Invacare PinDot ® Seating 899 Cleveland Street Elyria, OH 44036 800/451-3553 Revision date: 12/10/2008 1 At Invacare PinDot Seating, our goal is to provide the most efficient and cost-effective means of completing your ContourU order. The success of each ContourU system in providing the optimal seating system for your client depends in part upon the accuracy of the information that you provide to us. It is our goal to work with you to create the best possible product possible. To this end, we have once again revised the ContourU Technical Notes, ContourU Order Forms and the PinDot Series Price List. To serve you better, the new order forms make numerous references to the revised Technical Notes, which provide additional and detailed information about the ContourU system and its capabilities. To assist you in placing your order, our internal customer service department is dedicated exclusively to Invacare PinDot Seating products. They are available to assist you by phone between the hours of 8:00 a.m. and 5:00 p.m. EST, Monday through Friday. Additional support is also available through our design technicians and managers who can be contacted through our customer service department when necessary. You may also fax questions and information to 800.870.4928. The phone number to PinDot customer service is 800.451.3553. Thank you for choosing ContourU. Invacare PinDot ® Seating Invacare PinDot ® Series Custom Seating Systems
At Invacare PinDot Seating, our goal is to provide the most efficient andcost-effective means of completing your ContourU order. The success of eachContourU system in providing the optimal seating system for your client dependsin part upon the accuracy of the information that you provide to us. It is our goalto work with you to create the best possible product possible. To this end, wehave once again revised the ContourU Technical Notes, ContourU Order Formsand the PinDot Series Price List. To serve you better, the new order forms makenumerous references to the revised Technical Notes, which provide additional anddetailed information about the ContourU system and its capabilities.
To assist you in placing your order, our internal customer servicedepartment is dedicated exclusively to Invacare PinDot Seating products. Theyare available to assist you by phone between the hours of 8:00 a.m. and 5:00 p.m.EST, Monday through Friday. Additional support is also available through ourdesign technicians and managers who can be contacted through our customerservice department when necessary. You may also fax questions and informationto 800.870.4928. The phone number to PinDot customer service is 800.451.3553.
Making a plaster cast 5installing molding bags 6 & 7tips for cleaning & caring for molding bags 8tools for plastering 9plastering 10splinting a cushion 11poor cast 12order forms 13
Marking the cast 14center line 15alignment lines 16penny marks 17 & 18
Cushion measurementswidth: chair versus cushion 19depth: seat cushion depth versus frame depth 20height: cushion back height versus total system height 21seat to back angle 22seat to floor angle 23cushion depth 24
With Chair/On Chair 25
Upholstery options 26
Junctions 27universal 28hip control 29fixed recline 30pelvic control 31junction comparisons 32growth style 33gapping 34back tongue 35
The following describes our manufacturing capabilities. Please refer to the appropriate sectionsin the Technical Notes for detailed information on the modifications discussed.
1. DepthThe maximum depth or thickness for a ContourU® cushion is 12” for vinyl or naked cushions,and 10” for cloth cushions.
2. Minimum thickness of lateral and adductorsThe minimum thickness is ¾”.
3. Maximum negative pullUndercuts, railcuts, extended abductors, extended adductors, and back tongues are all“negative pulls.” The maximum negative pull per cushion is 6”.For example: You may order a 2” undercut, railcut each side 1” and extend each adductor 1”.2”+1”+1”+1”+1”=6”. These options give you the maximum total of 6” of negative pull.
4. Maximum total railcutThe maximum width of a railcut per cushion is 4”. The standard railcut is 2” in height. Thefinished railcut width dimension must be indicated on the order form.
5. Maximum undercutThe maximum undercut is 2” deep. The minimum thickness is 1 ½”.
6. Maximum extension on abductor and adductorsThe maximum extension is 2”.
7. Minimum foam allowanceA cushion will have a standard foam allowance of 1 ½” on the seat and back. Certain optionsor combinations of options may raise the foam allowance. This allowance is added to theoverall thickness of the cushion.
8. Maximum tongue lengthThe maximum length of a back tongue is 3” with a minimum thickness of 1 ½”.
9. Recesses and sofspotsThe maximum depth for a recess or a sofspot is 2”. The minimum is 1”. The minimum foamallowance of 1” must be maintained under the seat and behind the back.
Careful and accurate plastering is essential to the production of an effec-tive ContourU system for your client. Make sure that you have all of the basicequipment as listed on page 9. Also, have your ContourU Technical Notes,Order Form, and Quick Start guide available. Before you begin, refer to pages17 & 18 for a description of the “penny method” for marking casts.
The following pages provide detailed information on the following topics:
In addition to a seat bag (MF10) and/or back bag (MF12) and frames, you will need, a wide-neck funnel, alcohol or similar cleaning agent, Allen key, 9/16” wrench, and 25 pounds of pellets(MF04) per molding bag.
Note – The seat and back bags are NOT interchangeable. The back bag has a valve stem forthe hose in the middle. The seat bag has a valve stem near the top right.
Instructions:Prepare the frame by removing the clamping bars and old bag. Remove any loose plaster from theedges of the frame.1. Place the bag in the frame. The top of the bag has a small opening on the left side. The top of the
frame has holes in it; the bottom does not. (Diagram 1) Place the top of the bag in the frame justbelow the holes in the frame and just to the right of the holes on the right side of frame. Be certainthe valve faces the rear of the frame. There will be extra bag hanging on the left side of the frame.You can use duct tape to help keep the bag aligned.
2. Fold bottom of bag under, leaving about ¼” of space between the bag and end of frame. (Diagram2)
3. Place clamping bar on right side, lining up the holes, and secure. Make sure you secure each screwby hand first, then tighten with an Allen tool.
4. Do the same on the left side.5. Make at least 3 folds (more is better) on the right side of the bags. Leave enough extra bag on the
left side to make a fold later over the opening. The first fold should begin just to the right of the firsthole. The first fold should be about 2”; the second fold about 2”; the third fold about 2”. (If you use6 folds, each will be approximately 1”.) They can be held in place with duct tape. Hold each fold inplace with your hand while you make the next fold. Place the large clamping bar over the folds.Secure bar to the frame. (Diagram3)
6. At the top of the left side of each bag there is an opening. Using a wide neck funnel, fill the bag withpellets. Each bag takes 25 pounds.
7. Once the bag is full, remove all loose beads from the opening. Wipe the opening with a clean tissue orcloth and an alcohol / cleaning agent.
8. Seal the bag with the adhesive provided by removing the protective paper and carefully press the twosides together. Make sure the seal is airtight and that no beads are trapped in the seal.
9. Make the final fold (s) in the bag over the opening. Place the remaining small bar on the frame andsecure. (Diagram4)
Attach the correct vacuum hose to the bag and secure using a 9/16” wrench. (Seat and back vacuum hosesare different.)
Clean after each use• Removing fresh plaster and fresh tape not only preserves the life of the Molding Bags, but prepares
the machine for the next user.Soap• Lanolin soap will help preserve the elasticity and integrity of the molding bagsWeather• Allow the molding bags to accommodate to room temperature when transporting them in from
extreme hot or cold vehicles.Transport issues• Be certain to tie down the shape sensor frame when transporting in a van or truck.• Remove the molding bags from the frame during transport.• Consider using the boxes the seat and back frames were originally shipped in to protect them
during transport for protection.Remove Tape• Use Cheap Masking tape to cover wrinkles and for marking the mold.• The cheaper it is, the easier it will be to remove the less sticky it is.• If it is too sticky, apply it to a fleece material first, allowing it to pick up lint and then to molding
bags.• Tape left on, even for only a few days, can cause a tear in the bag when removing it.Patching a hole• Consider using ROHO Patches• Use Duct tape if a hole is discovered in the molding process.• Leaks discovered between the bag and the side of the frame can temporarily be stopped with
Theraputty when vacuum is being applied to the bag.• Use good judgment when deciding when there are too many patches on the bag and replacement is
needed.• Remember the molding bag is NOT elastic over the area of a patch and will not capture contours
as closely. Patches in critical areas of the bag (sacral area, hips, etc.) usually indicate time for anew bag.
• When you cast, be sure to identify the patch as one, not an important identifying mark.Furdustin Powder by Sween• Put on bags before you mold.• It is like baby powder, but less chalky.• Makes the bag less sticky.• Bags last longer, and stay more pliable.StorageDo not use the ContourU machine as a storage shelf when not in use as items set on the molding bagstend to accumulate and may cause holes in the bags.
Shape SensorMolding bags for seat and back (plus an extra set)Vacuum pumpLarge mouth funnelDrop ClothMasking tapeDuct tapeTheraputtyBucket with plastic bag2 boxes of plaster (each box contains 12 rolls of 5” x 50” plaster bandages)Rubber malletGlovesBaby powderFraming squareAlignment toolTape measureAllen tool setAdjustable open end wrenchInk pencilContourU order formFabric samplesPolaroid® or digital camera12 penniesPitch angle gaugeGoniometerTowelsSheets / Clothes PinsExtra beadsPositioning accessories (Ethafoam blocks, plumb line, webbing)
Plaster the mold in one piece. Pay particular attention to the first layer as itcaptures the most details of the client’s shape. Place 4 layers of plaster verticallydown the back and continue along the seat. Place 4 layers horizontally across thefull surface of the seat and back. This is a total of 8 layers of plaster. Put enoughplaster around the laterals and adductors to provide a good surface for marking thealignment lines. Fold back the outer edges of the plaster strips to strengthen themold. Wait 24 hours before packaging.
Marking the cast (see page 14) can be completed using an ink pencil immedi-ately after the last plaster strip is finished.
The cast can be carefully removed from the simulator after markings are completed.First, release the vacuum by disconnecting the seat from the vacuum pump, andopening up the back valve. Allow several minutes for the vacuum to be released.Gently pull the bag away from the plaster cast along both sides, under the front ofthe seat, and behind the top of the back. Carefully lift the plaster cast off of thesimulator.
“Splinting” is making a plaster cast of a cushion. This splint can be used tomanufacture an identical cushion, or an additional cover. Before splinting, alwaysplace a layer of plastic wrap or plastic bag over the cushion. Place the cushion ona flat plane, such as a table or the floor.
Splinting to a flat plane. Using 8 layers as described in the section above,place the plaster over the cushion and extend it all the way to the plane, letting theplaster overlay approximately 1” onto the plane. After you remove the plaster fromthe cushion, it should sit flat on a plane. Alignment lines must be drawn parallel tothe flat plane.(See alignment lines page 16)
Splinting short of the plane. This method is preferable when the cushionhas undercuts or railcuts, as it allows you to easily remove the cast from thecushion. In this case, you cast the cushion without overlaying the plaster onto theplane. Alignment lines must be drawn parallel to the flat plane.(See alignment linespage 16)
If a cast arrives to us in a condition such that we cannot with certaintydetermine the client’s contours or we are unable to determine the seat-to-back angle,we will reject the cast and ship it back to you. Indicators of a poor cast resulting ina rejection are:
⇒ Voids and air pockets – caused by too much space between layers,too much space between plaster and molding baggier by using toomuch water on the plaster
⇒ Thin sections of plaster – caused by using too little plaster⇒ Squared-off contours – caused by failing to properly smooth
contours in molding bag⇒ Large gap between the seat and back – caused by failing to
sufficiently pull down back molding bag⇒ Plaster falling off the cast - caused by failing to use both horizontal
and vertical layers, using too little plaster, or squeezing too muchwater out of the plaster
⇒ Weak transition between the seat and back – caused by failing to useenough plaster in the transition area
⇒ Missing information as described on page 14⇒ Missing Penny Marks
Remember to allow the cast 24 hours to dry before packaging. Do not pack thecast in plastic. Use a generous amount of packing material to protect the cast whilein transit. Occasionally, despite your best efforts, a cast is damaged in shipping.Thus, it is important to adequately insure the cast.
In order for us to properly manufacture each ContourU order, you mustcomplete all sections of the ContourU order form. Failure to complete any sectionwill result in your order being placed on hold, therefore creating a delay inprocessing and extending the total lead-time of your order.
Please insure that you are using our most current order form. Our current version isform # 00-284.
For more information on Remakes, please refer to page 63 of this manual.
There are several pieces of information, which must be marked, on each castbefore it ships to us for processing. This information is vital for both tracking thecast and for manufacturing the cushions. Each cast must have the followinginformation:
♦ Client Name♦ Date♦ Dealer Name♦ Dealer telephone number♦ Dealer contact name♦ 12 Penny marks (see pages 17 & 18)
The following modification landmarks must be marked on the cast in orderfor us to properly place that particular modification:
♦ Sofspots♦ Recesses♦ Pelvic Strap Notches♦ Strap Slots (Naked only)♦ Cross Brace Notches♦ Modifications different from “As Molded”
You must also mark on the cast the following information about the client’sorientation in the simulator:
♦ Center lines (see page 15)♦ Alignment lines (see page 16)
The center line provides manufacturing critical indicators concerning theclient’s orientation in the simulator. It tells us the orientation of the client from left toright, i.e., whether the client was leaning to the left or right when in the simulator andby how much. The center line indicates the center of the simulator, not the client orcast. You must mark the center line while the cast is still on the simulator.Center lines placed after removing the cast from the simulator will not be accurate.
Mark the cast at the midpoint between the left and right sides (10” from theside of the molding bag pan) at the top of the back and at the front of the seat. Ifyou are marking a seat only, there must be a mark on the front of the seat and on therear of the seat. If you are marking a back only, there must be a mark on the top ofthe back and on the bottom of the back.
Because the center line is marked with reference to the center of thesimulator, it is not always in the center of the cast. We will center the cast if “centershape” is indicated on page 1 of the order form. If the center line must be in aparticular location due to asymmetries, then select “leave as marked” on the orderform. (i.e. windswept deformities orspecific joystick placement.)
Note - if we center the shape by shift-ing the center line, we shift it so thatthere is equal distance between thecenter line and the widest point on thecast. This does not change the cast’sshape or contours. Shifting the centerline causes the entire shape to shift,therefore centering the client’s body inthe wheelchair.
Alignment lines provide critical data allowing us to maintain properorientation between seat and back. To draw alignment lines, it is necessary to havesufficient plaster on the sides of the cast. Using your marking tool, you mustmark the alignment lines while the cast is still in the simulator. Use a markerthat will make a permanent, dark line. An alignment line must be marked on eachlateral and adductor.
To make an alignment line, mark 2 points on each lateral or adductor that areeach the same distance from the molding bag pan. Make a line by connecting the 2points. The alignment lines should be at least 4” long and at the same distance fromthe molding bag pan on the left and right sides of the cast, (i.e., if you made a mark3” from the pan on the right side of the seat, make a corresponding mark 3” fromthe pan on the left side of the seat). The alignment lines of the seat need to matcheach other in height from the pan but do not need to match the alignment lines ofthe back in height from the pan.
When completed, you should have a set of lines that are parallel to the seat pan andto the back pan.alig
Once the simulation is completed and before the plaster is applied, youmust take measurements at several key locations. These molding bagmeasurements are transferred to the order form and are used during production toensure consistency and quality. We will verify the measurements on the cast withthe measurements on the order form prior to processing your cushions. Before acushion is shipped, we will recheck the measurements as part of the final auditprocess.
After the molding bags are prepared, attach pennies (or washers) to themolding bags using masking tape. This is to identify the exact locations of themeasurements. Tape pennies to the molding bag with half of their surface exposed.The impression will transfer to the plaster, giving precise locations formeasurements. In order to ensure that the measurements are taken consistently,extend the tape measure across a level plane and hold the ends at the center of eachcoin.
Anchor point – Tape a penny to the seat surface so that the center of the penny is1” from the back and midway across the adductor supports. This point will be usedas the starting point for several critical measurements.
Chest width – the chest width is measured acrossthe lateral trunk supports, just below the axilla.If the lateral trunk supports do not extend thishigh, then take the measurement in the chest area.(Location A)
Waist width – The waist width is measuredacross the lateral trunk supports at the topof the pelvis. (Location B)
Hip width – The hip width is measured across the hips at the greater trochanters.(Location C)
Leg length – right and left – The center of the penny should be placed at theexact location where the seat is to end for each leg, and should be positioned in thecenter of each leg trough. The measurements are taken from the anchor point toeach penny. If a leg length extension is needed, and was not molded in, the desiredextension will be measured from the center of the penny. (Location D & E)
Back height – The center of the penny should be placed at the exact locationwhere the back is to end. Measurement is then taken from the anchor point.(Location F) Note: When growth is applied to a cushion, it may change the depthof the cushion at the location of the penny mark. In such cases, the back heightwill measure taller than as stated on the order form: however, the total systemheight will remain the same as when molded.
Top of laterals – right and left - The center of the penny should be placed at theexact location where the lateral is to end. This measurement is taken by measuringfrom the anchor point to the penny. Please note that this mark is used as a locatorpoint for modifying the laterals (raising, lowering, or square pulling) as well as forperforming the final audit. Unless otherwise specified, laterals will be made asmolded. (Location G & H)
Overall cushion width will be the “finished” width of the final product,irregardless of the penny marks. Seat width is generally the same as chair width,unless rail cuts, or partial rail cuts allow cushion width to overhang the side of thechair. In most cases, the seat width will be the same as the back width also.However, the seat and back cushions can have different widths. An example wouldbe when mounting the ContourU back between the back canes of the wheelchair, itgenerally needs to be 2 ½” narrower than the chair width to accommodate themounting hardware.
Measure from thewidest point on one side ofthe cushion to the widestpoint on the other, includingthe thickness of either thelaterals or adductors. (Mini-mum thickness is ¾”).
Before you even putyour client into thesimulator it is imperative that you consider the size of the mobility base onto whichthe cushions will be mounted. If the client’s chair is 16” wide, for example, thenwhen the client is still in the simulator, check to see if the positioning is such that thecushion will fit into a 16” chair. If the positioning will result in the cushion beingwider than the chair width, you must decide whether you can position the client in anarrower position, get a larger chair, or use one of the options listed below.
Cushion depth is the final length of the entire finished seat cushion, NOT seatdepth, and NOT the length of the Penny marks.
To measure the cushion depth, measure from the most rear-word aspect ofthe seat to the penny mark noting where the longest leg length will end, and then add1 ½” to this measurement for the posterior wall of the seat cushion (or the backtongue).
The wheelchair frame depth will need to be at least the same length as thefinished cushion depth unless modifications are made to the cushion to allow it to fitonto a shorter frame.
Modifications possible include:
• Front Rigging notches; to allow thefront of the cushion to fit over thefront rigging hanger weldments.
• Undercut front; to allow the entirefront of the cushion to overhang thefront of the wheelchair.
Rear cane notches; to allow the rear ofthe cushion to recess between the backcanes, - also requiring the wheelchairback to fit between the canes.
Height – Cushion Back Height vs. Total System Height
Back height noted on the form will NOT be the back height of the finishedContourU back as the system height will be different, depending on the differentseat to back junctions chosen. Back however, the height noted on the order formwill be the total height of the completed/assembled seating system.
System height noted on the order form will not be the cushion back height.Back height will be different depending on which junction is chosen.
To measure system height, measure the distance from the lowest point of theseat to the penny mark on the top of the back. Add 1 1/2” for minimum foamallowance.
This dimension will determine theback height of the wheelchair needed toaccommodate the seating system. i.e., Ameasurement of 18” will require a backcane height of 18” unless the top of theback is modified to position above thepush handles of the canes.
Note - Cushion modifications such asrailcuts and sofspots could increasetotal system height.
This measurement is for the clinician or supplier mounting the completed systemand is not used in manufacturing. Noting this angle off the cast will assure matching thedesired/molded seat to back angle when mounting the completed system on the chair.
Take this measurement off of the cast using a goniometer, noting the anglemeasured on the order form. The goniometer can be placed on either the back or thefront of the cast when taking this measurement.
Seat to back angle taken off of the shape sensor will often NOT match the angle takenfrom the cast as the thickness of the back molding bag is usually not consistent fromtop to bottom, as created in the molding process.
This measurement is also for the clinician or supplier mounting the completedsystem and is not used in manufacturing.
This measurement is taken off of the Shape Sensor Frame to assure that thecompleted/assembled system will match the captured mold in all aspects.
When creating a ContourU mold for an individual with an existing mobility base, it isoften helpful to match the seat to floor angle of the Shape Sensor to the seat to floorangle of the mobility base. If a different seat to floor angle is required in the mold fromthe existing angle on the base, modification of the wheelchair can be planned at thistime.
The cushion thickness will be the overall thickness of your cast, plus1-1/2” for foam allowance. “Foam allowance” is the minimum thickness of foamfound at any point on the cushion. This minimum is has been established toprevent the cushion from “bottoming out”. If a cushion bottoms out, there will beno padding under bony prominences, possibly leading to skin damage. You shouldalso note that some modifications or options may increase minimum foamallowance requirements.
Cushion thickness is measured from the lowest part of the cast to thetop of the highest point (usually the lateral or adductor). The maximum cushionthickness is 12 inches.
••••• Recess – At least 1” foam behind or underneath the recess.••••• Wood Mount – Additional ½” of minimum thickness (1-1/2” foam
plus 1/2” wood.)••••• Negat ive Pull – If there is any “negative pull”, i.e. railcuts, undercut,
extended adductors, extended abductor, back tongue, the minimumfoam allowance may increase depending on the amount of negative pulland location.
As a continued effort to decrease lead times and increase efficiency, InvacareCustom Seating is now able to offer both a “With Chair” and an “On Chair” optionwhen ordering a ContourU and an Invacare mobility base.
When the “With Chair” option is selected, your ContourU and your mobilitybase will be shipped from Invacare together. You will therefore receive the ContourUand the mobility base at the same time and be sent a single invoice for the two.
When the “On Chair” option is selected, all mounting hardware will be installedon the mobility base and the ContourU. The system will then be physically mounted tothe base. If possible, the sysetm will remain on the base for shipment so that when itarrives, you are required to merely make final adjustments during client fitting. If forsome reason packaging or product configuration prohibit the system from shippingcompletely assembled, the seating system will be packed separately, hardware intact,and shipped together.
At this time ALL “With Chair”and “On chair orders MUST be placedthrough Custom Seating customer service. Custom Seating customer servicecan not accept any phoned in orders or direct entry orders (EDI or X.12) forthe Invacare wheelchair.
When mailing in your ContourU order, it must include the following:
• ContourU plaster cast• ContourU order form• Invacare wheelchair order form
At the time of printing this version of tech notes, only certain configurations of ContourUseating systems are available factory mounted on select mobility bases. Contact your
Custom Seating Customer Service Representative for details.
ContourU® cushions are available either vinyl covered (CM01) or “naked”(CM02). A vinyl cushion is made with vinyl upholstery vacuum-formed around themold. A urethane foam is then injected into the vinyl. See order form for current vinylcovering color options.
Vinyl covered cushions offer the greatest strength and durability and are thefirmest of the ContourU cushions. They are easy to clean and are appropriate if theclient is incontinent. A removable cover is available at an additional charge.
A naked cushion does not have any upholstery over the foam— i.e. it is“naked”. Naked cushions always include a removable cloth cover (3 cover options)and are softer than the vinyl cushions. The naked foam is coated with a sprayurethane to increase durability and improve moisture resistance. The naked foam canbe modified in the field and the urethane coating repaired with our waterproofing kit(CRK).
Cover patterns are included in the price of Naked ContourU cushions. We willkeep this pattern on file for 3 years and will fabricate extra covers as needed at anadditional charge.
An important feature of the ContourU Seating System is the ability to choosea specific Seat to Back Junction. The junction is the manner in which the seat andback cushions join together.
Each junction offers postural support and control in a manner unique to thatsystem, as well as modifications to that junction.
There are 4 Choices to choose from.
• Universal• Pelvic Control• Hip Control• Fixed Recline
The following pages 28 through 35 provide detailed information on eachjunction, a comparison of the different choices, and an explanation of modificationsthat can be made.
By providing adductors that extend to the back of the cushion (maximumheight = 3”), the universal junction provides the client with maximum control of thehips through the seat. All sacral support is provided through the back with atongue that matches the seat contour. (see page 32) It is manufactured with anopen rear for growth and allows for angle adjustability (90° to 105°) of the seatingsystem.
The hip control junction is recommended when the client needs maximumcontrol of the pelvis through the back cushion. This junction is most helpful when thelateral wall of the back needs maximum surface area to prevent the individual fromcollapsing on that side. The back laterals extend down to the seat where the hipguides and adductors are approximately 1” tall. (1” above the lowest point on theseat) The hip control junctions allows for adjustability (90°to 105°) of the seatingsystem. The hip control junction is manufactured with an open rear and growth isavailable. A back tongue is standard and will be added to the back cushion if a gap isnot specified.
With the fixed recline junction, the rear portion of the seat is manufactured tocreate an angle. When mounted properly with the back cushion, the angle createdduplicates the seat to back angle prescribed for the client. This junction is best forclients with a generally fixed hip position. A fixed recline junction is manufacturedwith a posterior wall, similar to the pelvic control junction, therefore there is nogrowth option available. This is the only junction available if the seat to backangle is equal to or greater than 105°. We are able to manufacture this junctionopen to the rear with a tongue. A gap can also be manufactured, either full ortongue.
The pelvic control junction allows for maximum control of the pelvis throughthe seat. It has a posterior wall in the seat that wraps around the sacrum to the hipguides in the seat. Neither growth nor a back tongue is available with the pelviccontrol junction.
This junction is also recommended when interfacing a ContourU seat cushionwith an aftermarket back. In this case, adding notched rear corners allow mountingadjustments for a clean seat to back junction.
The arrow indicates the area availableto grow the system.
Growth is available on ContourU® systems with the universal and hip controljunctions. Growth is provided in the seat by adding the growth amount to the rearof the seat. For example, if the seat length is 14” and you want 3” of growth, wewill add 3” to the rear of the seat cushion for a total seat length of 17”.
Note - Because the contour of the seat is extrapolated rearward, beginning atthe lowest point and extending to the back of the seat cushion, the exactmeasurement (top of seat cushion to top of back cushion) of the final product willnot match the molding bag measurements listed on page 1 of the order form.Although the desired back height, as indicated on the order form and plaster cast,will be achieved, the difference in actual measurement will be equal to the differencein height between the anchor point penny location and the deepest point of the seat(the point from which the growth was extrapolated).
A gap is the space that exists between the seat and back cushions after thesystem is fit together. A gap allows for some flexibility in the lateral height, airmovement, and accessibility to the rear of the client to check positioning.
A full gap is created by removing the specific amount of material from thebottom of the back cushion to achieve the desire gap (see figure 2). To maintainhip control with the laterals and still provide space between the seat and back, wealso offer a tongue gap (see figure 3).
A back tongue is the portion of a back that extends down intothe contour of the seat. A back tongue is standard on universal andhip control junctions unless a gap is specified. It is not available withthe pelvic control junction, but can be requested with a fixed reclinejunction. The maximum length of a tongue is 3” and the minimumthickness is 1 1/2”.
To provide your client with maximum support in areas of particular concern,we can extend the adductors or an abductor up to 2”, and we can also raise theabductor up to the height of the adductors.
If you extend the abductor or adductors, or raise the abductor in the cast,there is no additional charge. However, if we must make the change duringmanufacturing, there is an additional charge. (refer to price list) We will raise orextend to the depth indicated on the order form.
To reinforce adductors or abductors, we add a piece of 3/16” thick ABSwhich is formed to the proper contour. The edges of the reinforcements are linedwith a foam edging, then centered within the adductor or abductor. This edge maybe visible on naked cushions and should not be viewed as a defect. Both “L-shaped” and aluminum reinforcements are also available for adductors. With wrap-around reinforcements, the ABS extends all the way to the bottom of the adductorand wraps around toward the center of the cushion approximately 3 “. An aluminumreinforcement is a single piece which extends from the top of one adductor to thebottom of the cushion, across the entire width of the cushion, then back to the top ofthe other adductor. Both L-shape and aluminum reinforcements provide additionalstability.
An abductor that rises less than 6” from the bottom of the leg trough cannotbe reinforced. The design of the cuhion generally provides sufficient support in thisarea.
If your adductor wall is greater than 3” wide, we will thin the wall for appear-ance purposes unless you tell us not to.
Laterals will always be thinned to approximately ¾” – 1” thick. If for somereason you want them thicker or at the minimum ¾”, please specify on your orderform under special instructions. The thinning process will be symmetrical from topto bottom with the outside of the cushion being cut back even with the depth of theback where it joins the lateral support.
The standard method for manufacturing laterals is “as molded.” “As molded”means that the shape of the laterals will be the same as you molded in the cast.
The “Square Pull” option will change the original shape of the laterals. Thelateral will be pulled out or extended to the depth that is indicated on the order form.If “square pull” is needed, you must specify it on the cast and on the order form.
To reinforce laterals, we add 3/16” ABS or aluminum formed to fit thecontour of the lateral. The edges of the reinforcements are lined with foam,centered within the lateral, then molded ing making contact with the foremost pointof the cushion. This edge may be visible and should not be viewed as a defect.
Straight reinforcements: A straight piece of ABS which when molded intothe lateral prohibits the lateral itself from flexing.
Wrap-around or “L-shaped” reinforcements: Provide the same features asstandard reinforcements, but also, due to the “L” shape design which wraps partway across the back of the cushion, adds strength to the entire cushion, limiting theamount of flex that would otherwise be evident where the lateral meets the backwall of the cushion.
Aluminum reinforcements: With this option, two pieces of ABS (one in eachlateral) is replaced with a single piece of aluminum. This aluminum wrapscompletely around the back of the cushion, forming a U-shape which providesexcellent stability and strength to the lateral wall, especially in our naked cushions.
Reinforcements provide extra support for the client and help stabilize deepcushions. Except as described below, if you want reinforcements, you mustspecify what type on the order form.
We always add standard (straight) lateral reinforcements in naked backcushions and all back cushions that the laterals are at least 6” deep.
A leg-length discrepancy modification is where the seat cushion ismanufactured with different leg lengths to accommodate a client who has one leglonger than the other. If the cast was not molded to reflect the discrepancy, we canadd the discrepancy. A reference point (penny mark) must be provided and thedesired amount of lengthening marked on the cast and on the order form. Even ifthere is a discrepancy molded in a cast, you must also select it on the order form.
If you are pan mounting a seat cushion with a leg-length discrepancy, youmust decide whether you want the pan to fit the longer leg or the shorter leg. Keepin mind that if you opt to have the pan fit the longer leg, you will have to modifythe pan to accommodate the shorter leg. If you choose to order a pan to fit theshorter leg, you must also order an undercut so that the longer leg will fit properlyover the front edge of the pan. On naked cushions only, you may opt to slot thebottom of the cushion under the longer leg to accommodate the pan rather thanundercutting. This option is not available on vinyl cushions.
Front rigging notches are available on the bottom front of the ContourU cush-ion to allow for ease of access to the legrest hardware. This allows you to maintain ashorter depth on the wheelchair frame and still have access to the swing-away mecha-nism of the legrest. You must provide us with the dimensions of the cutout, usingAppendix d. Feel free to make copies of this drawing for future use.
Pelvic strap notches are cutouts on the seat cushion that allow for a moredirect pull of a lap belt across the client’s hips. Standardly, we place each pelvicstrap notch in the middle of the adductor, directly in front of the place where thelateral meets the adductor. Each notch is 2” long. The depth of the notch variesaccording to the depth of the seat cushion. You may specify a different placementand size of the pelvic strap notches by marking the placement and size on the cast.
Note - Because the rear of each adductor is only 1”, pelvic strap notches arenot necessary with a hip control junction.
We can manufacture your seat cushion with cross brace notches to allow thecushion to drop between the seat rails. This is not available with pan mounting. Themaximum drop allowed is 2”. You must provide us with the dimensions and locationof the cutouts, using Appendix A. Feel free to make copies of this drawing forfuture use. Note: Please remember to measure from the back canes forward, notfrom the back of the cushion forward.
Notched corners are needed if you would like to mount a seat cushionbetween the back canes of the wheelchair. Keep in mind that if you order notchedcorners and also pan mounting; you will need have the pan modified toaccommodate the notches. We will do this for you upon request. We no longerhave a “standard” notch due to the numerous configurations of mobility bases.Please specify on the order form, the finished width and depth dimensions of thenotch. (See Appendix d) Feel free to make copies of this drawing for future use.
Note - To insure maximum adjustability on certain configurations ofSolara product, a 2” x 2” notch is recommended.
If the back cushion has railcuts, and you are also ordering untrimmed, uphol-stered bottom, or wood mounting, we will automatically notch the seat to match therailcuts in the back. If you are pan mounting, we can still notch the seat. However,because you would have to modify the seat pan to accommodate the notches, wewill contact you before we notch the seat.
We also recommend notched rear corner when using an aftermarket back forproper seat to back alignment.
Loose fit increases the overall inside width of the cushion, but not the depthor thickness. It may result in increasing the overall width, if the laterals andadductors are already at minimum thickness. When ordering a “loose fit” optionyou must specify the amount you want us to widen the cushion.
Loose fit can allow for weight gain or anticipated immediate growth, but willnot provide the individual with as much support or postural control as an “asmolded” seat or back would.
loose fit
loo
se fit
Cushions before loose fit. Cushions after loose fit. In thiscase, the overallwidth of the
For a railcut, the lower portion on the side of a cushion is cut in to allowthe cushion to be mounted between the seat rails or the back uprights. Pleasespecify the desired final width and depth (1/4” increments) on your order form.(See Appendix c) Feel free to make copies of this drawing for future use.
Note - When mounting a back cushion to a Solara, certainconfigurations require that the cushion be rail cutas well as notch-ing the bottom corners of the cushion to allow for maximum heightadjustability. If unsure of the exact location that the cushion is tobe mounted, please note on the order form “Solara notches” andspecify the size of the chair.
If the front of a seat is wider than the rear of the seat, we can “partialrailcut” only the front portion of the seat to accommodate the mobility base.
An undercut can be added to the front of a seat or to the top of a back. Thesurface at the front edge of the seat is cut back to allow for calf clearance oraccommodate tight hamstrings. The undercut can be produced with differentamounts of undercut under each leg to accommodate a leg length discrepancy thatis 2” or greater. This is called a 2-step undercut.
Similarly, the top edge of a back can be undercut. Undercutting the top of aback or the front of a seat allows an oversized cushion to fit in a pan. For ex-ample, the back height is 19” and the existing pan is 18” deep. In this case we canundercut the top of the back 1” to allow the cushion to fit the pan.
A diagonal cut may be made on the front of a seat or at the top of a backcushion. A diagonal cut on a seat means that the front of the seat is manufactured atan angle. Generally, a diagonal cut front seat accommodates a client who is“windswept”. If the client is windswept, then the cast should reflect that. We cannotadd a diagonal cut on the front of the seat unless it is present in the cast.
A diagonal cut on a back means that the top of the back is manufactured at anangle. Generally, this accommodates a client who has a severe shoulder obliquity.We cannot add a diagonal cut to the top of a back unless it is present in the cast ordrawn on the cast.
If a diagonal cut is requested with pan mounting, an undercut will also beneeded so that the cushion will properly fit in the pan.
When it is necessary to place any type of strap through a cushion rather thanaround it (such as a pelvic or chest strap), we can mold slots into the cushion at thedesired place. These slots will go completely through the cushion, will be coatedwith the standard urethane spray, and will measure ½” wide by 1-1/2” long. Othershapes and sizes may be available, but must be quoted as a special. You mustindicate on your cast, the exact location of these slots and must allow a minimumof 1” foam between the slot and the nearest edge of the cushion. Strap slots cannot intersect a sofspot. The removable cover will have stitched holes to accommo-date all slots.
A recess is a cut out area in the surface of the ContourU. The purpose ofa recess is to accommodate some other softer material, e.g. sofspot, gel, t-foam,etc. In order for us to make a recess, you must mark the location on the cast.A recess can be 1” or 2” deep. Minimum foam allowance behind a recess is 1”.
A sofspot is made by adding a soft pad of HR foam to a 1” or 2” deeprecess. The foam is cut to fit in the recess and to match the cushion’s contour.When ordered with a vinyl cushion (CM01), the sofspot pad is sprayed withurethane and a Darlexx® cover is added. The sofspot is then placed in the recesswith Velcro®. Sofspots ordered with naked cushions (CM02) are glued into place,are not removable and do not have a Darlexx® cover.
In order for us to make a sofspot, you must mark the location on the cast.
When ordering a vinyl cushion with a sofspot, it is possible to order aduplicate or replacement sofspot at that time. The second sofspot will be manu-factured exactly the same as the first. Should the original sofspot become lost ordamaged, this second sofspot will fit the existing recess without any modifica-tion. This option is not available with naked cushions, as the sofspot is notremovable.
We offer several methods and hardware options for mounting a ContourUsystem onto a mobility base. ContourU systems can also be manufactured tomount into existing pans or back shells or you may supply your own method ofmounting..
As part of our “On Chair” program, we offer the mounting options describedbelow. These options are also available using the “With Chair” option as well oras stand alone equipment. Other options are available through our parts catalog.
HWPMK01 & HWPMK78
This hardware kit is used to flush mount ContourU pans to the mobility base. Itconsists of 4 horse shoe brackets, lanyards and locking pins , and fixed rail clampsand is bolted directly to the aluminum pan. Available to fit either 1” or 7/8” tubing.
HWWMK01 & HWWMK78
This hardware kit is used to flush mount cushions with the “Wood mount w/T-nut” option to the mobility base. Also available for use on 1” or 7/8 tubing, theycontain the same style of components as used for pan mounting.
“NEW” On Chair Mounting Kit (OCMK) 1” and 7/8”
This hardware kit contains 4 each adjustable “J” and “L” brackets and 2 fixed railclamps and 2 twist release rail clamps. These kits are used when mounting theseating system above or below the seat rail and/or in front of or between the backcanes.
All hardware listed above also contains hardware necessary to attach all brackets tothe chair or the cushion.
You may purchase a ContourU aluminum pan to mount your ContourU systemto the mobility base. Our pans are custom made to work with our cushions. TheContourU cushion is manufactured with ridges along the side so that the cushion willsnap into place in the pan. Once in the pan, the cushion is secure and will not slideout. Our pans are available in heights/lengths ranging from 10”-24” in 1” increments.Widths are available ranging from 10”-24” in ½” increments.
If you already have a pan and you would like the ContourU to be manufacturedto fit that pan, you must specify that you have an “existing pan” on the order form.You must also provide the width and the length of that pan.
Our pans have pre-punched holes that make it easy to attach and adjustinterfacing hardware and accessories. To mount a pan-mounted ContourU on to themobility base, we offer the On Chair Mounting kit (OCMK), Adjustable BackMounting Hardware (HWABK) and pan mounting bracket kits. The OCMK andHWABK hardware are available to mount ContourU pans onto or between the backcanes. The Pan mounting bracket kits are available for 1” (HWPMK01) or 7/8”(HWPMK78) cane diameters. These kits include 2 pair of pan mounting brackets and4 fixed rail clamps. You need 1 kit per pan, seat or back. If you are linking thecushions together with our links, then we recommend one pair of mounting bracketsfor each cushion. You can purchase the pan mounting brackets separately for thatpurpose. (MB04P & MB12P)
You may select to wood mount your ContourU system. A 3/8” thick piece ofplywood is custom cut to the size of the cushion. The wood is then applied to thefoam before the vacuum-forming process. A piece of ABS is placed over the wood sothat the cushion will have a finished appearance. The wood will or will not haveT-nuts depending upon your selection on the order form.
Wood mount with T-nuts is available to make it easier to attach and adjustinterfacing hardware and accessories. T-nuts are located to ( 1 5/8” and 2 5/8” fromfinished edge of cushion to allow flush mounting of the cushions using ourHWWMK01 and MWWMK78 hardware kits. To mount between or in front of thecanes/rails using any of our OCMK options, the T-Nuts are positioned 1” and 2”from the finished edge. Our wood mounts are available in heights/lengths/widthsranging from 10”-24”. If you are using the wood mount with cross brace notches tobe used as a drop base, 20” is the maximum width available. If you require widths of21”-24” the wood mount is only available flush mount to seat rails.
If you would like any modification to the pre-drilled T-nut pattern on the woodmount, you MUST note this in the special instructions on the order form and use theline drawing (Appendix b) to indicate your modifications. Feel free to make copies ofthis drawing for future use.
If you choose to use your own wood, you can supply the wood to us in the size/shape needed and we will apply it to the foam during the vacuum forming process.
An untrimmed cushion is made with at least 4” of extra vinyl or cloth mate-rial extending out from the edges of the cushion. This allows you to use yourown substrate for interfacing and to upholster the back side of a cushion in anymanner you choose. We cannot make a naked cushion untrimmed.
We can upholster the back of a cushion to make it more durable.
The upholstered bottom can be manufactured with or without Velcro®.With the Velcro® option we will sew 2 strips of Velcro® loop to the upholsteredbottom of the cushion. This option is convenient when the mobility base comeswith seat upholstery and you want to ensure that the cushion stays in place, orwhen mounting to drop seats, car seats or strollers. You do not need to pur-chase mounting hardware with this option.
We can manufacture your cushion to attach to a contoured seat pan or backshell. The cushion will be molded to fit the pan or shell, and will be supplied withan upholstered back with Velcro for attachment purposes. To order, you will berequired to send us the pan or shell so that we can match the contours. The shellwill then be returned to you with your cushions.
Note – If ordering with a Tarsys shell, you will only need to supply uswith the width and height/length and whether it is for a 1st or 2nd genera-tion. (You do not need to supply us with a shell if it is 2nd generation.)Please be sure to order the shell on your mobility base order form.
Wood slats (approximately 1-1/2” wide) will be added to all vinyl cushions.The purpose is to provide support to the vinyl cushion both during and after themanufacturing process. If for some reason they are not desirable; you may omitthem by checking the appropriate block on the order form.
Wood slats are not standard on naked cushions however; they will providesome additional support to the back. They can be added at your request and withno additional charge.
Please indicate that you want wood slats added/removed by checking theappropriate box on the order form.
If an Invacare customer is dissatisfied with their ContourU seating system, they have theopportunity to request up to 2 remakes within 180 days from date of shipment of the originalcushion. The following steps will need to be followed:
••••• The customer must call the Custom Seating Customer Service group at (800) 451-3553 toobtain a Return Authorization (RA) number.
••••• Once a Return Authorization number has been provided to the customer, the customermust return the previous cushion in order for manufacturing to fabricate the remake.They will also be given full credit of the original invoice amount at that time. Please notethat remakes can not be processed without the previous cushion being returned.
••••• The customer must follow the procedure for ordering a remake by sending in a splint ornew cast if required changes are other than dimensional AND complete the necessaryorder forms. (Dimensional changes include; seat width, seat depth, back width and backheight)
••••• If a remake is requested after 90 days from the shipment of the original order, a new castor splint is required for ALL remakes, even if the changes are dimensional AND completethe necessary order forms.
••••• Modified cushions will not be accepted.••••• No extensions will be granted.
If more than 2 remakes are requested, the customer will be charged for the full price of thenew system AND a new cast will be required.
If the customer decides that they do not want a remake and would like to return the cushionfor credit, they must contact Custom Seating Customer Service within 180 days from date ofshipment of the original cushion to receive a Return Authorization number to return theproduct. They will then receive a 75% credit and the normal 25% restock fee will beassessed.
Invacare will accept other product returns, such as miscellaneous hardware or simulatorsaccording to the following guidelines:
••••• A customer has 30 days from receipt of an order to obtain a Return Authorization.••••• A 25% restock fee will be assessed.••••• The customer will have 90 days after receiving the Return Authorization number, to
••••• ContourU and Silhouette seating products are warranted to be free from defects in materials andworkmanship. The following product breakdown for warranty is listed below:
Cushions (Seat & Back) 2 yearsService Parts 6 monthsCovers 90 daysHardware and Accessories 1 year
••••• During the warranty period, any defective product shall be repaired or replaced, at Invacare’soption. The Warranty does not include any labor or shipping charges incurred in the replacementor repair of the defective product.
••••• A copy of the Bill of Sale issued to the purchaser of the product may be required prior toprocessing a warranty claim.
Invacare does not warrant goods that have been misused or abused.
