Welding of lumbar belts
Frequently asked questions about welding lumbar belts
Some of today’s most widely-used medical devices can trace their origins back to antiquity, or even earlier. Orthoses, such as lumbar belts, were already widely used by Greek and Roman athletes.
At that time, to combat back or rib pain and injury, simple bands were wrapped around the athlete’s thorax. Since then, these medical devices have become much more complex and effective. Today, the most common method of producing orthotics is by welding medical devices together.
What are the different categories of lumbar belts?
In fact, there are different categories of lumbar belts, which can be classified according to their therapeutic purpose or manufacturing method.
The most frequently used classification system is based on the therapeutic functions of the various lumbar belts. For mild back pain with no identified pathology, lumbar support belts are used. In the case of limited aches and pains corresponding to clearly identified mild pathologies, lumbar support belts are used. Finally, immobilization belts are used for acute pathologies after diagnosis, within the framework of a medical prescription.
The technology used to manufacture back belts is another way of classifying them. These orthoses can be either standard or custom-made, with some brands being molded directly on the patient.
The other classification criteria for lumbar belts are as follows:
- the degree of rigidity or flexibility of the orthosis,
- the size and height of the back belt,
- the material used (plaster, fabric, steel, plastic, etc.).
Orthotics made from thermoplastic materials are assembled from different parts, in the form of a lumbar belt weld.
What materials are used to manufacture medical lumbar belts?
Depending on the therapeutic objectives of the lumbar support belt, the materials used to manufacture them vary considerably, as do the methods used to produce and market them.
Available from your local pharmacy, soft lumbar belts are mass-produced by orthopedic laboratories in women’s, men’s and children’s models. They are made from flexible or non-formed fabrics by weaving or knitting. Fitted with reinforcements (back bands, rigid stays, etc.), these belts feature an adjustable fastener.
Lumbar support belts are custom-made under the supervision of an orthopedist-osthesist, with several fitting sessions during the manufacturing phase. They feature reinforcements in the form of either steel springs or thermoformed elements. These reinforcements are incorporated directly into the fabrics of the back and abdominal sections, as well as into the sides of the belt, to ensure back support.
Spinal immobilization and hyper-extension corsets are morphoadaptable, with anterior support points (pubic and sternal) and an adjustable dorsal plastron. The latter is held in place by a frame, which for a long time was made of metal but is now increasingly made of low-temperature thermoformable plastic.
Spinal immobilization corsets are adaptable to individual morphology, and can be mass-produced or custom-made to suit therapeutic needs. They are either made from reinforced, stretchable fabrics, or from thermoplastics formed at low temperatures by direct application.
The thermoplastics most commonly used for orthopedic belts and corsets are polyvinyl chloride and polyurethane, which are recognized for their strength and flexibility. They can be thermoformed to produce various components for seamless lumbar belts.
How are seamless lumbar belts assembled?
The manufacture of belts for medical use complies with very strict production standards to avoid any defects that would render them unusable by the people for whom they have been prescribed.
When made from thermoplastics, seamless lumbar belts are welded together using high-frequency or ultrasonic welding presses.
When made from resin or plaster, rigid belts and corsets are molded to the patient’s morphology. These manufacturing techniques make it possible to produce seamless belts, which would otherwise be a source of discomfort or even additional pathologies.
What technologies are used in lumbar belt welding machines?
Lumbar belt welding machines are based on the most frequently used technologies for thermoplastic assembly.
High-frequency technology involves subjecting the components to be joined to a welding press emitting an electromagnetic field that causes molecular agitation. This machine generates a weld that is regular, highly resistant and free of asperities.
Ultrasonic technology ensures lumbar belt welding by means of vibrations emitted by the sonotrode of the welding press, which agitates the molecules at the edges of the parts to be welded. This technology produces welds that are even, strong and flat.
