A manufacturing system for contoured foam cushions

A NEW CUSTOM-CONTOURED CUSHION SYSTEM BASED ON FINITE ELEMENT MODELING PREDICTION

High internal stress in the deep tissues adjacent to bony prominences can cause deep tissue injuries. Therefore, internal stress in the soft tissue should be considered when the performance of anti-decubitus cushions is evaluated during cushion design. This paper reports on a custom-contoured cushion (CCC) system incorporated with a three-dimensional (3D) slice subject-specific finite element (FE) model to investigate the internal stress distribution in the soft tissues. This stress distribution was used to transform the interface pressure into the carving depth of the fabricated cushions based on the biomechanical characteristics of the cushion materials. The internal stress in the soft tissues was investigated using an FE model of buttocks and cushion made from three cushion materials. The cushion design was optimized according to the properties of the material. The simulated interface stress between the buttocks and the cushion (18 kPa) was consistent with the measured interface pressure of the CCC (17.1 kPa). The 3D FE model predicted the internal stress and displacement of the soft tissues and cushion. Additionally, it efficiently optimized the selection of cushion material. Fifty subjects (25 subjects with spinal cord injuries (SCI) and 25 healthy subjects) were recruited to investigate the interface pressure and perform subjective comfort evaluation. The CCC decreased the interface pressure under the buttocks and simultaneously increased the subjective comfort and stability. The effectiveness of the cushion materials was predicted by the CCC system, which also validated the clinical performance of decreasing interface pressure.

Seat cushion optimization: a comparison of interface pressure and tissue stiffness characteristics for spinal cord injured and elderly patients

OBJECTIVE

A method for designing tissue deformation minimizing seat surfaces was evaluated. Pressure and stiffness criteria were used to optimize surface shape. The method's efficacy for patients with spinal cord injuries (SCI) and a comparison of cushion performance and interface characteristics with a group of 30 elderly patients are presented.

DESIGN

Repeated measures, prospective study.

SETTING

University medical center.

PATIENTS

SCI (n=12), elderly (age 65 + years) [n=30].

INTERVENTIONS

One flat and two custom foam seat cushions.

MAIN OUTCOME MEASURES

Interface pressure measured using a pressure sensing pad; tissue stiffness and pressure recorded on a rigid programmable seat surface.

RESULTS

Pressure distributions on contoured cushions for the SCI group contained lower values than distributions on flat cushions. A comparison of the pressure data between the elderly and SCI showed that significant differences exist between interface characteristics. The SCI group had higher peak interface pressures for all cushions tested. Tissue stiffness measurements were similar for each group.

CONCLUSIONS

Results showed improved effectiveness of custom contoured foam seat cushions versus flat foam cushions. The results suggest that pressure distributions for SCI are more sensitive to support cushion characteristics than for the elderly. Further research is needed to determine the extent of the difference between the populations represented by these groups.

Seat cushion design for elderly wheelchair users based on minimization of soft tissue deformation using stiffness and pressure measurements

A method for designing seat support surfaces using interface pressure and soft tissue stiffness criteria was evaluated. An algorithm designed to drive a rigid support surface on a programmable seating system to a shape for which the externally applied pressure is inversely related to the measured stiffness of adjacent soft tissue was evaluated on 30 elderly subjects (age 65 years or older). The resulting support surface shapes were transferred to compliant foam cushions and evaluated using interface pressure measurements. Pressure and stiffness measurements on the seating system indicated the surface shape control algorithm met the desired programmed criteria by achieving an inverse relationship between pressure and stiffness, as it converged to an "optimal" support surface shape. Evaluation of interface pressures on the compliant foam cushions showed that the pressure distributions on the cushions contoured to the optimal surface shapes were more uniform and had lower values than distributions on flat foam cushions and foam cushions contoured to shapes measured using state-of-the-art load-deflection devices. The results suggest that support surfaces designed using tissue stiffness as a criteria can provide loading conditions intended to minimize relative deformation and, thus, stress in load-bearing soft tissue.

A system for the analysis of seat support surfaces using surface shape control and simultaneous measurement of applied pressures

A system for the design and analysis of seat support and buttock tissue interfaces has been developed. It has the ability to control the seating surface shape while measuring the pressure applied to the buttocks by the surface. Pressures are measured over an 11 x 12 rectangular array of support elements using silicon pressure sensors mounted in a swiveling head atop each support element. Control of surface shape is mediated by selective linear translation of the support elements along their respective vertical axes. Closed-loop control of the system allows for the dynamic formulation of a support surface on the basis of programmable criteria. The system is intended to function as a research tool to facilitate the study of the relationships between support surface shape and interface pressure, and support surface shape and soft tissue distortion. The purpose of this paper is to present the system instrumentation and the rationale behind its design and development. The paper also presents the results of several tests to evaluate the accuracy and performance of the system. This evaluation included a pilot study on 10 able-bodied subjects. The results of these system evaluations indicate that the system is capable of making repeatable and precise measurements of pressure and surface element position and can formulate support surface shapes that satisfy specified optimization criteria.