1 Invacare PinDot Series Custom Seating Systems At Invacare PinDot Seating, our goal is to provide the most efficient and cost-effective means of completing your ContourU order. The success of each ContourU system in providing the optimal seating system for your client depends in part upon the accuracy of the information that you provide to us. It is our goal to work with you to create the best possible product possible. To this end, we have once again revised the ContourU Technical Notes, ContourU Order Forms and the PinDot Series Price List. To serve you better, the new order forms make numerous references to the revised Technical Notes, which provide additional and detailed information about the ContourU system and its capabilities. To assist you in placing your order, our internal customer service department is dedicated exclusively to Invacare PinDot Seating products. They are available to assist you by phone between the hours of 8:00 a.m. and 5:00 p.m. EST, Monday through Friday. Additional support is also available through our design technicians and managers who can be contacted through our customer service department when necessary. You may also fax questions and information to 800.870.4928. The phone number to PinDot customer service is 800.451.3553. Thank you for choosing ContourU. 1 Invacare PinDot Seating
table of contents 2 table of contents Manufacturing Standards 4 Making a plaster cast 5 installing molding bags 6 & 7 tips for cleaning & caring for molding bags 8 tools for plastering 9 plastering 10 splinting a cushion 11 poor cast 12 order forms 13 Marking the cast 14 center line 15 alignment lines 16 penny marks 17 & 18 Cushion measurements width: chair versus cushion 19 depth: seat cushion depth versus frame depth 20 height: cushion back height versus total system height 21 seat to back angle 22 seat to floor angle 23 cushion depth 24 With Chair/On Chair 25 Upholstery options 26 Junctions 27 universal 28 hip control 29 fixed recline 30 pelvic control 31 junction comparisons 32 growth style 33 gapping 34 back tongue 35 2
table of contents 3 Seat and Back modifications and options Abductors and Adductors 36 As molded, raised, extended and reinforced Laterals 37 & 38 As molded, square pull, reinforced Other modifications leg length discrepancy 39 front rigging notches 40 pelvic strap notches 41 cross brace notches 42 notched rear corners 43 loose fit 44 railcuts 45 undercut 46 diagonal cut 47 strap slots 48 recess 49 sofspot 50 duplicate sofspot 50 Mounting 51 pan mounting pan accessories & hardware 52 & 53 wood mounting & hardware 54 untrimmed 55 upholstered bottom - Velcro mounting 56 custom fit to existing shells 57 wood slats 58 Appendices 59-62 Remake/Returns Policy 63 Warranty Policy 64 Notes 65 & 66 3 table of contents
manufacturing manufacturing standards 4 The following describes our manufacturing capabilities. Please refer to the appropriate sections in the Technical Notes for detailed information on the modifications discussed. 1. Depth The maximum depth or thickness for a ContourU cushion is 12 for vinyl or naked cushions, and 10 for cloth cushions. 2. Minimum thickness of lateral and adductors The minimum thickness is ¾. 3. Maximum negative pull Undercuts, railcuts, extended abductors, extended adductors, and back tongues are all negative pulls. The maximum negative pull per cushion is 6. For example: You may order a 2 undercut, railcut each side 1 and extend each adductor 1. 2 +1 +1 +1 +1 =6. These options give you the maximum total of 6 of negative pull. 4. Maximum total railcut The maximum width of a railcut per cushion is 4. The standard railcut is 2 in height. The finished railcut width dimension must be indicated on the order form. 5. Maximum undercut The maximum undercut is 2 deep. The minimum thickness is 1 ½. 4 standards 6. Maximum extension on abductor and adductors The maximum extension is 2. 7. Minimum foam allowance A cushion will have a standard foam allowance of 1 ½ on the seat and back. Certain options or combinations of options may raise the foam allowance. This allowance is added to the overall thickness of the cushion. 8. Maximum tongue length The maximum length of a back tongue is 3 with a minimum thickness of 1 ½. 9. Recesses and sofspots The maximum depth for a recess or a sofspot is 2. The minimum is 1. The minimum foam allowance of 1 must be maintained under the seat and behind the back.
making a plaster cast Careful and accurate plastering is essential to the production of an effective ContourU system for your client. Make sure that you have all of the basic equipment as listed on page 9. Also, have your ContourU Technical Notes, Order Form, and Quick Start guide available. Before you begin, refer to pages 17 & 18 for a description of the penny method for marking casts. The following pages provide detailed information on the following topics: 5 Page 6 & 7 Page 8 Page 9 Page 10 Page 11 Page 12 Installing molding bags Cleaning & caring for molding bags Tools required Plastering Splinting a cushion Poor and unacceptable casts 5 making a plaster cast
installing molding bags 6 installing molding bags In addition to a seat bag (MF10) and/or back bag (MF12) and frames, you will need, a wideneck funnel, alcohol or similar cleaning agent, Allen key, 9/16 wrench, and 25 pounds of pellets (MF04) per molding bag. Note The seat and back bags are NOT interchangeable. The back bag has a valve stem for the hose in the middle. The seat bag has a valve stem near the top right. Instructions: Prepare the frame by removing the clamping bars and old bag. Remove any loose plaster from the edges of the frame. 1. Place the bag in the frame. The top of the bag has a small opening on the left side. The top of the frame has holes in it; the bottom does not. (Diagram 1) Place the top of the bag in the frame just below the holes in the frame and just to the right of the holes on the right side of frame. Be certain the valve faces the rear of the frame. There will be extra bag hanging on the left side of the frame. You can use duct tape to help keep the bag aligned. 2. Fold bottom of bag under, leaving about ¼ of space between the bag and end of frame. (Diagram 2) 3. Place clamping bar on right side, lining up the holes, and secure. Make sure you secure each screw by hand first, then tighten with an Allen tool. 4. Do the same on the left side. 5. Make at least 3 folds (more is better) on the right side of the bags. Leave enough extra bag on the left side to make a fold later over the opening. The first fold should begin just to the right of the first hole. The first fold should be about 2 ; the second fold about 2 ; the third fold about 2. (If you use 6 folds, each will be approximately 1.) They can be held in place with duct tape. Hold each fold in place with your hand while you make the next fold. Place the large clamping bar over the folds. Secure bar to the frame. (Diagram3) 6
installing molding bags (cont d) 6. At the top of the left side of each bag there is an opening. Using a wide neck funnel, fill the bag with pellets. Each bag takes 25 pounds. 7. Once the bag is full, remove all loose beads from the opening. Wipe the opening with a clean tissue or cloth and an alcohol / cleaning agent. 8. Seal the bag with the adhesive provided by removing the protective paper and carefully press the two sides together. Make sure the seal is airtight and that no beads are trapped in the seal. 9. Make the final fold (s) in the bag over the opening. Place the remaining small bar on the frame and secure. (Diagram4) Attach the correct vacuum hose to the bag and secure using a 9/16 wrench. (Seat and back vacuum hoses are different.) 7 7 installing molding bags (cont d)
tips for cleaning molding bags 8 cleaning molding bags Clean after each use Removing fresh plaster and fresh tape not only preserves the life of the Molding Bags, but prepares the machine for the next user. Soap Lanolin soap will help preserve the elasticity and integrity of the molding bags Weather Allow the molding bags to accommodate to room temperature when transporting them in from extreme hot or cold vehicles. Transport issues Be certain to tie down the shape sensor frame when transporting in a van or truck. Remove the molding bags from the frame during transport. Consider using the boxes the seat and back frames were originally shipped in to protect them during transport for protection. Remove Tape Use Cheap Masking tape to cover wrinkles and for marking the mold. The cheaper it is, the easier it will be to remove the less sticky it is. If it is too sticky, apply it to a fleece material first, allowing it to pick up lint and then to molding bags. Tape left on, even for only a few days, can cause a tear in the bag when removing it. Patching a hole Consider using ROHO Patches Use Duct tape if a hole is discovered in the molding process. Leaks discovered between the bag and the side of the frame can temporarily be stopped with Theraputty when vacuum is being applied to the bag. Use good judgment when deciding when there are too many patches on the bag and replacement is needed. Remember the molding bag is NOT elastic over the area of a patch and will not capture contours as closely. Patches in critical areas of the bag (sacral area, hips, etc.) usually indicate time for a new bag. When you cast, be sure to identify the patch as one, not an important identifying mark. Furdustin Powder by Sween Put on bags before you mold. It is like baby powder, but less chalky. Makes the bag less sticky. Bags last longer, and stay more pliable. Storage Do not use the ContourU machine as a storage shelf when not in use as items set on the molding bags tend to accumulate and may cause holes in the bags. 8
tools for plastering Tools for Simulating and Plastering: 9 Shape Sensor Molding bags for seat and back (plus an extra set) Vacuum pump Large mouth funnel Drop Cloth Masking tape Duct tape Theraputty Bucket with plastic bag 2 boxes of plaster (each box contains 12 rolls of 5 x 50 plaster bandages) Rubber mallet Gloves Baby powder Framing square Alignment tool Tape measure Allen tool set Adjustable open end wrench Ink pencil ContourU order form Fabric samples Polaroid or digital camera 12 pennies Pitch angle gauge Goniometer Towels Sheets / Clothes Pins Extra beads Positioning accessories (Ethafoam blocks, plumb line, webbing) 9 tools for plastering
plastering 10 plastering Plaster the mold in one piece. Pay particular attention to the first layer as it captures the most details of the client s shape. Place 4 layers of plaster vertically down the back and continue along the seat. Place 4 layers horizontally across the full surface of the seat and back. This is a total of 8 layers of plaster. Put enough plaster around the laterals and adductors to provide a good surface for marking the alignment lines. Fold back the outer edges of the plaster strips to strengthen the mold. Wait 24 hours before packaging. Marking the cast (see page 14) can be completed using an ink pencil immediately after the last plaster strip is finished. The cast can be carefully removed from the simulator after markings are completed. First, release the vacuum by disconnecting the seat from the vacuum pump, and opening up the back valve. Allow several minutes for the vacuum to be released. Gently pull the bag away from the plaster cast along both sides, under the front of the seat, and behind the top of the back. Carefully lift the plaster cast off of the simulator. 10
splinting a cushion Splinting is making a plaster cast of a cushion. This splint can be used to manufacture an identical cushion, or an additional cover. Before splinting, always place a layer of plastic wrap or plastic bag over the cushion. Place the cushion on a flat plane, such as a table or the floor. Splinting to a flat plane. Using 8 layers as described in the section above, place the plaster over the cushion and extend it all the way to the plane, letting the plaster overlay approximately 1 onto the plane. After you remove the plaster from the cushion, it should sit flat on a plane. Alignment lines must be drawn parallel to the flat plane.(see alignment lines page 16) 11 Splinting short of the plane. This method is preferable when the cushion has undercuts or railcuts, as it allows you to easily remove the cast from the cushion. In this case, you cast the cushion without overlaying the plaster onto the plane. Alignment lines must be drawn parallel to the flat plane.(see alignment lines page 16) 11 splinting a cushion
poor cast 12 poor cast If a cast arrives to us in a condition such that we cannot with certainty determine the client s contours or we are unable to determine the seat-to-back angle, we will reject the cast and ship it back to you. Indicators of a poor cast resulting in a rejection are: Voids and air pockets caused by too much space between layers, too much space between plaster and molding baggier by using too much water on the plaster Thin sections of plaster caused by using too little plaster Squared-off contours caused by failing to properly smooth contours in molding bag Large gap between the seat and back caused by failing to sufficiently pull down back molding bag Plaster falling off the cast - caused by failing to use both horizontal and vertical layers, using too little plaster, or squeezing too much water out of the plaster Weak transition between the seat and back caused by failing to use enough plaster in the transition area Missing information as described on page 14 Missing Penny Marks Remember to allow the cast 24 hours to dry before packaging. Do not pack the cast in plastic. Use a generous amount of packing material to protect the cast while in transit. Occasionally, despite your best efforts, a cast is damaged in shipping. Thus, it is important to adequately insure the cast. 12
order form In order for us to properly manufacture each ContourU order, you must complete all sections of the ContourU order form. Failure to complete any section will result in your order being placed on hold, therefore creating a delay in processing and extending the total lead-time of your order. Please insure that you are using our most current order form. Our current version is form # 00-284. For more information on Remakes, please refer to page 63 of this manual. 13 13 order form
marking marking the cast 14 There are several pieces of information, which must be marked, on each cast before it ships to us for processing. This information is vital for both tracking the cast and for manufacturing the cushions. Each cast must have the following information: Client Name Date Dealer Name Dealer telephone number Dealer contact name 12 Penny marks (see pages 17 & 18) The following modification landmarks must be marked on the cast in order for us to properly place that particular modification: 14 the cast Sofspots Recesses Pelvic Strap Notches Strap Slots (Naked only) Cross Brace Notches Modifications different from As Molded You must also mark on the cast the following information about the client s orientation in the simulator: Center lines (see page 15) Alignment lines (see page 16)
center line 15 The center line provides manufacturing critical indicators concerning the client s orientation in the simulator. It tells us the orientation of the client from left to right, i.e., whether the client was leaning to the left or right when in the simulator and by how much. The center line indicates the center of the simulator, not the client or cast. You must mark the center line while the cast is still on the simulator. Center lines placed after removing the cast from the simulator will not be accurate. Mark the cast at the midpoint between the left and right sides (10 from the side of the molding bag pan) at the top of the back and at the front of the seat. If you are marking a seat only, there must be a mark on the front of the seat and on the rear of the seat. If you are marking a back only, there must be a mark on the top of the back and on the bottom of the back. Because the center line is marked with reference to the center of the simulator, it is not always in the center of the cast. We will center the cast if center shape is indicated on page 1 of the order form. If the center line must be in a particular location due to asymmetries, then select leave as marked on the order form. (i.e. windswept deformities or specific joystick placement.) Note - if we center the shape by shifting the center line, we shift it so that there is equal distance between the center line and the widest point on the cast. This does not change the cast s shape or contours. Shifting the center line causes the entire shape to shift, therefore centering the client s body in the wheelchair. CENTER MARKS 15 center line
alignment lines 16 Alignment lines provide critical data allowing us to maintain proper orientation between seat and back. To draw alignment lines, it is necessary to have sufficient plaster on the sides of the cast. Using your marking tool, you must mark the alignment lines while the cast is still in the simulator. Use a marker that will make a permanent, dark line. An alignment line must be marked on each lateral and adductor. To make an alignment line, mark 2 points on each lateral or adductor that are each the same distance from the molding bag pan. Make a line by connecting the 2 points. The alignment lines should be at least 4 long and at the same distance from the molding bag pan on the left and right sides of the cast, (i.e., if you made a mark 3 from the pan on the right side of the seat, make a corresponding mark 3 from the pan on the left side of the seat). The alignment lines of the seat need to match each other in height from the pan but do not need to match the alignment lines of the back in height from the pan. When completed, you should have a set of lines that are parallel to the seat pan and to the back pan. LATERAL ALIGNMENT LINES 16 alignment lines
penny marks 17 Once the simulation is completed and before the plaster is applied, you must take measurements at several key locations. These molding bag measurements are transferred to the order form and are used during production to ensure consistency and quality. We will verify the measurements on the cast with the measurements on the order form prior to processing your cushions. Before a cushion is shipped, we will recheck the measurements as part of the final audit process. After the molding bags are prepared, attach pennies (or washers) to the molding bags using masking tape. This is to identify the exact locations of the measurements. Tape pennies to the molding bag with half of their surface exposed. The impression will transfer to the plaster, giving precise locations for measurements. In order to ensure that the measurements are taken consistently, extend the tape measure across a level plane and hold the ends at the center of each coin. 17 Anchor point Tape a penny to the seat surface so that the center of the penny is 1 from the back and midway across the adductor supports. This point will be used as the starting point for several critical measurements. Chest width the chest width is measured across the lateral trunk supports, just below the axilla. If the lateral trunk supports do not extend this high, then take the measurement in the chest area. (Location A) Waist width The waist width is measured across the lateral trunk supports at the top of the pelvis. (Location B) penny marks
penny marks (cont d) 18 Hip width The hip width is measured across the hips at the greater trochanters. (Location C) Leg length right and left The center of the penny should be placed at the exact location where the seat is to end for each leg, and should be positioned in the center of each leg trough. The measurements are taken from the anchor point to each penny. If a leg length extension is needed, and was not molded in, the desired extension will be measured from the center of the penny. (Location D & E) Back height The center of the penny should be placed at the exact location where the back is to end. Measurement is then taken from the anchor point. (Location F) Note: When growth is applied to a cushion, it may change the depth of the cushion at the location of the penny mark. In such cases, the back height will measure taller than as stated on the order form: however, the total system height will remain the same as when molded. 18 penny marks (cont d) Top of laterals right and left - The center of the penny should be placed at the exact location where the lateral is to end. This measurement is taken by measuring from the anchor point to the penny. Please note that this mark is used as a locator point for modifying the laterals (raising, lowering, or square pulling) as well as for performing the final audit. Unless otherwise specified, laterals will be made as molded. (Location G & H)
cushion measurements Width Chair vs. Cushion Overall cushion width will be the finished width of the final product, irregardless of the penny marks. Seat width is generally the same as chair width, unless rail cuts, or partial rail cuts allow cushion width to overhang the side of the chair. In most cases, the seat width will be the same as the back width also. However, the seat and back cushions can have different widths. An example would be when mounting the ContourU back between the back canes of the wheelchair, it generally needs to be 2 ½ narrower than the chair width to accommodate the mounting hardware. 19 Measure from the widest point on one side of the cushion to the widest point on the other, including the thickness of either the laterals or adductors. (Minimum thickness is ¾ ). 19 Before you even put your client into the simulator it is imperative that you consider the size of the mobility base onto which the cushions will be mounted. If the client s chair is 16 wide, for example, then when the client is still in the simulator, check to see if the positioning is such that the cushion will fit into a 16 chair. If the positioning will result in the cushion being wider than the chair width, you must decide whether you can position the client in a narrower position, get a larger chair, or use one of the options listed below. Railcuts Partial Railcuts Armrest Spacers Invacare Custom Seating Armrests Growing the Chair cushion - width
cushion measurements 20 Depth Seat Cushion Depth vs. Frame Depth Cushion depth is the final length of the entire finished seat cushion, NOT seat depth, and NOT the length of the Penny marks. To measure the cushion depth, measure from the most rear-word aspect of the seat to the penny mark noting where the longest leg length will end, and then add 1 ½ to this measurement for the posterior wall of the seat cushion (or the back tongue). The wheelchair frame depth will need to be at least the same length as the finished cushion depth unless modifications are made to the cushion to allow it to fit onto a shorter frame. WIDTH: CHAIR VS. CUSHION 20 cushion - depth Modifications possible include: Front Rigging notches; to allow the front of the cushion to fit over the front rigging hanger weldments. Undercut front; to allow the entire front of the cushion to overhang the front of the wheelchair. Rear cane notches; to allow the rear of the cushion to recess between the back canes, - also requiring the wheelchair back to fit between the canes.
cushion measurements 21 Height Cushion Back Height vs. Total System Height Back height noted on the form will NOT be the back height of the finished ContourU back as the system height will be different, depending on the different seat to back junctions chosen. Back however, the height noted on the order form will be the total height of the completed/assembled seating system. System height noted on the order form will not be the cushion back height. Back height will be different depending on which junction is chosen. To measure system height, measure the distance from the lowest point of the seat to the penny mark on the top of the back. Add 1 1/2 for minimum foam allowance. 21 This dimension will determine the back height of the wheelchair needed to accommodate the seating system. i.e., A measurement of 18 will require a back cane height of 18 unless the top of the back is modified to position above the push handles of the canes. Note - Cushion modifications such as railcuts and sofspots could increase total system height. cushion - height
cushion cushion measurements 22 Seat to Back Angle This measurement is for the clinician or supplier mounting the completed system and is not used in manufacturing. Noting this angle off the cast will assure matching the desired/molded seat to back angle when mounting the completed system on the chair. Take this measurement off of the cast using a goniometer, noting the angle measured on the order form. The goniometer can be placed on either the back or the front of the cast when taking this measurement. Seat to back angle taken off of the shape sensor will often NOT match the angle taken from the cast as the thickness of the back molding bag is usually not consistent from top to bottom, as created in the molding process. 22 - back angle
cushion measurements 23 Seat to Floor Angle This measurement is also for the clinician or supplier mounting the completed system and is not used in manufacturing. This measurement is taken off of the Shape Sensor Frame to assure that the completed/assembled system will match the captured mold in all aspects. When creating a ContourU mold for an individual with an existing mobility base, it is often helpful to match the seat to floor angle of the Shape Sensor to the seat to floor angle of the mobility base. If a different seat to floor angle is required in the mold from the existing angle on the base, modification of the wheelchair can be planned at this time. 23 cushion - floor angle
cushion thickness 24 cushion depth The cushion thickness will be the overall thickness of your cast, plus 1-1/2 for foam allowance. Foam allowance is the minimum thickness of foam found at any point on the cushion. This minimum is has been established to prevent the cushion from bottoming out. If a cushion bottoms out, there will be no padding under bony prominences, possibly leading to skin damage. You should also note that some modifications or options may increase minimum foam allowance requirements. Cushion thickness is measured from the lowest part of the cast to the top of the highest point (usually the lateral or adductor). The maximum cushion thickness is 12 inches. Recess At least 1 foam behind or underneath the recess. Wood Mount Additional ½ of minimum thickness (1-1/2 foam plus 1/2 wood.) Negat ive Pull If there is any negative pull, i.e. railcuts, undercut, extended adductors, extended abductor, back tongue, the minimum foam allowance may increase depending on the amount of negative pull and location. 24
with chair / on chair 25 As a continued effort to decrease lead times and increase efficiency, Invacare Custom Seating is now able to offer both a With Chair and an On Chair option when ordering a ContourU and an Invacare mobility base. When the With Chair option is selected, your ContourU and your mobility base will be shipped from Invacare together. You will therefore receive the ContourU and the mobility base at the same time and be sent a single invoice for the two. When the On Chair option is selected, all mounting hardware will be installed on the mobility base and the ContourU. The system will then be physically mounted to the base. If possible, the sysetm will remain on the base for shipment so that when it arrives, you are required to merely make final adjustments during client fitting. If for some reason packaging or product configuration prohibit the system from shipping completely assembled, the seating system will be packed separately, hardware intact, and shipped together. 25 At this time ALL With Chair and On chair orders MUST be placed through Custom Seating customer service. Custom Seating customer service can not accept any phoned in orders or direct entry orders (EDI or X.12) for the Invacare wheelchair. When mailing in your ContourU order, it must include the following: ContourU plaster cast ContourU order form Invacare wheelchair order form with chair At the time of printing this version of tech notes, only certain configurations of ContourU seating systems are available factory mounted on select mobility bases. Contact your Custom Seating Customer Service Representative for details.
upholstery options 26 ContourU cushions are available either vinyl covered (CM01) or naked (CM02). A vinyl cushion is made with vinyl upholstery vacuum-formed around the mold. A urethane foam is then injected into the vinyl. See order form for current vinyl covering color options. Vinyl covered cushions offer the greatest strength and durability and are the firmest of the ContourU cushions. They are easy to clean and are appropriate if the client is incontinent. A removable cover is available at an additional charge. A naked cushion does not have any upholstery over the foam i.e. it is naked. Naked cushions always include a removable cloth cover (3 cover options) and are softer than the vinyl cushions. The naked foam is coated with a spray urethane to increase durability and improve moisture resistance. The naked foam can be modified in the field and the urethane coating repaired with our waterproofing kit (CRK). 26 upholstery options Cover patterns are included in the price of Naked ContourU cushions. We will keep this pattern on file for 3 years and will fabricate extra covers as needed at an additional charge.
junctions 27 An important feature of the ContourU Seating System is the ability to choose a specific Seat to Back Junction. The junction is the manner in which the seat and back cushions join together. Each junction offers postural support and control in a manner unique to that system, as well as modifications to that junction. There are 4 Choices to choose from. Universal Pelvic Control Hip Control Fixed Recline 27 The following pages 28 through 35 provide detailed information on each junction, a comparison of the different choices, and an explanation of modifications that can be made. junctions
universal By providing adductors that extend to the back of the cushion (maximum height = 3 ), the universal junction provides the client with maximum control of the hips through the seat. All sacral support is provided through the back with a tongue that matches the seat contour. (see page 32) It is manufactured with an open rear for growth and allows for angle adjustability (90 to 105 ) of the seating system. 28 28 universal
hip control The hip control junction is recommended when the client needs maximum control of the pelvis through the back cushion. This junction is most helpful when the lateral wall of the back needs maximum surface area to prevent the individual from collapsing on that side. The back laterals extend down to the seat where the hip guides and adductors are approximately 1 tall. (1 above the lowest point on the seat) The hip control junctions allows for adjustability (90 to 105 ) of the seating system. The hip control junction is manufactured with an open rear and growth is available. A back tongue is standard and will be added to the back cushion if a gap is not specified. 29 29 hip control
fixed recline With the fixed recline junction, the rear portion of the seat is manufactured to create an angle. When mounted properly with the back cushion, the angle created duplicates the seat to back angle prescribed for the client. This junction is best for clients with a generally fixed hip position. A fixed recline junction is manufactured with a posterior wall, similar to the pelvic control junction, therefore there is no growth option available. This is the only junction available if the seat to back angle is equal to or greater than 105. We are able to manufacture this junction open to the rear with a tongue. A gap can also be manufactured, either full or tongue. JUNCTION: FIXED RECLINE 30 30 fixed recline
pelvic control The pelvic control junction allows for maximum control of the pelvis through the seat. It has a posterior wall in the seat that wraps around the sacrum to the hip guides in the seat. Neither growth nor a back tongue is available with the pelvic control junction. This junction is also recommended when interfacing a ContourU seat cushion with an aftermarket back. In this case, adding notched rear corners allow mounting adjustments for a clean seat to back junction. 31 31 pelvic control
junction comparison Fixed Recline Control hips with both seat and back Manufactured with angle in seat Pelvic Control Control hips with seat. Manufactured at 90 Minimum cut line is 2 to max depth on adductors No tongue available 90 to 105 range No growth style available 32 Universal Hip Control Control hip with back Control hip with seat Manufactured at 90 Manufactured at 90 Cut line at angle 1-2 cut line 3 cut line (maximum) No standard with tongue, but tongue is available Standard tongue to match seat contour Standard tongue to match seat contour 90 + (if 105 +, this is the only junctiion available) 90 to 105 range 90 to 105 range No growth style available Growth will accomodate both the widest area of the hip and of the seat Growth will accomodate both the widest area of the hip and of the seat
growth style 33 Growth is available on ContourU systems with the universal and hip control junctions. Growth is provided in the seat by adding the growth amount to the rear of the seat. For example, if the seat length is 14 and you want 3 of growth, we will add 3 to the rear of the seat cushion for a total seat length of 17. Note - Because the contour of the seat is extrapolated rearward, beginning at the lowest point and extending to the back of the seat cushion, the exact measurement (top of seat cushion to top of back cushion) of the final product will not match the molding bag measurements listed on page 1 of the order form. Although the desired back height, as indicated on the order form and plaster cast, will be achieved, the difference in actual measurement will be equal to the difference in height between the anchor point penny location and the deepest point of the seat (the point from which the growth was extrapolated). 33 growth style The arrow indicates the area available to grow the system.
gapping A gap is the space that exists between the seat and back cushions after the system is fit together. A gap allows for some flexibility in the lateral height, air movement, and accessibility to the rear of the client to check positioning. A full gap is created by removing the specific amount of material from the bottom of the back cushion to achieve the desire gap (see figure 2). To maintain hip control with the laterals and still provide space between the seat and back, we also offer a tongue gap (see figure 3). 34 34 gapping figure 1 figure 2 figure 3
back tongue A back tongue is the portion of a back that extends down into the contour of the seat. A back tongue is standard on universal and hip control junctions unless a gap is specified. It is not available with the pelvic control junction, but can be requested with a fixed recline junction. The maximum length of a tongue is 3 and the minimum thickness is 1 1/2. 35 35 back tongue back tongue
abductors and adductors To provide your client with maximum support in areas of particular concern, we can extend the adductors or an abductor up to 2, and we can also raise the abductor up to the height of the adductors. If you extend the abductor or adductors, or raise the abductor in the cast, there is no additional charge. However, if we must make the change during manufacturing, there is an additional charge. (refer to price list) We will raise or extend to the depth indicated on the order form. 36 abductors and adductors To reinforce adductors or abductors, we add a piece of 3/16 thick ABS which is formed to the proper contour. The edges of the reinforcements are lined with a foam edging, then centered within the adductor or abductor. This edge may be visible on naked cushions and should not be viewed as a defect. Both Lshaped and aluminum reinforcements are also available for adductors. With wraparound reinforcements, the ABS extends all the way to the bottom of the adductor and wraps around toward the center of the cushion approximately 3. An aluminum reinforcement is a single piece which extends from the top of one adductor to the bottom of the cushion, across the entire width of the cushion, then back to the top of the other adductor. Both L-shape and aluminum reinforcements provide additional stability. An abductor that rises less than 6 from the bottom of the leg trough cannot be reinforced. The design of the cuhion generally provides sufficient support in this area. If your adductor wall is greater than 3 wide, we will thin the wall for appearance purposes unless you tell us not to. 36
laterals 37 Laterals will always be thinned to approximately ¾ 1 thick. If for some reason you want them thicker or at the minimum ¾, please specify on your order form under special instructions. The thinning process will be symmetrical from top to bottom with the outside of the cushion being cut back even with the depth of the back where it joins the lateral support. The standard method for manufacturing laterals is as molded. As molded means that the shape of the laterals will be the same as you molded in the cast. The Square Pull option will change the original shape of the laterals. The lateral will be pulled out or extended to the depth that is indicated on the order form. If square pull is needed, you must specify it on the cast and on the order form. 37 laterals Square Pull
reinforced laterals 38 To reinforce laterals, we add 3/16 ABS or aluminum formed to fit the contour of the lateral. The edges of the reinforcements are lined with foam, centered within the lateral, then molded ing making contact with the foremost point of the cushion. This edge may be visible and should not be viewed as a defect. Straight reinforcements: A straight piece of ABS which when molded into the lateral prohibits the lateral itself from flexing. Wrap-around or L-shaped reinforcements: Provide the same features as standard reinforcements, but also, due to the L shape design which wraps part way across the back of the cushion, adds strength to the entire cushion, limiting the amount of flex that would otherwise be evident where the lateral meets the back wall of the cushion. 38 reinforced laterals Aluminum reinforcements: With this option, two pieces of ABS (one in each lateral) is replaced with a single piece of aluminum. This aluminum wraps completely around the back of the cushion, forming a U-shape which provides excellent stability and strength to the lateral wall, especially in our naked cushions. Reinforcements provide extra support for the client and help stabilize deep cushions. Except as described below, if you want reinforcements, you must specify what type on the order form. We always add standard (straight) lateral reinforcements in naked back cushions and all back cushions that the laterals are at least 6 deep.
leg-length discrepancy 39 A leg-length discrepancy modification is where the seat cushion is manufactured with different leg lengths to accommodate a client who has one leg longer than the other. If the cast was not molded to reflect the discrepancy, we can add the discrepancy. A reference point (penny mark) must be provided and the desired amount of lengthening marked on the cast and on the order form. Even if there is a discrepancy molded in a cast, you must also select it on the order form. If you are pan mounting a seat cushion with a leg-length discrepancy, you must decide whether you want the pan to fit the longer leg or the shorter leg. Keep in mind that if you opt to have the pan fit the longer leg, you will have to modify the pan to accommodate the shorter leg. If you choose to order a pan to fit the shorter leg, you must also order an undercut so that the longer leg will fit properly over the front edge of the pan. On naked cushions only, you may opt to slot the bottom of the cushion under the longer leg to accommodate the pan rather than undercutting. This option is not available on vinyl cushions. 39 leg length discrepancy
front rigging notches Front rigging notches are available on the bottom front of the ContourU cushion to allow for ease of access to the legrest hardware. This allows you to maintain a shorter depth on the wheelchair frame and still have access to the swing-away mechanism of the legrest. You must provide us with the dimensions of the cutout, using Appendix d. Feel free to make copies of this drawing for future use. 40 40 front rigging notches
pelvic strap notches Pelvic strap notches are cutouts on the seat cushion that allow for a more direct pull of a lap belt across the client s hips. Standardly, we place each pelvic strap notch in the middle of the adductor, directly in front of the place where the lateral meets the adductor. Each notch is 2 long. The depth of the notch varies according to the depth of the seat cushion. You may specify a different placement and size of the pelvic strap notches by marking the placement and size on the cast. Note - Because the rear of each adductor is only 1, pelvic strap notches are not necessary with a hip control junction. 41 41 pelvic strap notches
cross brace notch We can manufacture your seat cushion with cross brace notches to allow the cushion to drop between the seat rails. This is not available with pan mounting. The maximum drop allowed is 2. You must provide us with the dimensions and location of the cutouts, using Appendix A. Feel free to make copies of this drawing for future use. Note: Please remember to measure from the back canes forward, not from the back of the cushion forward. 42 42 cross brace notch
notched rear corners 43 Notched corners are needed if you would like to mount a seat cushion between the back canes of the wheelchair. Keep in mind that if you order notched corners and also pan mounting; you will need have the pan modified to accommodate the notches. We will do this for you upon request. We no longer have a standard notch due to the numerous configurations of mobility bases. Please specify on the order form, the finished width and depth dimensions of the notch. (See Appendix d) Feel free to make copies of this drawing for future use. Note - To insure maximum adjustability on certain configurations of Solara product, a 2 x 2 notch is recommended. If the back cushion has railcuts, and you are also ordering untrimmed, upholstered bottom, or wood mounting, we will automatically notch the seat to match the railcuts in the back. If you are pan mounting, we can still notch the seat. However, because you would have to modify the seat pan to accommodate the notches, we will contact you before we notch the seat. We also recommend notched rear corner when using an aftermarket back for proper seat to back alignment. 43 notched rear corners
loose fit Loose fit increases the overall inside width of the cushion, but not the depth or thickness. It may result in increasing the overall width, if the laterals and adductors are already at minimum thickness. When ordering a loose fit option you must specify the amount you want us to widen the cushion. Loose fit can allow for weight gain or anticipated immediate growth, but will not provide the individual with as much support or postural control as an as molded seat or back would. 44 18 19 44 +3/8 +3/8 loose fit +3/8 +3/8 Cushions before loose fit. Cushions after loose fit. In this case, the overallwidth of the cushion increased 1.
railcuts For a railcut, the lower portion on the side of a cushion is cut in to allow the cushion to be mounted between the seat rails or the back uprights. Please specify the desired final width and depth (1/4 increments) on your order form. (See Appendix c) Feel free to make copies of this drawing for future use. Note - When mounting a back cushion to a Solara, certain configurations require that the cushion be rail cutas well as notching the bottom corners of the cushion to allow for maximum height adjustability. If unsure of the exact location that the cushion is to be mounted, please note on the order form Solara notches and specify the size of the chair. 45 45 railcuts If the front of a seat is wider than the rear of the seat, we can partial railcut only the front portion of the seat to accommodate the mobility base.
undercut An undercut can be added to the front of a seat or to the top of a back. The surface at the front edge of the seat is cut back to allow for calf clearance or accommodate tight hamstrings. The undercut can be produced with different amounts of undercut under each leg to accommodate a leg length discrepancy that is 2 or greater. This is called a 2-step undercut. Similarly, the top edge of a back can be undercut. Undercutting the top of a back or the front of a seat allows an oversized cushion to fit in a pan. For example, the back height is 19 and the existing pan is 18 deep. In this case we can undercut the top of the back 1 to allow the cushion to fit the pan. 46 46 Standard Undercut undercut Standard Undercut with Leg Length Discrepancy 2-Step Undercut with Leg Length Discrepancy
diagonal cut A diagonal cut may be made on the front of a seat or at the top of a back cushion. A diagonal cut on a seat means that the front of the seat is manufactured at an angle. Generally, a diagonal cut front seat accommodates a client who is windswept. If the client is windswept, then the cast should reflect that. We cannot add a diagonal cut on the front of the seat unless it is present in the cast. A diagonal cut on a back means that the top of the back is manufactured at an angle. Generally, this accommodates a client who has a severe shoulder obliquity. We cannot add a diagonal cut to the top of a back unless it is present in the cast or drawn on the cast. 47 If a diagonal cut is requested with pan mounting, an undercut will also be needed so that the cushion will properly fit in the pan. 47 diagonal cut
strap slots This option available on NAKED CUSHIONS only When it is necessary to place any type of strap through a cushion rather than around it (such as a pelvic or chest strap), we can mold slots into the cushion at the desired place. These slots will go completely through the cushion, will be coated with the standard urethane spray, and will measure ½ wide by 1-1/2 long. Other shapes and sizes may be available, but must be quoted as a special. You must indicate on your cast, the exact location of these slots and must allow a minimum of 1 foam between the slot and the nearest edge of the cushion. Strap slots can not intersect a sofspot. The removable cover will have stitched holes to accommodate all slots. 48 48 strap slots
recess A recess is a cut out area in the surface of the ContourU. The purpose of a recess is to accommodate some other softer material, e.g. sofspot, gel, t-foam, etc. In order for us to make a recess, you must mark the location on the cast. A recess can be 1 or 2 deep. Minimum foam allowance behind a recess is 1. 49 49 recess
sofspot A sofspot is made by adding a soft pad of HR foam to a 1 or 2 deep recess. The foam is cut to fit in the recess and to match the cushion s contour. When ordered with a vinyl cushion (CM01), the sofspot pad is sprayed with urethane and a Darlexx cover is added. The sofspot is then placed in the recess with Velcro. Sofspots ordered with naked cushions (CM02) are glued into place, are not removable and do not have a Darlexx cover. In order for us to make a sofspot, you must mark the location on the cast. 50 50 sofspot naked vinyl duplicate sofspot When ordering a vinyl cushion with a sofspot, it is possible to order a duplicate or replacement sofspot at that time. The second sofspot will be manufactured exactly the same as the first. Should the original sofspot become lost or damaged, this second sofspot will fit the existing recess without any modification. This option is not available with naked cushions, as the sofspot is not removable.
mounting We offer several methods and hardware options for mounting a ContourU system onto a mobility base. ContourU systems can also be manufactured to mount into existing pans or back shells or you may supply your own method of mounting.. As part of our On Chair program, we offer the mounting options described below. These options are also available using the With Chair option as well or as stand alone equipment. Other options are available through our parts catalog. HWPMK01 & HWPMK78 51 This hardware kit is used to flush mount ContourU pans to the mobility base. It consists of 4 horse shoe brackets, lanyards and locking pins, and fixed rail clamps and is bolted directly to the aluminum pan. Available to fit either 1 or 7/8 tubing. 51 HWWMK01 & HWWMK78 This hardware kit is used to flush mount cushions with the Wood mount w/tnut option to the mobility base. Also available for use on 1 or 7/8 tubing, they contain the same style of components as used for pan mounting. NEW On Chair Mounting Kit (OCMK) 1 and 7/8 This hardware kit contains 4 each adjustable J and L brackets and 2 fixed rail clamps and 2 twist release rail clamps. These kits are used when mounting the seating system above or below the seat rail and/or in front of or between the back canes. mounting All hardware listed above also contains hardware necessary to attach all brackets to the chair or the cushion.
pan mounting You may purchase a ContourU aluminum pan to mount your ContourU system to the mobility base. Our pans are custom made to work with our cushions. The ContourU cushion is manufactured with ridges along the side so that the cushion will snap into place in the pan. Once in the pan, the cushion is secure and will not slide out. Our pans are available in heights/lengths ranging from 10-24 in 1 increments. Widths are available ranging from 10-24 in ½ increments. If you already have a pan and you would like the ContourU to be manufactured to fit that pan, you must specify that you have an existing pan on the order form. You must also provide the width and the length of that pan. 52 pan mounting Our pans have pre-punched holes that make it easy to attach and adjust interfacing hardware and accessories. To mount a pan-mounted ContourU on to the mobility base, we offer the On Chair Mounting kit (OCMK), Adjustable Back Mounting Hardware (HWABK) and pan mounting bracket kits. The OCMK and HWABK hardware are available to mount ContourU pans onto or between the back canes. The Pan mounting bracket kits are available for 1 (HWPMK01) or 7/8 (HWPMK78) cane diameters. These kits include 2 pair of pan mounting brackets and 4 fixed rail clamps. You need 1 kit per pan, seat or back. If you are linking the cushions together with our links, then we recommend one pair of mounting brackets for each cushion. You can purchase the pan mounting brackets separately for that purpose. (MB04P & MB12P) 52 appendix b
pan mounting, continued Links are available in the following options: Regular Extra Strong Dial required if seat to back angle is >105 53 53 pan mounting
wood mounting You may select to wood mount your ContourU system. A 3/8 thick piece of plywood is custom cut to the size of the cushion. The wood is then applied to the foam before the vacuum-forming process. A piece of ABS is placed over the wood so that the cushion will have a finished appearance. The wood will or will not have T-nuts depending upon your selection on the order form. 54 Wood mount with T-nuts is available to make it easier to attach and adjust interfacing hardware and accessories. T-nuts are located to ( 1 5/8 and 2 5/8 from finished edge of cushion to allow flush mounting of the cushions using our HWWMK01 and MWWMK78 hardware kits. To mount between or in front of the canes/rails using any of our OCMK options, the T-Nuts are positioned 1 and 2 from the finished edge. Our wood mounts are available in heights/lengths/widths ranging from 10-24. If you are using the wood mount with cross brace notches to be used as a drop base, 20 is the maximum width available. If you require widths of 21-24 the wood mount is only available flush mount to seat rails. 54 wood mounting If you would like any modification to the pre-drilled T-nut pattern on the wood mount, you MUST note this in the special instructions on the order form and use the line drawing (Appendix b) to indicate your modifications. Feel free to make copies of this drawing for future use. If you choose to use your own wood, you can supply the wood to us in the size/ shape needed and we will apply it to the foam during the vacuum forming process. 1/16 ABS 3/8 plywood
untrimmed An untrimmed cushion is made with at least 4 of extra vinyl or cloth material extending out from the edges of the cushion. This allows you to use your own substrate for interfacing and to upholster the back side of a cushion in any manner you choose. We cannot make a naked cushion untrimmed. 55 55 LATERAL REINFORCEMENTS untrimmed
upholstered bottom We can upholster the back of a cushion to make it more durable. The upholstered bottom can be manufactured with or without Velcro. With the Velcro option we will sew 2 strips of Velcro loop to the upholstered bottom of the cushion. This option is convenient when the mobility base comes with seat upholstery and you want to ensure that the cushion stays in place, or when mounting to drop seats, car seats or strollers. You do not need to purchase mounting hardware with this option. 56 56 upholstered bottom upholstered bottom with Velcro
custom fit We can manufacture your cushion to attach to a contoured seat pan or back shell. The cushion will be molded to fit the pan or shell, and will be supplied with an upholstered back with Velcro for attachment purposes. To order, you will be required to send us the pan or shell so that we can match the contours. The shell will then be returned to you with your cushions. Note If ordering with a Tarsys shell, you will only need to supply us with the width and height/length and whether it is for a 1 st or 2 nd generation. (You do not need to supply us with a shell if it is 2 nd generation.) Please be sure to order the shell on your mobility base order form. 57 57 custom fit