DESIGN TECHNOLOGY PRODUCT DESIGN

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2Product Design and Analysis

IntroductionThe product I have chosen to work on is the Koolpak Instant Ice Pack (Figure 1), used to treat soft tissue injuries and to reduce pain and swelling. I have chosen this because I often find weaknesses when working with them as a first aider with St John Ambulancefor 6 years, and believe that it can be improved in order to increase its effectiveness.

FunctionThe primary function of the instant ice pack is to act as a form of medical treatment for soft tissue injuries or as a cold-compress. It is a one-use pack that becomes instantly cold to alleviate pain from minor injuries, they are a convenient direct replacement for crushed ice used as first aid. The instant ice pack use an endothermic reaction between water and urea to cool down quickly. They can be stored at room temperature, without needing to be cooled before use. It can also remain at 0˚C for up to 40 minutes which is generally enough time for the pain from an injury to begin to subside.

SafetyThere are numerous safety concerns when using and storing the instant ice pack; the major safety concern is regarding the contents of the pack. If the pack is punctured or opened the contents are extremely toxic if ingested, therefore causing the person/s to require immediate medical treatment. The chemicals used in the pack are however regulated by the European Agency for Safety and Health at work, which prevents any use of Ammonium Nitrate (a high explosive if heated) in any packs manufactured in the EU. (See link below)There is also the safety concern that the pack can cause freeze burns if applied directly to skin without any sort of material in-between the pack and the injury, such as a bandage or cloth.

Ergonomics and AnthropometricsThe Koolpak Instant ice pack is rectangular shaped (150 x 160mm) which is easy to hold because it’s size is suited well to an average human hand size. It also makes it is very easy to store indrawers as many can be packed together, this is particularly useful when restocking first aid posts as it makes the process simpler and quicker. However the size of the pack does make it harder to wrap around larger injuries, therefore causing discomfort to the user. The pack is also reasonably light as it may be needed to be carried around inside a first aid pack and therefore must be ergonomic to people of all strengths. The pack is activated by breaking a small internal water pouch inside of it; this sometimes can be difficult as the water pouch must not break accidentally, therefore making the pack useless for when it is needed. Generally people use a method of holding the pack in the palm of one hand, and using the other hand to punch the pack in order to break the pouch. However, this is not in my opinion the most effective, safe and ergonomic way to activate the pack. It is also not the instructed method shown on the pack printed on the reverse. (Figure 2)Generally users will try to apply the pack onto the injury by tucking it into a piece of clothing, however this causes the pack contents to become uneven, as well as making it very uncomfortable for the user as the pack often becomes dislodged easily and so usually falls out.

MaterialsThe outside packet of the pack is made from polyethylene, the most common plastic, this plastic is used because it is reasonably cheap to manufacture, it is also easy to manipulate and move around. This is useful when applying the pack to a curved injury. The contents of the pack include urea and an internal water pouch.

PackagingThe packs are shipped in boxes of 25, however there is very little packaging for the packs because they do not require it, this being said the packs are more susceptible to damaging if they are not packaged. The Koolpak logo is printed on the front of the pack,with the safety instructions and contents printed on the front and back.

CostSt John Ambulance - £0.40 (Single)

- £9.50 (25 pcs)Medisave - £0.50 (Single)

WeaknessesI have found several key weaknesses that the Koolpak Instant Ice Pack has: 1. The small rectangular shape, although being very

useful for carrying in personal first aid kits and storing many into drawers, is flawed as it is too small to be able to wrap evenly around injuries on the body. The rectangular pack is also not the best shape for curved body parts, this makes the coverage of the icepack over the injury incomplete and therefore decreases its effectiveness.

2. The pack has no ability of being able to be attached to an injury easily without it moving around and becoming dislodged quickly and often. Therefore users tend to try and tuck the pack into a piece of clothing (as mentioned in Ergonomics and Anthropometrics) which is extremely ineffective as the pack usually falls out repeatedly, creating more hassle for the user.

3. The pack cools to temperature of 0˚C, this however is dangerous because it could cause freeze burns for the user if they do not use any form of fabric material in-between the back and the injury. This is particularly hazardous because soft tissue injuries are more susceptible to freeze burns than healthy skin and tissue.

4. The pack contents often become uneven inside the pack so does not provide a evenly distributed coverage on a soft tissue injury, this can cause ineffective treatment and renders the pack useless as a cold compress.

Figure 2Picture showing the warning

information printed on the front of the pack.

Figure 3Pictures showing the instructed method of activating the pack.

Figure 1The Koolpak Instant Ice Pack

Figure 4Video detailing the

disadvantages of the Koolpak Instant Ice Pack

with a qualified St John Ambulance First Aider.

European Agency for Safety and Health at work EC Regulation 1907/2006

Throughout the presentation, links will be in a turquoise box with a link symbol.

Throughout the presentation, videos will be in an orange

box with a video symbol.

Video

3Manufacturer Needs

Target MarketThe manufacturer’s target market for the Koolpak instant icepack is mainly first aid providers, charities and companies, such as St John Ambulance, The Red Cross and the NHS Ambulance Service. As well as sports clubs, gyms, and personal home use, generally via pharmaceutical commercial outlets, for example Boots and Superdrug. As the ice pack is one-use then the main target market is commercial users because only one person uses the product. This is because commercial users are required by law to use sterile products and not have any cross contamination, which would occur if a multi-use ice pack was used.

LabourBecause of the involvement of toxic chemicals in the product, the ice pack is made using automated machines on a large scale batch production. There is therefore very little human interaction during manufacture only semi-skilled machine operators and therefore very little labour is needed, especially as one operator might be operating multiple machines. However, pre-production labour is greater because of the requirement of laboratory testing and rigorous health and safety checks.

Cost of ProductionThe cost of production, including laboratory testing, is high because of the need for chemicals testing and safety checks, as well as materials cost. The product must also be kept clean throughout the manufacture and transport, this increases the cost of production because extra precautions are carried out to ensure the cleanliness of the ice pack before use.

AssemblyThe ice pack is assembled quickly, the polyethylene outer pack is cut and the sides heat sealed. Then the urea and inner water pouch are inserted inside the outer pack an the top of the pack heat sealed. The pack is air tight and there is no leakage unless punctured. All of the assembly is carried out by

TransportThe transport cost of the ice pack is relatively small, as the product is shippedfrom the UK internally. They are also packed in boxes of 25 (Figure 1) for shipping to the consumer, this allows the manufacturer to transport numerous packs in one container.

Environmental Issues

There are numerous environmental issues associated with the Koolpak Instant Ice Pack, mainly due to the chemicals used inside the pack. The urea is harmful to aquatic organisms as well as being toxic if ingested and an irritant to the eyes and skin. This means that the manufacturer must ensure the safe disposal of the packs where it wont end up being released into the ocean or other aquatic habitats, the urea forms ammonia when it reacts which can cause fish and other aquatic mammals to die (Figure 2). The manufacturer must also ensure that the outer pack isstrong enough that it wont burst accidentally, releasing harmful chemicals into the environment.The outer pack is made from polyethylene, which is created using crude oil drilled from the ground. This is using limited fossil fuels and releasing harmful CO₂ into the atmosphere, leading to global warming and the greenhouse effect.

Consumer Needs

CostThe price of the Koolpak instant ice pack varies from different retailers. The St John Ambulance branded ice pack is sold at £9.50 (ex. VAT) for 25 packs, and £0.40 (ex. VAT) for a single pack. From Koolpak the price is more expensive at £0.70 (ex. VAT) each single pack, and from Medisave each single pack is £0.50 (ex. VAT). This is not too expensive for the consumer and allows companies, such as St John Ambulance to buy numerous packs for an inexpensive cost.

MaintenanceThe instant ice pack is one-use and so does not require any maintenance. The pack has an expiry date of roughly 3 years, after which it should not be used and replaced immediately. This is a reasonable life span for the consumer and they are not too expensive to replace.

Ease of UseThe instant ice pack needs to be easily manipulated so that the inner water pouch is broken, allowing the pack to activate and get cold. It also needs to be able to wrap around injuries easily, which is difficult when using the Koolpak Instant Ice Pack.

InstructionsThere are instructions printed on the back of the pack which are relatively simple to follow and are not too small so consumers misread them. The instructions should be easily understood because people who have never used one before should be clearly informed on how to activate the pack, in-case they do need to use one in an emergency.

ErgonomicsThe pack is relatively ergonomic in that it fits in the average persons hand easily and can be activated quickly. However the pack needs to be able to fit to numerous sizes of soft tissue injuries, as well as not being too heavy to hold or carry. The pack should also be comfortable when used because otherwise it can irritate the injury and cause pain to the user.

Safety and StorageThe storage of the instant ice pack is critical to its effectiveness and usefulness. If the ice pack is stored incorrectly during shipping to a consumer then the pack could activate accidentally, and therefore cannot be used again by the user, making the product useless. This means the user has to replace the packs before they can even be used. The pack can however be stored in drawers easily as they can be packed neatly into rows and stacked into columns. This allows the consumer to efficiently store the packs in drawers in a first aid posts, in ambulances and in portable first aid kits.The safety to the consumer is also important because the chemicals inside the pack are toxic and harmful. Therefore the product must not be easily punctured or cut, this would allow the contents to leak out of the pack, posing a safety risk to both consumers and the environment. This health and safety information and warnings should be printed on the pack by law, as well as to inform the consumer on how to safely store and use the pack. This information is printed on the reverse of the pack (Figure 3) in three easily understood diagrams so that anyone can use the pack if needed.

Product AfterlifeAfter the product is used then it cannot be reused for health and infection prevention reasons. Therefore there is a large number of instant ice packs that are disposed of regularly, especially after events where a large number are used such as the London Marathon and other athletics events. However, the ice packs must be disposed of safely because the chemicals inside the pack are hazardous to health and the environment. The consumer must know what kind or disposal method to use and is told on the reverse of the pack.

Figure 2Picture showing

the effects of ammonia in

water.

Product Design and Analysis cont.

Figure 1Picture showing two boxes of

25 packs, one opened and one unopened.

Figure 3Picture showing the instructions on the reverse of the pack.

4Key Criteria

IntroductionIn this section I will discuss the key decisions the designer made when planning and designing the Koolpak Instant Ice Pack.

FunctionThe function of the ice pack the designers thought about the most is the ability for the ice pack to cool down rapidly and to act as a cold compress on soft tissue injuries. The design of the pack revolves around this function and therefore the designers did not make the pack overcomplicated but focussed on making it a simple replacement for slow liquid ice packs that have to be kept in a freezer until needed.

MaintenanceThe product has no maintenance needs as it is one use, however the product must be replaced if not activated before its expiration, this is roughly 3 years after production and assembly. The designers did not make this a planned obsolesce of the ice pack however, but were forced to make this life span because the pack can become hazardous if used after the chemicals are not activated after a few year.

StorageThe ice pack is designed to be easily stored in drawers and first aid kits as it both small and compact, this is only limited by the packs ability to withstand being activated accidentally. This decision of making the pack small was made for storage convenience rather than practicality when being used, this is evident when trying to wrap the pack around an injury.

ErgonomicsThe designers thought more about the portability of the product rather than the ability for the pack to wrap around injuries. The pack is however small enough to be easily held in one hand and not too difficult to activate for an average person.

AssemblyThere are 3 main components of the ice pack, the polyethylene outer pack, the Urea contents and the water inner pouch. Firstly the contents and inner pouch are prepared, then the outer pack is assembled by heat sealing and folding into a pack using automated machines. The assembly process is carried out using automated machines operated by a semi-skilled workforce, possibly operating numerous machines.MaterialsThe materials, polyethylene, urea and water, were chosen primarily so that the pack would chemically achieve the reaction needed for the pack to cool rapidly. However the designers had to compromise as the contents of the pack are toxic and harmful to the environment, although this is unavoidable when trying to make an instant ice pack because toxic chemicals are the only option. The designers would have also spent time working with laboratory chemists to find the correct proportions of chemicals to use in the pack so the pack does not become too cold or not remain cold for long enough.

WeightThe designers thought about the weight very carefully and decided that lightweight was a better option fro practicality reasons. Weighing 124.91g the ice pack is light enough to carry in a portable first aid kit which makes is much more user friendly and useful to first aiders and ambulance workers. It is also not too heavy so people can have it attached to them in a pouch or holder without it weighing them down.

SafetyThe product has several safety concerns that could be avoided, firstly the pack must not be punctured or opened however the pack can be easily broken because of the outer pack is made of thin plastic which isn't very strong. When designing the product the designers evidently thought more about the ability for the pack to bend and curve rather than the strength of the plastic and whether

it can withstand being punctured.

CompetitionThe Koolpak Ice Pack has competition from many other ice pack manufacturers, the designers however designed the pack primarily for St John Ambulance as it is branded with both companies. St John Ambulance then supply to their own first aiders as well as other companies and consumers. This is also the reason why the price of the pack is relatively cheap compared to some other ice packs.

Quality Testing and SafetyThe product must be tested thoroughly and have adequate safety checks because of the involvement of toxic chemicals in the pack, the designers would have had to tested the chemicals in the laboratory pre-production to investigate the correct ratio of chemicals, they also had to design the outer pack so that it would not leak the chemicals easily.Demonstration of the Product

On the reverse of the pack are three diagrams showing how the product should be activated and used, however many users find that this is not the easiest way to use. For example, some users tend to punch the ice pack to pop the inner water pouch and activate the product. This can be dangerous and it is easy to break the pack, therefore releasing the inner toxic chemicals.

Product Design and Analysis cont.

Figure 2Video

demonstrating how the Koolpak Instant

Ice Pack is used by a qualified First Aider.

Figure 1Picture showing the instructions and diagrams for use printed on the reverse of the pack.

Video

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Figure 3 (Left)Picture showing the Spencer Instant Ice Pack

Figure 4 Picture showing the Spencer Instant Ice Pack compared to the Koolpak Instant Ice Pack

Strengths and Weaknesses ComparisonIntroductionIn this section I will compare the Koolpak Instant Ice Pack ice pack with other similar and related products to investigate the strengths and weaknesses of the ice pack and to find common mistakes other designers have made so that I can avoid them.

My ProductKoolpak Instant Ice Pack (Figure 1)

FunctionThe pack cools instantly when

activated and acts as a cold compress fairly efficiently. It quickly relieves pain and swelling of soft tissue injuries and is a convenient replacement for crushed ice or gel packs that have to be frozen and kept in freezers.

The pack is also very useful in that it does not need to be cooled before use and can be kept at

room temperature. The pack gets too cold when activated and

can cause freeze burns on soft tissue, this makes the product dangerous to use without material between the pack and skin.The pack is also difficult to wrap around injuries on curved areas, such as the calf or the elbow as it is too small, and when placed in a holder, it can become dislodged easily.

Suitability of MaterialsThe polyethylene outer pack is made from lightweight, easily to manipulate material that keeps the pack sealed and does not rot or decompose when left out. It also is easy to print instructions and information onto the outer pack.The outer pack’s material is however too thin so can be easily punctured, therefore posing a safety concern as the products are toxic and harmful. Because the chemicals also become too cold, the outer pack does not insulate the chemicals, therefore increasing the

temperature slightly, and so the pack would be able to be applied directly to the injury.

IngredientsThe chemicals inside the pack are useful because they allow the pack to function as an instant ice pack. This therefore means that the chemicals must be used in the pack and cannot be substituted.There are some limitations however because of the toxicity of the chemicals and their affect on the environment, especially aquatic life and habitats.

Manufacturing ProcessThe manufacturing process is quick and simple, without complicated processes, the pack therefore can be easily manufactured my a small workforce operating multiple machines to make the process more effective.The only negative of the manufacturing process is the time needed during pre-production in chemistry laboratories to test the chemicals, however once this is complete it does not need to be repeated.

Ergonomic SuitabilityThe pack is small so it is convenient to carry around in first aid kits and hold in one hand, it is also suitable for small soft tissue injuries. The pack has difficulty wrapping around large injuries as well as on curved skin. It is alsodangerous to use without a wrap or towel to cover the pack in order to prevent freeze burns.

AestheticsThe aesthetics of the ice pack are clear and crisp, they are clinical and clean, this is evident in the reason why the pack is predominately white so that it can show up any dirt on it easily.

CostThe ice pack is inexpensive at £0.40 each and £9.50 for 25 which is convenient for large consumers such as First Aid providers or Physiotherapists.Similar ProductsPrimary Research - Spencer Instant Ice Pack (Figure 3)

FunctionThe pack acts efficiently as a cold compress and to relieve pain and swelling of soft tissue injuries. It therefore replaces the need for crushed ice. The pack gets too cold similarly to the Koolpak potentially causing freeze burns. The pack still has difficulty wrapping round large injuries however. It can also activate accidentally without human interaction.

Suitability of MaterialsThe outer pack is easy to manipulate and is flexible, it also has a large volume for the contents. The outer pack also is sealed and does not decompose during its lifespan.The pack is easy to puncture and open letting the toxic contents out of the pack which is dangerous. It is also too thin so does not insulate the pack enough, adding to the potential risk of freeze burns.

IngredientsThe pack functions because of the chemicals reaction that takes place using the ingredients, this allows the pack to become cold instantly.The inner chemicals are extremely toxic, they are a mixture of nitrogenous salts that, when released into aquatic areas, such as rivers ad lakes, can devastate fish and other aquatic wildlife.

Manufacturing ProcessRequires only small semi-skilled labour to operate computer controlled machines to manufacture the product.Pre-production costs of laboratory work and workforce needed to carry out the experiments. Only required once however.

CONT. ON NEXT SLIDE.

KeyPositiveNegativeComparisonConclusionElements to Carry Forward

Figure 1Picture showing the Koolpak Instant Ice Pack

VideoFigure 2

Video discussing some advantages or the pack

with a First Aider and regular consumer.

6Strengths and Weaknesses Comparison cont.

Ergonomic SuitabilityEasy to hold and carry around in portable first aid kits due to its small size and it being lightweight.Hard to wrap around large injuries and attach to injuries, it is also easily activated accidentally therefore making it useless as it cannot be reused after being activated.

AestheticsThe aesthetics are clinical and simple, the pack is mostly white with the Spencer logo on the front, it therefore can show any defects and dirt easily. The instructions are printed in 4 languages on the reverse.There are no diagrams to explain how to use the ice pack which is generally simpler than worded instructions.

CostInexpensive at £0.60 per pack and £15.00 for 25 packs, it is therefore an acceptable price for consumers to pay.

The Koolpak and Spencer Instant Ice Packs are very similar, however there are a few differences between them. The Spencer Pack is slightly larger than the Koolpak and this therefore helps it wrap around larger injuries slightly better compared to the Koolpak, it is still however difficult to attach to the body without it becoming dislodged easily. The Koolpak has a stronger inner water pouch so doesn’t activate accidentally, therefore increasing its usefulness. Both products are white and it is useful so you can see any imperfections, both during quality control and as a consumer, it is also easy to see any dirt on the pack. The Spencer Ice Pack has its instructions printed is multiple languages, this is more convenient for users who may be different nationalities.

In conclusion I think that, even both products are very similar in both their function and aesthetics and both have their own strengths and weaknesses, the Koolpak is slightly better mainly because is does not activate

accidentally as easily as the Spencer Ice Pack, which is important otherwise it cannot function when needed.Primary Research - Milk & More Gel Ice Pack (Figure 1)

FunctionIt is used as a method to relieve pain and swelling from soft tissue injuries and as a cold-compress. It has the ability to be refrozen and used multiple times.It must be kept in a freezer until used and as it warms up the pack starts to form condensation on the outside of the pack which gets the user’s clothes wet. The pack can also get too cold so may cause freeze burns if used without insulating material.

Suitability of MaterialsThe outer pack keeps the contents in and sealed, it also is easy to move and fold, especially due to the separated pockets. Whilst the pack is frozen then the pack is not easily penetrated, as the gel is solid, however when the gel melts then the pack can be easily punctured letting the gel out.

IngredientsThe gel contents is non-toxic and so is not harmful to the environment or humans, it is also very slow-flowing when liquid so does not spill easily.

Ergonomic SuitabilityThe pack wraps around large injuries easily due to the separated gel pockets. It also can be folded to fit into portable first aid kits and can held by one hand. The pack forms condensation on the outside of the pack that can cause the user to get wet. The gel is also becomes very hard when frozen so is uncomfortable for the user. There is no ability for the pack to be attached to a person as well.

Compared to the Koolpak Instant Ice Pack, the gel pack has more limitations with regards to convenience and storage, however the gel pack is easier to wrap around injuries and fold due to its separate gel pockets.

The Milk and More Ice Pack has been useful is finding one possible way to allow the pack to wrap easily around injuries.Primary Research - Addis Solid Ice Pack (Figure 2)

FunctionUsed primarily in cold bags to keep food cold, but also used as a first aid cold-compress, it can also be frozen many times.It has to be stored in a freezer until used and forms a lot of condensation on the outside of the pack which can get neighbouring products or clothes wet quickly. The pack cools to a very low temperature which can cause freeze burns.

Suitability of MaterialsThe outer pack cannot be easily punctured as it is made of hard plastic, therefore not let any of the contents out.

IngredientsThe contents is made up of non-toxic gel which does not harm the environment and does not spill easily.

Ergonomic SuitabilityThe pack can be easily held in one hand and is small enough to fit in freezers easily.The pack cannot be manipulated so is uncomfortable to use on injuries as it does not morph to the shape of the area being treated. It also has no ability to be attached to anything easily. The pack also becomes very slippery when the condensation forms so it is easily dropped.

The Addis Ice Pack has many weaknesses when being used as a first aid treatment, however the outer pack is much stronger than the Koolpak outer pouch so does not easily puncture, this does mean that the pack cannot be manipulated and is uncomfortable however.

In conclusion the Addis Ice Pack is more suited as a method of keeping foodstuffs cold rather than as a first aid treatment product.

KeyPositiveNegativeComparisonConclusionElements to Carry Forward

Figure 1 Pictures showing the Milk & More Gel Ice Pack

Figure 2 Pictures

showing the Addis Gel Ice

Pack

VideoFigure 3Video detailing the comparison

between the Koolpak Instant Ice Pack, the Gel Ice Pack and the

Solid Ice Pack.

7Strengths and Weaknesses Comparison cont.

Secondary Research - Koolpak Original Instant Ice Pack (Figure 1)FunctionThe pack acts efficiently as a cold compress and to relieve pain and swelling of soft tissue injuries. It can therefore replaces the need for crushed ice as it doesnot need to be kept frozen and activates instantly.The pack gets very cold and can potentially cause freeze burns if applied directly to the Skin

Suitability of MaterialsThe outer pack is made of a inner plastic membrane and a outer fabric-like membrane. This helps the pack avoid condensation on the outside and makes the pack slightly more insulated. It also is difficult to puncture.

IngredientsThe chemicals inside the pack allow the pack to function as an instant ice pack as, when activated, they instantly become very cold.The inner chemicals are very toxic and are extremely harmful to aquatic life as well as humans and other animals, released into the environment increases chemical pollution.

Ergonomic SuitabilityEasy to wrap around injuries as

it is long and easily manipulated it is also coated with a soft material so is comfortable to the user.

Large and heavy so is difficult to fit multiple in a first aid kit, as well as trying to hold with one hand. It has no ability to be able to be attached to a person also.

AestheticsThere are large diagrams showing instructions of use

on the reverse so that anyone can use it.

CostThey are expensive at £3.95 per 2 packs and £34.95 for 20 packs, this is higher than most other instant ice packs.

The Koolpak Original Ice Pack has some important advantages but also some disadvantages. The larger pack allows it to be able to wrap around injuries unlike my product, however it can sometimes be too big for small first aid kits which is an important factor and that my product meets. The outer pack material is very useful at avoiding condensation and making a more comfortable texture for the outer pack, this material is different to the Koolpak Instant Ice Pack which ahs a plastic outer which can get slippery and does not have a comfortable texture. The large diagrams showing instructions for use are also useful, these are similar to my product’s diagrams and are important for demonstrating how to correctly use the pack.

In conclusion the Koolpak Original Ice Pack has some aspects that I will carry forward however there are some features I will be looking to avoid.

Related ProductsPrimary Research - Clasps, Belts and Straps

Rubber Watch Clasp Adjustable and doesn’t move around

when tight. Comfortable and easy to use and take off quickly.

Does not cover all sizes, clasp can break if under too much pressure.

Metal Watch Clasp Strong when attachedClasp easily broken and is difficult to

attach and undo. Only one size.

Pandora Bracelet Clasp StrongDifficult to use and take off, clasp is also

difficult to manufacture. Not adjustable.

Necklace Clasp Easily broken, difficult to do up and it

cannot be adjusted easily.

Bowtie Clasp Easy to undo and attach.Easily becomes loose and breaks.

Belt and Belt Buckle Comfortable on skin, easy to use and

take off and adjustable to an extentWorn out quickly and clasp may break.

Side Release Clip Belt Easy to use quickly and can

withstand a lot of pressure and still be able to be released. Adjustable to any length with little difficulty.

Very difficult to fix if it breaks, generally bulky and easy to catch fingers in mechanism.

Elasticated Adjustable Strap Adjustable and elasticated. Easy to put on

and take off, doesn’t rip or break easily. One size fits all.

Can become loose easily.

Backpack Strap Adjustable and also easy to adjust,

doesn’t become loose easily and mechanism strong and sturdy.

Can become difficult to undo when very tight.

KeyPositiveNegativeComparisonConclusionElements to Carry Forward

Figure 1 Picture showing the

Koolpak Original Instant Ice Pack

Video

Figure 2 YouTube Video demonstrating the Koolpak Original Instant Ice Pack

8Strengths and Weaknesses Comparison cont.

Slap on StrapEasy to use, very quick to put on and take

off. Doesn’t become loose easily and durable, it also fits to any size.

Can be dangerous if used incorrectly.

Slap on Scuba Goggles(Secondary Research)One size fits all and easy to put on and take

off. Doesn’t become loose and is durable.May cause a minor injury if used

incorrectly.

Slap on Watch StrapFits to any size, doesn’t become loose and

comfortable to wear. It is very durable and does not break easily.

Velcro Hi-Vis StrapEasy to attach and take off, adjustable

and is strong, reusable and durable.Sometimes uncomfortable if worn

incorrectly.

Shoe Velcro StrapSecure, easy to use and undo. Adjustable

and durable.May become loose if not secured correctly.

Blood Pressure Cuff StrapLarge Velcro Strap to fit to most sizes of

arms and legs, Very secure and does not become loose quickly or easily. Comfortable and easy to

use.Sometimes too difficult to take off as there is

a lot of Velcro to secure it in place.

Leg Wii Remote Holder StrapErgonomically designed to fit

comfortably around the leg.Easy to use and simple to put on and off.

Holds remote securely and easy to adjust

Heat Transfer and Ergonomic MaterialsHot Water BottleDurable and does not break, can be

manipulated and has non-slip properties.Insulates too much, very heavy and large. Synthetic rubber not easily

manufactured and disposed of.

Hot Water Bottle CoverSoft on skin and insulates well,

elasticated and can fit around most objects. Does not become loose or move around also.

Becomes dirty and can soak up fluids easily which is a health risk.

Memory FoamSoft and very comfortable. Moulds to the

body shape and keeps its shape easily. Too insulating so would not keep the pack

too warm.

Neoprene (Wetsuit Material)Comfortable, water resistant and durable.Maybe too insulating if too thick.

Conclusion

From my research I have investigated many different products similar and related to the Koolpak pack and its weaknesses.

Positives to Carry Forward I have found that I need to look at the size of the

pack and that a slightly larger pack will be useful to wrap around injuries, I have also discovered that using separated pockets of chemicals is useful in folding and wrapping and means the pack can fit into smaller places.

I have also looked at the aesthetics of similar products, this has indicated to me that keeping the product predominately white is a good idea as it looks more clinical and clean, it is also easier to print instructions onto white. Diagrams are an important method of instructing people on how to use the pack, it is also useful to have the important information in multiple languages.

The material and texture of the product is important because it must be comfortable for the consumer to use, it also must not limit the packs function of acting as an ice pack. The material can also be used to insulate the pack so that it cannot cause freeze burns. The hot water bottle cover is an example of a good insulating material that wont inhibit the packs function, thin memory foam may also be an option as it is very comfortable for the user.

From looking at different clasps, straps and belts, I have found several different methods of attaching the pack to an injury to investigate further and test. An elasticated strap is useful as it can fit to any size, the slap on straps are quick to use and are fairly strong and don’t become loose easily, also I think that the use of Velcro is important as it is very strong but is also easy to use and take off. The main factor of the strap is that it must be adjustable and easy to put on and take off, this why I have chosen these elements to carry forward.

Negatives to Dismiss I would like to dismiss any elements that would

mean that the pack would not be able to be lightweight and portable, such as making the pack too big, or using heavy materials.

I am also dismissing elements that would mean the pack would not function efficiently as an ice pack, such as using thick material for the outer pack or ineffective clasps for the straps.

KeyPositiveNegativeComparisonConclusionElements to Carry Forward

9Introduction

In this section I will research and highlight the moral implications the Koolpak Instant Ice Pack has and the areas that compromises have been made in when designing and manufacturing the product.

Environmental IssuesSource of Raw materialsThe Koolpak Instant Ice Pack has three main materials, Polyethylene for the outer pack and inner water pouch, Urea for the inner chemicals and Water for the inner water pouch.

PolyethylenePolyethylene is the most common plastic, produced mainly in the USA, and its constituent raw material is generally petroleum or natural gas, it is used to make plastic bags, packaging and bottles. Roughly 90 million barrels of petroleum are used globally each day, this use of non-renewable fossil fuels have a negative impact on the Earth’s atmosphere, resulting in the Greenhouse Effect and Global Warming caused by pollutants. By far the largest producer of crude oil, the component that makes up petroleum, is the Middle East, producing in 2010 roughly 23 million barrels per day, followed by Russia and North America (Figure 1). The impact of drilling so greatly has devastating effects on the environment, firstly by using precious non-renewable fossil fuels and the releasing of harmful gas pollutants, but also the visual and noise pollution associated with the drilling of oil.

UreaUrea is produced on an industrial scale, in 2012, worldwide production was approximately 184 million tonnes. Urea is generally made from ammonia and carbon dioxide (Figure 2), however as large quantities of CO2 are produced in ammonia production, the urea production plant is usually situated directly next to the ammonia plant. Therefore Urea production is in fact fairly environmentally friendly as it uses up potentially harmful greenhouses gases.The main producers of Urea worldwide are China, followedby India, Russia andthe USA, however Only a small percen-tage goes to instantice pack manufacture, over 80% is used as fertilisers for agricultural crops.

WaterThe water used in the Instant Ice Pack is purified water collected from rain and river water. It is readily available and is renewable, especially in developed countries where the pack is manufactured. The water used for manufacture is collected from the UK

ProductionProduction of the Ice Pack is in the UK by Koolpak Ltd.

however as seen explained earlier, the majority of the raw materials are sourced globally. Each of the raw materials also goes through extensive production lines to prepare it for transport and final manufacture, this required a lot of energy to power the factories which is generated from burning fossil fuels, releasing harmful gases which can cause global warming and/or acid rain.

TransportThere is a lot of transport of materials required in the production of the Ice Pack, this is because many different materials are used to manufacture it which are produced in different areas of the world (Figure 4). Therefore the environmental impact of transporting raw materials to the UK for final manufacture, including transporting the Crude Oil from the middle east to the USA, is very dramatic. Fossil fuels, generating harmful greenhouse gases, are used when vehicles either fly or ship the raw materials to their destination. And once the product is manufactured, more transport is needed to move is to the warehouses, then to dispatch it to the customers. Therefore, with every part of transportation, greenhouse gases are released which damage the environment, as well as the impact of wildlife and habitats when the roads, needed for the vehicles, were built.

Disposal of MaterialsThe product can be discarded in regular household waste, however the impact of this on the environment is extremely damaging. Thousands of packs are disposed of every year onto landfill sites, therefore releasing vast volumes of Urea into the environment, if this Urea happens to end up in rivers or lakes then

it can harm aquatic life and habitats.

The polyethylene outer pack is not bio-degradable and therefore poses a

risk to wildlife when disposed of, it also takes a very long time to break down so will take up

valuable landfill space.

CONT. ON NEXT SLIDE.

Moral Implications

Figure 1Map showing world crude oil production

1980-2010

Figure 2Flow diagram

showing the manufacturing

of Urea

Figure 3Picture showing a Urea factory connected to a

Ammonia factory

Urea Factory

Ammonia Factory

Crude Oil -

Urea -Water -

Polyethylene -

Figure 4Map showing the

sources, transportation and production

of the materials used in the

Instant Ice Pack

10Environmental Ethical DebateOverall the impact of the Koolpak Instant Ice Pack, including manufacture, materials, and disposal, on the environment is large. The materials used are non-renewable and require a vast amount of energy to produce, increasing the amount of greenhouse gases released into the atmosphere. However, these effects are caused by choices the manufacturers made when designing the product and planning its production, and can therefore be decreased by different methods. For example, the raw materials for the pack are sourced from around the world, this causes the impact from transporting the materials to increase, although making the production easier as the materials are sourced from areas with abundant supplies of that resource. So, in order to decrease some of the impact of transporting materials around the world before final manufacture of the product, the raw materials could be sourced locally where possible so that the transport cost between production and final manufacture is smaller, decreasing the use of valuable fossil fuels and impact on global warming. The choice of placing the Urea factory directly next to the Ammonia factory is very important, although not the manufacturers choice entirely. This is because the waste CO₂ from producing Ammonia is fed directly into the Urea factory, therefore avoiding possibly dramatic consequences of releasing harmful pollutants into the atmosphere. In my opinion this was a very wise choice of the Urea manufacturers and is fairly environmentally friendly.One other possible way to decrease the environmental impact of the Ice Pack is to change the polyethylene outer pack for a biodegradable form of plastic, this would reduce the impact when disposing of the product, however there are some disadvantages to this. Firstly, biodegradable plastic is difficult to manufacture and more expensive than regular polyethylene, it is also not as easy to manipulate and bend unless it is very thin which would cause the pack to be easily punctured. Another main reason for not using biodegradable plastic is that when the outer pack breaks down in the landfill site, it will allow the toxic chemicals to be released into the environment much quicker are easier, this could have a far more detrimental effect on the environment than if the polyethylene pack is used.In conclusion, the manufacturer has done a reasonable amount to lessen the environmental implications of producing the Koolpak Instant Ice Pack, for example using Urea that has only been produced directly next to a Ammonia factory, however there are some changes that

could be made to reduce its impact.Social IssuesSafetyThe are various safety issues associated with the Instant Ice Pack both during manufacture and for the consumer. For example, as a consumer, the pack can cause freeze burns if applied directly to an injury, this is due to the outer pack material being too thin so does not insulate the pack enough. The pack is also easily punctured or cut which can release the toxic and harmful chemicals into the environment where they could harm users, animals or plants.The manufacturers safety is also important, the main safety issue when manufacturing the pack is that Urea (Figure 1) can be made into a high explosive is produced incorrectly, therefore special precautions are made to reduce the risk of this happening so that no workers are put at risk when in the factory. The factory also has to have higher security than most other factories to prevent any form of attack from an outside party trying to create their own improvised explosive devices. As well as Urea being a possible explosive, it can also be harmful to humans if ingested and can irritate the skin, eyes and mouth, therefore workers are required to wear the appropriate safety equipment when dealing with the chemicals. However, this is mainly the case during pre-production testing in laboratories, carried out by scientists, and during the production of urea, not during manufacture of the pack itself because most of the procedures are carried out by automated machines, precautions are still carried out in the event of a spillage for example.

Low wage and working conditionsIn some countries there are extreme cases of poor working conditions for workers, especially in factories and manufacturing plants, the most well known example of this are Chinese sweatshops. However this happens around the world, in December 2013 The Guardian published an article about poor working conditions and wages in Cambodia’s garment factories (See below). The factory owners claim that they do not have the power to increase the wage of their workers, nor their working conditions, however the companies investing in the garment factories only pay the factories for their services, so change is possible however as quoted from Khmom, the focus of the article, “One cannot break a stone with an egg.”

However, the Koolpak Instant Ice Pack is made in the UK therefore, working conditions and wages are subject to government jurisdiction and so are much better for workers and benefit both the manufacturer and the worker.

Effects of ManufacturingCompanies often get the raw materials needed for their products by extracting them from countries leaving very little infrastructure for the community. They will use up the resources of the area, possibly employing a workforce from the country, and once extraction is complete, they leave however, this causes devastating effects on the community and society. Some companies are trying to be more sustainable when manufacturing, for example Nestlé. Every year Nestlé aim to improve the areas where they get their raw materials from they try and improve literacy of children, teaching them good nutrition and life skills, they also try to improve human rights and development in poorer countries.

Social Ethical DebateIn my opinion, companies should give more back to countries where they get their raw material using schemes that are proven to work, such as that of Nestlé. This helps build communities and society and helps sustainable growth in developing countries and communities. In relation to my product, Koolpak aim to help raise awareness on first aid, especially around sports injuries, so that people know how to treat soft tissue injuries quickly and safely. They do this by including detailed first aid guides with their packs, detailing techniques such as R.I.C.E and the recovery position. This helps society in preventing possibly devastating injuries and reducing the risk of deaths that could be prevented. The safety of both the consumer and manufacturer is very important to society, the product will not be allowed to be used if it is unsafe and causes harm to the user, nor will consumers buy the product if the manufacturer has a poor record of keeping its workers safe whilst the product is being manufactured. Therefore all the specific safety regulations that are carried out, such as wearing correct safety clothing, are put in place for a reason so that no-one is harmed during manufacturing, therefore society benefits as possibly more people would work in the factories because it is a safer working environment.

Moral Implications cont.Figure 1

Picture showing granulated Urea

The Guardian Article - Cambodia Garment Case Study

11Economic ImplicationsEmploymentThe various jobs required for manufacture of the Ice Pack has a great effect of the community and economic growth, it creates more job opportunities for workers which reduces unemployment rates. It can also lead to new skills being taught and learnt by the community, this allows society to develop individually without constant economic support from governments or external providers. A good example of this is Nestlé’s involvement of youth in the UK to try and encourage employment for youths, targeted at both other companies and unemployed youth (Figure 1).The strategy uses apprenticeships, work experience and graduate schemes to encourage greater employment so that economic growth is possible and to decrease the demand for specialised professions, such as engineers. These concepts can be translated for use by numerous different companies, such as Koolpak, therefore opening the market for employment globally.

Obtaining Raw Materials and ManufacturingThe cost of obtaining the raw materials needed to make my product varies greatly, for example, the cost of crude oil can differ depending on global oil prices and shares, however the cost of the water needed for each pack is fairly constant and is very easy to obtain. Polyethylene is one of the cheapest plastics to manufacture, hence its popularity, but often the cost of transporting the materials in and out of the factories is greater than the manufacturing cost, increasing the cost on the customer wanting to purchase the material, this then causes the product to increase in price which may deter potential consumers from purchasing that particular Instant Ice Pack.The main economic implication of manufacturing are the wages of the workers in the factory, and as

the majority of jobs are machine operators there are fewer workers needed to manufacture the product, therefore decreasing total expenditure on workers.

Value for MoneyAs the pack is one use only, it must be moderately inexpensive so that consumers can buy multiple packs for a fair price. Therefore

Moral Implications cont.the cost of production should be small so that a profit is made with each sale and the manufacturer will not go into debt, this would have large economic implications including job losses, wasted time and money.

Economic Ethical DebateThere are numerous economic advantages and disadvantages related to manufacturing, for example, new jobs are created when starting a new manufacturing line, this increases the skill set of the community so that they can then go on to get new, higher paying jobs elsewhere in society. This benefits the economic development of both communities and countries so that future generations can live better, more improved lives.

Sustainability Strength

/ Durabilit

y

Safety

Manufacturing

Transport

Recyclability

Cost of Producti

on

Ergonomics

Eco-Design Web Introduction In this section I will outline the key improvements I will make compared to my

product before any changes, this is shown in a web diagram below. Before improvements -

After improvements -

Poor -

Inadequate -

Satisfactory -

Good -

Excellent -

Moral Implications Sourceshttp://www.essentialchemicalindustry.org/chemicals/urea.htmlhttp://www.essentialchemicalindustry.org/polymers/polyethene.htmlhttp://www.theguardian.com/global-development/2013/dec/16/cambodia-garment-workers-low-wages-poor-conditionshttp://www.nestle.com/asset-library/documents/library/documents/corporate_social_responsibility/nestle-csv-summary-report-2013-en.pdfhttp://www.bbc.co.uk/news/business-24954692

The product must be economical to produce, this does mean however that some wages of workers are smaller than they should, and exploitation of mass workers is used in countries with very low or no minimum wages.

I will heavily improve the ergonomics on

my product, creating a easily adjustable and attachable ice

pack with a large surface coverage

over injuries.

I will try to slightly decrease the cost of production to

make the pack have more value for money.

I will make the pack more sustainable by using more

environmentally friendly materials that can be recycled.

I will improve the strength and durability of the pack, especially so that the pack is more difficult to puncture.

I will greatly improve the safety of the pack, decreasing likelihood of freeze burns, preventing puncturing and overall product safety.

The manufacturing process may be improved slightly, possibly by sourcing local materials to decrease transportation impacts on the environment and cost.Transport impacts will be decreased by

sourcing local materials with fewer air miles.

I will use materials that can be recycled, however the

inner chemicals will still remain toxic and may harm

the environment.

VideoFigure 1

Video showing a BBC news

report about Nestlé youth

employment strategies

12Design Brief

I have conducted research into my product, its manufacture and its company. As well as conducted comparisons between the Koolpak Instant Ice Pack and 4 other similar products on the market currently. Through this I identified different strengths and weaknesses with my product, these are shown below as a reminder. With my improved design I aim to improve several weaknesses and avoid common mistakes made with other instant ice packs by different manufacturers. For example, the causation of freeze burns by many instant ice packs, the inability for the pack to wrap around injuries and wounds and the uneven nature of the contents of the pack leading to an irregular coverage over an injury.

Reminder of Weaknesses1. The small rectangular shape, although being

very useful for carrying in personal first aid kits and storing many into drawers, is flawed as it is too small to be able to wrap evenly around injuries on the body. The rectangular pack is also not the best shape for curved body parts, this makes the coverage of the icepack over the injury incomplete and therefore decreases its effectiveness.

2. The pack has no ability of being able to be attached to an injury easily without it moving around and becoming dislodged quickly and often. Therefore users tend to try and tuck the pack into a piece of clothing (as mentioned in Ergonomics and Anthropometrics) which is extremely ineffective as the pack usually falls out repeatedly, creating more hassle for the user.

3. The pack cools to temperature of 0˚C, this however is dangerous because it could cause freeze burns for the user if they do not use any form of fabric material in-between the back and the injury. This is particularly hazardous because soft tissue injuries are more susceptible to

freeze burns than healthy skin and tissue. 4. The pack contents often become uneven inside

the pack so does not provide a evenly distributed coverage on a soft tissue injury, this can cause ineffective treatment and renders the pack useless as a cold compress.

In order to develop my ideas further and improve the weaknesses of my product I will sketch, design, model and test multiple ideas and get feedback on them from professionals.

Brief and Specifications for Improving the ProductKeyFunction, Infection Prevention and Control, Safety, Ergonomics, Materials, Storage, Technical Details, Aesthetics, Comfort, AfterlifeSpecificationsFunctionF1 - My product must cool down instantly when activated so that treatment is rapid in the even of an emergency.F2 - My product must act as a cold compress to treat soft tissue injuries effectivelyInfection Prevention and ControlIPC1 - My product must be hygienic as it is used for clinical treatment so it should not easily spread diseaseIPC2 - My product must be easy to clean so that in the event of it becoming dirty, it is can be wiped down with anti-bacterial wipesSafetyS1 - My product must not harm the user when being used so that additional injury is not causedS2 - My product should withstand being punctured to a degree so that the inner toxic chemicals are harder to release and cause harm to the user and environmentS3 - My product must no cause freeze burns if directly applied to skin as this is extremely dangerous and painfulErgonomicsE1 - My product must be able to fit around the majority of soft tissue injuries on the body and provide an even coverage over the injury E2 - My product must be able to attach round an injury so that it does not move easily but can be attached and taken off quickly and easily in an emergencyMaterialsM1 - The inner contents must include a water pouch and Urea chemicals as this causes the pack to cool down instantlyM2 - My product must have an adequate outer material so that the pack can function as a cold compress, but it must insulate the pack enough so that it will not cause freeze burs if directly applied to the skinM3 - My product should use reasonably sustainable resources that are readily available and can be locally sourced without global shipping neededStorageSt1 - My product must be able to be packed into drawers and cupboards easily so that they can be stored at first aid posts and in ambulances easilySt2 - My product must be able to be packed into a small portable first aid kits and carried around by first aiders and sports physiotherapists easily without any difficultyTechnical DetailsT1 - My product must not be too large so that it cannot be used by a single person easily, however it must also be able to cover a wide range of soft tissue injury sizes with easeT2 - My product must be small enough and lightweight so that it can be carried in a portable first aid kit for long periods of time, or attached to a person during treatment. The size must not be greater than 250mmx150mm due to sizes of portable first aid kitsAestheticsA1 - My product must look clean and clinical so that dirt, or any imperfections, can be easily seen on the packA2 - My product must have the safety instructions printed somewhere which are easily readable and understandable, the ingredients must also be printed on the pack by lawA3 - My product should have the appropriate branding for whichever service provider and/or consumer it is being sold to if requiredComfort C1 - My product should be comfortable to the user when being used and must not worsen an injury that it is treatingAfterlifeAf1 - My product should be easily disposed of and not harm the environment more than is necessary, it should also have clear instructions of disposal

13Development of Improvement

Introduction

In this section I will focus on improving my product in the 4 areas where my weaknesses are and develop ideas from my previous research. I will carry this out by sketching, modelling, and gaining feedback from various ideas I will have.

Key

Ideas will be labelled as follows: 1.1, 1.2, 2.1, 3.1 etc. The first number refers to the weakness

number (1, 2, 3 or 4) The second number/s refer to the idea

numberIdeas to take forward

Ideas to dismiss

Development

Function, Infection Prevention and Control, Safety, Ergonomics, Materials, Storage, Technical Details, Aesthetics, Comfort, Afterlife

Weakness 1

Figure 1Images showing a paper model of idea 1.1 including a simple test to see how easily it wraps around an arm.

1.1.1

1.1.2

1.1.3

My first weakness corresponds to the shape of the ice pack and its ability to wrap around the body. The original pack was small and rectangular so I decided to alter the shape into a simple rectangle. This provides a larger surface area on the body that the pack can treat and allows the pack to have some more flexibility so that it can be wrapped round the body. This does however pose some other problems, it will not hold the contents evenly which is a major problem, it will take up more space in first aid kits and will use a lot more material which will increase production cost dramatically. I will therefore not be taking this exact idea forward.

This rectangular shape can be adapted however in order to make it more aesthetically pleasing and ergonomically suitable. For example in 1.1.2 I have altered the middle section to allow the pack to wrap more comfortably around an injury. In 1.1.3 I curved the cuts from 1.1.2 which allowed more manuvarabilty when I tested it with a simple paper model.

These models do have wastage of material that cannot be reused, however idea 1.1.3 will be developed further in the following slides.

To create more realistic models for idea 1.1, I first used a acetate border to give the pack the rectangular shape, then laminated thin fabric filled with foam to represent the outer pack and chemical contents. This model (Figure 3) worked well to represent the pack however, the contents were not able to move around so did not show how the pack’s coverage could become uneven.The new developed model used rice for the contents, this represented the inner chemicals well and moved around easily. I also removed the acetate and sewed the fabric together, this created a more flexible model.

1.1.1 cont.

Figure 3 (Below)2 Developed models for idea 1.1.1. The second 3 pictures are of a fabric pack using rice as the contents. This showed that the pack would be very flexible but the contents would not stay even inside the pack.

Figure 2 (Left)Initial

developed model for

idea 1.1

14Development of Improvement cont.

1.2 1.3

In a more accurate model I found that the contents of the pack often became uneven and could not get into the thin corners, which was also uncomfortable for the user when the pack was used under the elbow and knee. It would also be difficult to manufacture this shape of pack because of the complex shape and wastage when cutting away excess.

1.4

From idea 1.1.3 I have developed the shape of the ice pack back into an originally square shape but with 2 of the sides concave so that it could easily wrap around an arm or leg. When I modelled this with paper, I found that it wrapped around the arm well however it did not provide a large surface area for the pack to cool the injury.

Developing from idea 1.2 I have differed the design to have a convex curve on the outer side as opposed to a concave side.This means that the shape it forms around injuries is very different, when I tested the shape with a paper mode I found it was more comfortable however the large straight edges did not fit comfortably around the elbow and knee.

Function, Infection Prevention and Control, Safety, Ergonomics, Materials, Storage, Technical Details, Aesthetics, Comfort, Afterlife

I decided to sketch slightly different alterations to the initial sketch for 1.3 first by reducing the curve size, this did not aid the pack and was not comfortable. A larger curve provided a better coverage and wrapping ability, however a too large curve reduced the ease of use of the pack and got in the way most of the time.

Idea 1.4 mixes both idea 1.2 and 1.3 to create a fully ergonomic pack that fits comfortably around nearly all injuries, especially places like ankles, knees and elbows where soft tissue injuries are most prone. The pack can also tessellate easily which means that storing the packs is simple and effective as they do not waste any space. By incorporating both ideas into one, the contents can get into the corners of the pack so therefore produces a much more even coverage over an injury.

15Development of Improvement cont.

1.5.2

I began by sketching a basic rectangular design,inspired by idea 1.5.1, separated into tearable segments, I found that the easiest this would be one of the easiest designs to manufacture due to its simplistic shape, and ability to be produced in very long strips to be shipped out. And from talking to two skilled professionals with experience in industry, one of the key components of this design is the inexpensive manufacture and ease of use. I then made two paper models of my initial idea to test out the concept of perforations and tearing ability.

From these models I found that the size of the segments would have to be reasonably large so that they could accommodate a wide variety of injuries, however I also concluded that the perforations would have to be made so that they did not break accidentally if pulled whilst the pack was in use. Otherwise the pack would be ineffective. To find the best type of perforations needed I designed and tested out 3 types, you can see this in the right-hand section.

I decided to test out 3 different types of perforations to allow the pack to be ‘torn’. Firstly by designing the types on 2D design software and by cutting the designs on acetate using a laser cutter. I then tested the three types and asked 3 others to try them and give their feedback. From this I decided to take forward the smaller dashed perforations, (1) and the engraved line, (3).

1.5.1Another solution for the pack to be able to wrap around injuries is by creating a segmented pack, this allows the pack to bend between the segments and wrap easily around a leg or arm. This pack also solves part of my fourth weakness, where the contents become uneven inside the pack, as there are segments, the contents only have one direction they can move in whereas in the original pack they could easily become uneven. This pack is therefore very useful and effective in both its treatment and ergonomics. There are some faults however, the pack has a set length which would cause difficulty for a larger injury or small injury, it also has no means to be attached to the leg (this final fault will be resolved in a different stage of development).

Function, Infection Prevention and Control, Safety, Ergonomics, Materials, Storage, Technical Details, Aesthetics, Comfort, Afterlife

(1) (2) (3)

Figure 1 (Right)

Video analysing Idea

1.5.2

I then used acrylic and polyethylene sheets to create a more durable model that I could test out the durability of the designs and their ability to be wrapped around injuries easily. After using the pack with the engraved line (orange), I found that the segments easily came loose without human interaction, therefore I decided to pick the perforations (green) to take forward further.

(1) (2) (3)

(1) (2) (3)

An alternative idea to solve weakness 1, the size andshape of the pack, is to create a form of ice pack that as the ability to be torn into different shapes and sizes in order to fit numerous sized injuries.

Video

16Development of Improvement cont.

Figure 1 (Left & Above)Sketches and paper models of idea 2.1 with the strap attached to the KoolPak instant ice pack

Weakness 2

Developing from idea 2.1, I found that a detachable strap is an extremely important necessity so that the pack can easily be put on and off in a first aid situation so that it can function efficiently. In idea 2.1.1 I have introduced a very simple slotting strap that includes a small flap that bends upwards, when the strap in inserted, the flap locks it in place, only allowing it to be removed in one direction. I found this design very easy to make and design, it also does not use lots of materials which reduces cost and wastage, which in turn is better for the environment.I will therefore, be taking this idea forward and will look at an in-depth design of it during my final development stages.

Weakness 2 investigates the packs ability to be attached to an injury without it moving or slipping, it must however be easily removed in case of an emergency.I began by sketching different straps and the way they would attach together. Idea 2.1 shows a simple strap that is attached to the pack at both ends, this means that it is neither adjustable nor detachable. I tested this strap and the way it could be taken on and off (Figure 2). Because of this I decided to test different mechanisms for attaching straps together so that the pack could easily be

put on and removed quickly and efficiently.

Function, Infection Prevention and Control, Safety, Ergonomics, Materials, Storage, Technical Details, Aesthetics, Comfort, Afterlife

Figure 2 (Left)Video showing the way to put on the pack using the strap from idea 2.1

2.1

2.2

Figure 3 (Right)

Video discussin

g the flaws of idea 2.1

with a First

Aider

Idea 2.2 uses a slot buckle to attach the straps together. This is a very common clip and is often used for belts and straps on bags and walking clothing, this is mainly because of its simplicity and ease of use. However for my product it would be a waste of material, especially as every pack would have the straps attached to them. It also is not adjustable which is needed for different sized injuries.

Figure 5 (Above & Below)

Sketches and models of idea 2.2 showing how a

person would interact with the clip

2.1.1

Figure 4 (Left &Above)Paper and plastic models of idea 2.1.1

Video

Video

17

A very common type of strap used in numerous products on the market is the velcro strap. I investigated the velcro strap by using different designs of how the velcro would attach and their respective effectiveness and strength. Firstly I sketched 2 different ways of placing the velcro (above) from these sketched I decided that placing the velcro on opposite sides would provide the greatest strength and comfort for the user.My first design uses 2 small pieces of velcro on either end of each strap, they then join. This idea is not very ergonomic as it cannot be adjusted and also comes apart very easily. I then decided that I would have to make the velcro parts larger so that the strap could have multiple sizes.

To make the strap more adjustable and stronger I added 3 velcro parts on each strap, this allowed more difference in the size of strap, as well as reducing the risk of the strap becoming loose under stress and movement (Figure 1). However the pack still could move slightly and had only a specific number of option on sizes.

Because idea 2.3.2 was limited by the number of velcro parts it had, I decided that a fully, or nearly fully, velcro strap would be needed. I designed and modelled 3 different types of this strap, using parts of both idea 2.3.1 and 2.3.2, and tested them to find the best layout for the velcro to be on the strap.

From testing I found that (1) was not strong enough to withstand movement and fell off relatively easily. (2) was very successful in that it did not move when it was shaken, nor did it fall off easily because of the three velcro attachments compared to (1), it could also be taken off easily without the need for two hands. Although (3) was very strong and did not come loose at all (Figure 2) even after vigorous movement, it was more difficult to take off than (2) which means that it is not as effective as a strap.I will therefore be taking forward idea 2.3.3 specifically (3), I will look at how the strap could be made even more adjustable and ergonomic.

Development of Improvement cont.2.3

Function, Infection Prevention and Control, Safety, Ergonomics, Materials, Storage, Technical Details, Aesthetics, Comfort, Afterlife

Figure 1 (Above)Video showing idea 2.3.2 under movement.

2.3.1

2.3.2

2.3.3

(1) (2) (3)

Figure 2 (Above)Video showing idea 2.3.3

(3) under movement.

Video

Video

18

Developing from idea 2.3.3 I have added elastic to the velcro strap so that it has more flexibility and is more ergonomic to the user. It will also mean that varying amounts of pressure can be put onto an injury which is useful for many soft tissue injuries.

By adding the velcro the pack is much more easily attached to a person and allows the pack to have a greater range of sized limbs that it can be attached to. This therefore reduces the cost of manufacture as there only has to be one type of strap made to fit the target population, it also reduces material cost and environmental impact.

My final idea of using velcro and elastic is, by putting one of the velcro patches directly onto the pack, only one strap would be needed which reduces cost and wastage, it would also make the manufacturing process simpler.

Development of Improvement cont.

Figure 3 (Left)Sketches detailing the three versions of the magnetic strapFigure 4 (Above)Sketches showing how the magnetic strap would automatically connect so that the strap would stay in place

2.4.2

2.4.1Similarly to the Velcro straps in idea 2.3, I hare designed and modelled magnetic straps. Using a basis from the Velcro straps I did the same tests on each of the models using magnets and metal parts attached to the straps. I found from these tests that the magnets were not at all strong enough to hold the pack in place, and even when a larger magnet was used (2.5.3) the strap then became too inflexible for it to be ergonomically practical and function correctly.

Function, Infection Prevention and Control, Safety, Ergonomics, Materials, Storage, Technical Details, Aesthetics, Comfort, Afterlife

2.5

Figure 5 (Right)Models of each of

the versions of magnetic strap. In

every model I found that the

magnets were not strong enough to

stay in place. In idea 2.5.3 the strap was not

flexible enough to wrap around the

leg

2.5.1

2.5.2

2.5.3

Figure 2 (Above)Video discussing the magnetic straps and their main flaw

Video

19

well and often slid out of each end. Therefore I began to construct the second drawings from my sketching which included a mechanism to keep the strap in place efficiently whilst still being able to remove the strap if needed. (Next Slide ).

In order to reduce the cost of producing and manufacturing a strap attached to every pack, I decided that it would be more economical and environmental to have a mechanism for attaching the straps to the pack easily, quickly and efficiently, whilst still being able to remove the straps afterwards so that they could be reused if necessary. To begin with I researched into a few different mechanisms for holding straps in place, such as the clips on plastic belt buckles (Figure 2), or the magnetic holding mechanism on the new Apple iWatch (Figure 3).

Using these existing products as a basis for my mechanism, I began to sketch different ways of attaching the strap to the pack, including magnets, clips and slots.

Development of Improvement cont.

Figure 1 (Above)Metal clip belt using 2 sprung clasps to keep the male clip in placeFigure 3 (Below)Apple iWatch magnetic clip to hold the strap in placeVideo showing the mechanism in motion

2.6

I began modelling idea 2.6.3 using the CAD drawing (Figure 6) to cut the parts from acrylic, then by bonding the parts together I had the initial model for a mechanism to attach the strap to the pack. Although as previously planned the male part did not stay in place

Function, Infection Prevention and Control, Safety, Ergonomics, Materials, Storage, Technical Details, Aesthetics, Comfort, Afterlife

2.6.3 cont.

Figure 6 (Left)3D CAD Render of idea 2.6.1 showing the slotting feature

Figure 4 (Above & Right)Sketches of idea 2.6.3 with the slotting mechanism that allows the straps to slide into place on the pack Figure 5 (Below)Idea 2.6.1 with the straps attached to the pack by fitting the straps into their respective slots

Figure 2 (Above)Plastic clip belt using 2 plastic clips on the male part which can be removed by pressing down on the two clips.

2.6.3

Figure 7 (Above)Mechanism for locking the strap in place so that it is attached to the pack, this design is complicated and would require precise manufacture which is especially expensive for one use items. I am therefore dismissing this idea because of its complexity, it would also be difficult to use as the buttons would often become stuck or broken when used

2.6.2

2.6.1

Figure 8 (Left)Magnetic mechanism to keep the strap in place, however this design would not work very well at all because the flexible magnetic strip on the strap would not stay round the hook if it was pulled, therefore I am dismissing this idea early on and dismissing the use of magnets because of the high cost involved and the excess weight they add to the pack

2.6.1

Figure 9 (Above)3D Animation of idea 2.6.3

Video

Video

20Development of Improvement cont.

2.6.4

When I tested the acrylic model of idea 2.6.4 I found that part of the clip broke off as soon as it started to bend upwards, therefore I redesigned the clip (Figure 5).

Developing from idea 2.6.3 I sketched and modelled idea 2.6.4 where a clip would hold the strap in place so that it could not slip out of either end but the strap still being easily detachable if it was necessary.

Function, Infection Prevention and Control, Safety, Ergonomics, Materials, Storage, Technical Details, Aesthetics, Comfort, Afterlife

Overall, from the sketching and modelling I have completed, I found that adjustability increases the ergonomics and function of the pack greatly. By using elasticated band for the strap, the maximum sizes of injuries is greatly increased. In addition to this, by using Velcro to hold the strap in place, it provides an effective and efficient method of attaching and taking off the pack.The mechanism, from idea 2.6.5, for attaching the strap to the pack is very effective, although it does make the manufacturing process increase in complexity, it also would increase wastage which could harm the environment. However, the ease of use of the mechanism makes the strap very easy to attach and remove from the pack and so would be very convenient in a first aid situation.I also will take forward to my final stage of development idea 2.1.2 because of its simplicity and ease of manufacturing

Weakness 2 Overview

Plastic clip broken because

of pressure on it when it was bent to allow

the strap to slot in

Figure 6 (Right)Slow-motion

video showing the strap being

slotted and locked into the clip mechanism

I designed and added a small clip on one end of the slot (Figure 1), this would rise when the bump on the strap pushes it up and passes underneath, the clip would then flick back into place, holding the bump so that it cannot move (Figure 2)

The strap can also be removed without causing any harm to the clip, when pushed out with enough force the clip rises and allows the strap to be removed (Figure 3).

Figure 1 (Left)Idea 2.6.4 with the clip to allow the strap to slot and lock in place, whilst still being removable

Figure 4 (Below)Sketches of how idea 2.6.4 would work

Figure 3 (Above)3D Animation of idea 2.6.4

with the strap being inserted and removed

Figure 6 (Left)Video discussing a developed idea for the strap with the removable strap mechanism

Figure 5 (Right)2D CAD Drawings of the

2.6.4 clip (Top) compared to 2.6.5 clip

(Bottom)To solve the problem of the clip snapping when the strap is inserted, I thickened the clip size and reduced the angle that the clip is positioned at (Figure 5). I then made the new and improved design out of acrylic and tested it out, the strap slotted in smoothly and the clip locked it in place easily and efficiently (Figure 6). After testing the clip thoroughly I found that it has an approximate life span of 20 insertions and removals before the clip starts to bend out of place and stop locking the strap in correctly. This is adequate for the use it will get because each pack is only one use and the clip will be placed on the pack and therefore will generally only need to be used once.

2.6.5

Video

Video

Video

21

My 3rd weakness references the material of the outer pack and what insulation it gives to the user, the polyethylene material the Koolpak instant icepack uses has both its positives and negatives but it must still be improved. Although the polyethylene pack is very useful as it is both flexible, waterproof and durable, it is too thin and therefore the contents can cause freeze burns to the user if the pack is applied directly to the skin. Because of this, I will research, test, and model a material which can insulate the pack and therefore increase the temperature sufficiently that there will be no risk of freeze burns, but keeps the ice pack cool enough that it functions as a cold compress.I firstly researched into the temperatures that cause freeze burns so that I would know a benchmark temperature that must be met, this included internet research and speaking to qualified medical professionals. From this research I found that freeze burns occur when skin is in prolonged (10+ minutes) contact with a material which is less that 3˚C, therefore I knew that which ever materials I test, a successful material must insulate the pack to 3˚C+. I also researched into the possible different materials I could test, by speaking to first aiders and design technicians, I sourced 4 possible materials (Figure 1) that could be used to cover the ice pack, I also did some preliminary tests with them to find out some of their properties (Figure 2).These were:1. Polyester fabric2. Polypropylene sheet3. 3mm foam4. 6mm foamThese materials were chosen due to their flexibility, ease of manufacture, relative inexpensive cost and availability. However, all of these materials are not very sustainable and so are not the best materials to pick concerning the environment. But this issue could be looked into in my further improvements.I decided that I would test these materials in my testing stage of the project so that I could find out

first hand what the best material would be. The chosen material after testing can also be seen in the right-hand section on this slide.

Development of Improvement cont.

Polyester fabric• Not waterproof• Very flexible• Lightweight• Easy to cut• Thin

Polypropylene sheet • Waterproof• Not very flexible

(can only ben in one direction at a time)

• Fairly lightweight• Thick (compared to

material 1)

3mm foam• Waterproof• Flexible• Lightweight• Thick• Soft• Easy to cut

6mm foam• Waterproof• Harder to bend and

manipulate than the 3mm foam

• Fairly lightweight• Very thick• Very soft• Hard to cut

3.1

Function, Infection Prevention and Control, Safety, Ergonomics, Materials, Storage, Technical Details, Aesthetics, Comfort, Afterlife

As a development from idea 3.1 I have incorporated the chosen material into the design of the original ice pack (Figure 3). Although the addition of a second outer material would increase manufacturing time and cost, the icepack would still be able to be made inexpensively and with the benefit of a much safer pack to use for its function.Although this aids the packs safety and solves one of my weaknesses, there is one key negative with covering the pack in the material. This is that the safety instructions an branding are therefore not visible on the pack and they would have to be repositioned and either printed onto the insulation material or on another medium. This will have to be investigated and will be developed in my final stages of this section.

3.2

Weakness 3

Weakness 3 OverviewOverall, weakness 3 has been very short and quick to reach a final developed idea, this is mainly because of the “pass/fail” nature of the testing, therefore I will be taking forward idea 3.2 to my final stage of development.

Figure 2 (Above &

Right))Idea 3.2 with

the double layered

polyester fabric added

to the original instant

icepack

Figure 1 (Left)Pictures showing each of the 4 materials chosen

Figure 2 (Below)Pictures and details of the initial materials’ properties

22

Prototype 1

Prototype 1 (Figure 1) encompasses numerous of my developments from investigations of the separate weaknesses. From idea 1.5.2, I have taken the segmented design as it solved both weakness 1 and weakness 4 of the original Koolpak Instant Icepack. The segments of the design allow the pack to wrap around injuries very easily as well as preventing the contents of the pack from becoming uneven due to the smaller pack size, it also allows the pack to be torn into different sizes which means a greater range of injuries can be treated from one ice pack. I also incorporated idea 2.1.1 as the strap mechanism fro each segment so that the pack would be held against an injury easily. I chose this idea as opposed to other ideas, such as idea 2.6.5 because it requires very little material and it does not add to the weight of the ice pack that much, therefore making it more useful in everyday life if it were to be carried by a first aider in a first aid kit.Finally I chose idea 2.3.3 for the strap because velcro is easier to use than most other mediums of attaching the strap and lighter, it also is very strong and holds the pack in place tightly, the only possible improvement that could be made to the idea is to add elastic into the strap so that a tighter and more adjustable strap could be used.

Prototype 2

Prototype 2 (Figure 2) develops from prototype 1 by adding the strap mechanism to each segment and the insulating material on the reverse. From this model I found that the strap mechanism needed to be adjusted slightly so that each velcro strip fits neatly onto the mechanism and does not overhang, this will be fixed in prototype 3.

Prototype 3

Prototype 3 (Figure 3) is the final development of the icepack and takes into account all issues raised in previous developments and testing. Firstly the new strap mechanism allows easy addition and removal of the strap as well as enabling the pack to wrap around injuries and be secured tightly and easily.

I have also incorporated elastic into the strap (from idea 2.4.2) so that there is more adjustability in the strap and therefore allowing a greater number of different sized injuries to be treated on a large selection of limbs, all with slightly different sizes.In my next sections this final prototype will be tested by possible consumers and areas of the design will be scientifically tested to fin the best material for the pack, the whole development will then be analysed and any other improvements discussed.

Development of Improvement cont.

Figure 1 (below)Images showing prototype 1 of the final development icepack and video with technology teacher discussing the model and explaining some of the features of the development

Function, Infection Prevention and Control, Safety, Ergonomics, Materials, Storage, Technical Details, Aesthetics, Comfort, Afterlife

Final Development

Figure 2 (Above & Right)Prototype 2 of my final

development showing each of the main parts as well as the

difference in the size of the velcro and strap mechanism

Figure 3 (Right)

Prototype 3 of my final development showing

the final model and

it being used on a body part as well as

the tearing mechanism

Video

23In this section I will test my product by scientific testing and consumer feedback, this will aid me in my final analysis and will tell me if there are any future improvements to be made to the product.

In my development stage I found 4 different materials that could be used as an outer material for the pack to prevent freeze burns.

Plan for testing

I began by planning my scientific test and wrote up a basic method and experimental diagram (Figure 1). I will conduct my experiment by measuring the minimum temperature reached on the outside of the material being tested when the existing ice pack is placed on the inside and activated. I will then be able to measure the insulating quality of each material and decide which material will be best suited as the outer pack material of my new developed ice pack. The apparatus I will need to use a thermometer to measure the temperature of the outer material, I will also need to use a new instant icepack each time I conduct the experiment so that it is a fair test fro each material. The only variable that will be difficult to control will be the ambient temperature however I will conduct the experiment inside so therefore the room temperature should remain fairly constant throughout.

Testing

Figure 3 (Left)Table and Graph showing results of insulating materials experiments

Outer Material Testing

Material Minimum Temperature (˚C)

None 0

Polyester fabric (1 Layer)

2

Polyester fabric (2 Layers)

4

Polyester fabric (3 Layers)

5

Polypropylene sheet 14

Foam (3mm) 6

Foam (6mm) 9

None

Polye

ster fa

bric (

1 Laye

r)

Polye

ster fa

bric (

2 Laye

rs)

Polye

ster fa

bric (

3 Laye

rs)

Polyp

ropyle

ne sh

eet

Foam (3

mm)

Foam (6

mm)048

1216

Material

Min

imum

Tem

pera

ture

(˚C

)Figure 2 (Above)

The testing of each material as

part of idea 3.1 to see which

material would work best as an

insulating material for the pack to prevent

freeze burns

Figure 1 (Right)Experimental design of outer material testing

Polyester fabric (1 layer)

Polyester fabric (2 layer)

Polyester fabric (2 layer)

Foam (3mm)

24Consumer Testing

Interview questions

Proposed questions

1. How has the developed icepack been improved?

2. What improvements has the tearable ability and mechanism given to the ice pack?

3. Is it easier to use than the original icepack?4. Are there any other improvements the develop

icepack could have?

Testing cont.

Interview

Client: First Aider

Key points made from client:

• More segments in icepack• It can easily wrap around injuries• Prevention of freeze burns by insulating materials• Easy to attach the straps• Tearability useful for different limbs• May make small injuries difficult and awkward to

treat however

Questionnaire questions and feedback

Key points made from questionnaires:

• Average ergonomic rating = 4.25• Average ease of use rating = 4.67• Average safety rating = 4.75• Slightly more curved design to allow more comfort for the user• Other wrapping direction for smaller injuries• Easier to use straps with softer material• Area for adequate safety instructions and branding on the pack

Figure 1 (Above)Interview with client 1, a St John Ambulance First

Aider, about the developed icepack asking some of the proposed questions listed above

Figure 2 (Left)Completed questionnaire with answers to questions including mention of possible ergonomic improvements

Figure 3 (Above)Original Koolpak Instant Icepack compared to

the final development prototype

Video

25In this section I will summarise the results of testing, development and analyse my final development product and compare it against the original Koolpak Instant Icepack. I will then propose any further improvements that could be made to my final development.

Analysis of Testing

Outer Material Testing

The outer material testing has given me results that show that al of the materials insulated the pack, however from my research during development, I found that freeze burns can occur from temperatures lower than 3˚C. This fact therefore means that the material of choice would be 2 layers of polyester fabric due to its minimum temperature reaching 4˚C which would still function as a cold compress icepack and treat soft tissue injuries. From testing this, I then went back and added this material to my final development (Figure 1) as it was a key weakness of the original Koolpak Instant Icepack.

Consumer Testing

My consumer testing has shown me that my final development successfully approaches each of the weaknesses of the Koolpak Instant Icepack and solves them very well meaning the final development has improved greatly on the original pack.Despite this I have still discovered that there may be some areas that could be improved on the final development, such as the ergonomics of the pack and allowing the pack to be used on very small injuries, possibly on children or small limbs. The consumer testing has also shown that the design could be curved to allow it to be more ergonomic for the user, in my opinion I think that the final prototype could be greater curved to fit more comfortably round soft tissue injuries on joints such as ankles and knees. However during my development I looked into a curved pack idea from idea 1.4 (Figure 2) and although successful, I thought that the tearing ability of idea 1.5.2 (Figure 3) was more improved and would be a better development for the instant icepack.

Summary of ResultsAnalysis of Development

Weakness 1 The development of weakness 1 comprised of sketching and modelling ideas of the shape of the pack and increasing the ergonomics of the pack so that it would easily wrap around injuries on the body with it still being comfortable for the user. My original ideas for solving this problem was to directly change the shape of the pack and make it larger whilst curving the sides, ideas 1.1-1.4 (Figure 4). From modelling ideas I found that idea 1.4 (Figure 2) was the most ergonomic of the designs and it was very ergonomic and comfortable for the user, however I thought it would be too difficult for the pack to work efficiently once other developments were investigated and added to that idea.

After developing the shape of the pack I begun to look at how it could easily wrap around an injury, during this I developed what would become my final development prototype in idea 1.5.2 (Figure 3). This idea allowed an easy tear mechanism on segments of the pack so that any size pack could be used depending on the size of the soft tissue injury. The idea received very positive feedback from consumers and I found that it would be the best development to take forward for weakness 1. I also found that it solved weakness 4 in the process of development due to its segmentation which meant that the contents of the icepack would not have been able to move around, therefore leading to a more even coverage over an injury.

Figure 1 (Below)Reverse of my final development model with the successful tested insulating material attached in

order to prevent freeze burns

Material Minimum Temperature (˚C)

None 0Polyester fabric (1 Layer)

2

Polyester fabric (2 Layers)

4

Polyester fabric (3 Layers)

5

Polyethylene sheet 14Foam (3mm) 6Foam (6mm) 9

Figure 2 (Above)Idea 1.4 from the development section showing how the design

could wrap around different limbs where soft tissue injuries could

occurFigure 3 (Below)Idea 1.5.2 from the development section and the final developed model of prototype 3

Figure 4 (Above)Ideas 1.1-1.4 addressing the

development of the pack size and shape

26Weakness 2

Weakness 2 looked at the ability for the pack to attach itself to an injury, I developed models solving this by looking at straps and methods of attaching straps together. From my developments I found that velcro, idea 2.3.3 (Figure 1), was the most successful way of attaching the straps together, mainly because they are very strong but also lightweight.

I also developed ideas for a strap mechanism to enable each individual strap to attach to the pack in an easy to use, lockable but reversible manner. One of the main ideas, idea 2.6.5 (Figure 2), was to use a slotting and clip mechanism to attach the strap to the pack. This idea was very successful however I decided not to take this forward to my final development due to its high material usage and difficulty in attaching the mechanism to the pack.

Weakness 3

To solve weakness 3 I tested several different material types to find which would be best suited for the outer material of the icepack so that freeze burns would not occur when using the pack without protection but the icepack would still function as a

cold compress.

Further ImprovementsMy final developed product solves all of the original weaknesses of the Koolpak Instant Icepack however there are some areas that could be improved that have followed from my testing section.Firstly a future improvement that should be made to the design is the addition of the safety instructions and branding of the pack (Figure 3). This is a simple procedure however due to he additional outer material on one side of the pack, all of the branding and safety instructions will have to be printed on the upper side of the pack and/or on the removable strap.

Another possible improvement to my final development is a more rounded design to make it more ergonomic for curved injuries on some body

parts (Figure 4). My future improvement is to change the shape of the segments to a more semi-circular shape that repeats down the length of the produced packs, this should mean that the pack is much more ergonomic but still useful fro smaller injuries.

Finally the design of the final development is very useful for consumers as they can buy long sheets of segments and tear off as many as they need as and when the need to. It is also very simple to manufacture as you keep all of the products on a manufacturing line which then cuts off sheets of 20 at a time and then packages them ready for shipping. The design therefore lends itself to batch production, this also means that many different companies, such as British Red Cross or Spencer ltd. could send their branding to the manufacturer and therefore create their own instant icepacks for selling and using (Figure 5).

Summary of Results cont.

Figure 1 (Below)Idea 2.3.3 and other ideas of attaching the straps

together

Figure 2 (Above)Idea 2.6.5 and some other dismissed ideas aimed to solve part of weakness 2

Figure 3 (Above)Future improvement to the final development by adding the branding and safety instructions to the pack which would be printed on the front of the pack instead of on the reverse

Figure 5 (Below)Possible branding of front of pack depending on

company buying the instant icepack, this leads to greater selling market and larger manufacturing. Branding produced below is British Red Cross and

Spencer ltd.

Figure 4 (Right)Future improvement to

make the pack more ergonomic by increasing

the curve on each side of the pack, the tearing ability

will not be affected