a form of a ring that is interrupted at at least one point.

9. The method according to claim 1 wherein the first film layer and the second film layer are joined by gluing or welding them together.

10. A cushion for an orthopedic device, comprising: a first component which comprises a first film layer and a second film layer; a second component; at least one fluid-filled volume wherein the first component and the second component are joined with each other such that the at least one fluid-filled volume is between the first component and the second component, wherein the first film layer and the second film layer are joined to each other such that fluid is directable out of the at least one fluid-filled volume between the first film layer and the second film layer by increasing a pressure on a volume of the at least one fluid-filled volume.

11. The cushion according to claim 10, wherein the at least one fluid-filled volume comprises at least two fluid-filled volumes, and wherein the first film layer and the second film layer are joined to each other such that fluid between the first film layer and the second film layer is directable directed out of a first of the at least two fluid-filled volumes into a second of the at least two fluid-filled volumes by applying pressure to the first of the two fluid-filled volumes.

12. The cushion according to claim 10 wherein the first film layer and the second film layer are joined to each other such that there is at least one feed channel between the first film layer and the second film layer through which fluid from outside of the cushion is enterable into the at least one fluid-filled volume or exitable out of the at least one fluid-filled volume.

13. The cushion according to claim 10 further comprising at least one valve and at least one feed channel for directing fluid, wherein the at least one feed channel is opened and/or closed by the at least one valve.

14. A cushion produced by a method according to claim 1.

15. The method of claim 3 wherein the ring is interrupted at at least three points.

16. The method of claim 8 wherein the at least one point comprises a plurality of points, wherein at least one of the plurality of points is located in each of the at least two fluid-filled volumes.

17. The method of claim 9 further comprising heating at least one of the first film layer and the second film layer along the at least one connection line.

Description

[0031] In the following, an embodiment example of the invention will be explained in more detail with the aid of the accompanying drawings. They show

[0032] FIGS. 1 to 9different stages in the production of a cushion according to various embodiments of the present invention, and

[0033] FIG. 10a schematic top view of part of two joined films with accompanying sectional representations.

[0034] FIG. 1 shows a first film layer 2 and a second film layer 4, which have been jointly inserted into a mold comprising an upper mold 6 and a lower mold 8. The upper mold 8 has two downward projections 10, between which there is a space 12. In this step in the method, the two film layers 2, 4 are arranged between the two components of the mold. No differential pressure is applied.

[0035] FIG. 2 depicts a next step in the method. In the embodiment example shown, the space 12 between the two projections 10 is subjected to a negative pressure from a device that is not depicted. As a result, a part 14 of the first film layer 2 moves towards the upper mold 8, so that in this area a distance 16 emerges between the first film layer 2 and the second film layer 4. It should be noted that, in the example embodiment shown, the projections 10 are not resting against the first film 2. However, the part 14 of the first film 2 can still be moved by the negative pressure applied in the space 12. To this end, a pressure above this part 14 must be smaller than in the distance 16, i.e. between the two film layers 2, 4. A differential pressure is thus applied to the first film layer 2.

[0036] FIG. 3 depicts another embodiment. In this example, the upper mold 8 is first moved towards the lower mold 6 until the projections 10 rest on the first film layer 2.

[0037] In this embodiment example, the first film layer 2 and the second film layer 4 are clamped between the projections 10 of the upper mold 8 and the lower mold 6. In this example in FIG. 3, there has been no change in the pressure inside the space 12.

[0038] This changes in FIG. 4. The projections 10 of the upper mold 6, together with the lower mold 8, still clamp the first film layer 2 and the second film layer 4, but the air pressure is now reduced in the space 12, so that the part 14 of the first film layer 2 moves as in FIG. 2.

[0039] The two film layers 2, 4 are subsequently joined with each other along connection lines 18. This is shown in FIG. 5. The dividing line between the first film layer 2 and the second film layer 4 is interrupted in the areas of the connection lines 18. The figure shows that the two film layers 2, 4 are joined with each other as a result. In the sectional view shown, the connection lines 18 are of course not recognizable as a line, as they extend beyond the drawing plane. Once the connection lines 18 have been created and the first film layer 2 joined with the second film layer 4, the upper mold 8 can be removed upwards. The part 14 of the first film layer 2 remains at a distance 16 from the second film layer 4, thereby creating a cavity. If the first film layer 2 and the second film layer 4 are joined in a section without it leading to a movement or deformation of at least of the film layers 2, 4, a section forms between two connection lines 18 created in this manner that can be used as part of a valve, the film layers 2, 4 lying against each other across their entire surface in said section. However, it is not absolutely necessary to completely prevent a movement. A movement of the one film layer 2, 4 relative to the other film layer 4, 2 in a range of less than 0.5 mm, preferably less than 0.05 mm, produces a result that is sufficient for most applications.

[0040] FIG. 6 shows a further embodiment. The upper mold 8 again has two downward projections 10, between which the space 12 is located. However, in the embodiment example shown, the lower mold 6 comprises an indentation 20. Both the indentation 20 and the space 12 can be subjected to a negative pressure, a device, not depicted, being provided for this purpose. This causes the first film layer 2 to move in the area of the space 12 towards the upper mold 8, and the second film layer 4 to move in the area of the indentation 20 towards the lower mold 6. As a result, the distance 16 increases and the space between the two film layers 2, 4 becomes larger.

[0041] FIG. 7 depicts an embodiment in which three film layers are arranged between the upper mold 8 and the lower mold 6 from FIG. 6. An intermediate film layer 22 is located between the first film layer 2 and the second film layer 4. Once again, the space 12 and the indentation 20 are subjected to a negative pressure, so that the first film layer 2 and the second film layer 4 move as depicted in FIG. 6. However, the intermediate film 22 arranged in the middle does not move, so that two distances 16 emerge. The first distance 16 is between the first film layer 2 and the intermediate film layer 22. The second distance 16 is between the second film layer 4 and the intermediate film layer 22.

[0042] FIG. 8 shows a further embodiment in which the upper mold 8 comprises three projections 10. Between these are two spaces 12, which can be separately subjected to a negative pressure. As in FIGS. 6 and 7, the lower mold 6 comprises an indentation 20, which can likewise be subjected to a negative pressure. In the situation in FIG. 8, the intermediate film layer 22 is again located between the first film layer 2 and the second film layer 4, the intermediate film layer remaining stationary. Unlike in FIG. 7, a negative pressure is not applied to the space 12 in the upper mold, which lies opposite the indentation 20. Instead, a negative pressure is applied to the space 12 depicted on the right in FIG. 8. The two distances 16 are therefore at an offset relative to each other and can, for example, belong to different channels between the two film layers 2, 4. Even if in the embodiment example shown there is an intermediate film layer 22 between the first film layer 2 and the second film layer 4, the distances 16 there are positioned between the two film layers 2, 4.

[0043] FIG. 9 depicts a situation that corresponds to the situation shown in FIG. 9, the intermediate film 22, however, not being arranged between the first film 2 and the second film 4.

[0044] FIG. 10 shows a top view of a part of two film layers 2, 4 that are joined together. Three parts 24 of a connection line 18 collectively form a ring that is interrupted at three points 26. Consequently, in the areas of the parts 24, the upper first film layer 2 is joined with the underlying second film layer 4. In the areas 28 that abut the parts 24, the first film layer 2 is not joined with the second film layer 4, but the distance between the two film layers 2, 4 is not constant. Rather, it increases the further one moves away from the parts 24. In FIGS. 2 to 9, the proportions 28 correspond to the areas of the first film layer 2 in which the distance between the first film layer 2 and the second film layer 4 or the intermediate film layer 22 increases. They are depicted in FIG. 9. Between them are the parts 14 of the first film layer 2, which are arranged at a distance 16 from the second film layer 4. The special embodiment ensures that the first film layer 2 does not lie against the second film layer 4 in the middle of the depicted interrupted ring made up of the three parts 24. In this area, the first film layer 2 preferably comprises an opening, so that the fluid can enter the intermediate space between the two film layers 2, 4 from the volume.

[0045] The upper area of FIG. 10 shows the representation along the line of intersection AA. The first film layer 2 can be seen, which in the right-hand part is joined to the second film layer 4. This refers to the part 24. Adjacent to this is the area 28 in which the distance 16 between the first film layer 2 and the second film layer 4 increases. In the left-hand part of the sectional view, the first film layer 2 is already at the specified distance 16 from the second film layer 4, so that fluid can flow along here. The left-hand area of FIG. 10 shows the sectional view along the line of intersection B-B. In this area, the first film layer 2 is joined with the second film layer 4 via a further area. The part 14 in which the two film layers 2, 4 exhibit the distance only extends in the middle.

REFERENCE LIST

[0046] 2 first film layer [0047] 4 second film layer [0048] 6 lower mold [0049] 8 upper mold [0050] 10 projection [0051] 12 intermediate space [0052] 14 part [0053] 16 distance [0054] 18 connection line [0055] 20 indentation [0056] 22 intermediate film layer [0057] 24 part [0058] 26 point [0059] 28 area