F522 ice pack (117)

DESIGN TECHNOLOGY
PRODUCT DESIGN
A**** C**** ****
B****** SCHOOL
F322
1
Dear Moderator,
All videos work however
if they do not for some
reason then you can find
them in the folder marked
Videos under the slide
number and video
number.
Thank You

Product Design and Analysis
Introduction
The 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 Ambulance
for 6 years, and believe
that it can be improved in
order to increase its effectiveness.
Function
The 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.
Safety
There 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 Anthropometrics
The 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 in
drawers 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.
Materials
The 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.
Packaging
The 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.
Cost
St John Ambulance - £0.40 (Single)
- £9.50 (25 pcs)
Medisave - £0.50 (Single)
Weaknesses
I 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 2
Picture showing the warning
information printed on the front of
Figure 3
Pictures
showing the
instructed
method of
activating the
pack.
Figure 1
The Koolpak Instant Ice Pack
Figure 4
Video 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.
2
Video

Manufacturer Needs
Target Market
The 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.
Labour
Because 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 Production
The 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.
Assembly
The 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
Transport
The transport cost of the ice pack is
relatively small, as the product is shipped
from the UK internally. They are also
packed in boxes of 25 (Figure 1) for
shipping to the consumer, this allows the
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 is
strong 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
Cost
The 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.
Maintenance
The 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 Use
The instant ice pack needs to be easily manipulated so
Instructions
There 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.
Ergonomics
The 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 Storage
The 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 Afterlife
After 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
Figure 2
Picture showing the
effects of ammonia
in water.
Product Design and Analysis cont.
Figure 1
Picture showing two boxes of 25
packs, one opened and one
unopened.
Figure 3
Picture showing the instructions
on the reverse of the pack.
3

Key Criteria
Introduction
In this section I will discuss the key decisions the designer
made when planning and designing the Koolpak Instant
Ice Pack.
Function
The 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.
Maintenance
The 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.
Storage
The 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.
Ergonomics
The 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.
Assembly
There 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.
Materials
The 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.
Weight
The 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.
Safety
The 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.
Competition
The 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 Safety
The 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 2
Video demonstrating
how the Koolpak Instant
Ice Pack is used by a
qualified First Aider.
Figure 1
Picture showing the instructions and diagrams for use
printed on the reverse of the pack.
4
Video

Figure 3 (Left)
Picture showing the
Spencer Instant Ice
Pack
Figure 4
Picture
showing
the
Spencer
Instant
Ice Pack
compare
d to the
Koolpak
Instant
Ice Pack
Strengths and Weaknesses Comparison
Introduction
In 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 Product
Koolpak Instant Ice Pack (Figure 1)
Function
The 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 Materials
The 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.
Ingredients
The 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 Process
The 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 Suitability
The 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 also
dangerous to use without
a wrap or towel to cover
the pack in order to prevent freeze burns.
Aesthetics
The 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.
Cost
The 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 Products
Primary Research - Spencer Instant Ice Pack
(Figure 3)
Function
The 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.
The 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.
Ingredients
The 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 Process
Requires 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.
Key
Positive
Negative
Comparison
Conclusion
Elements to Carry
Forward
Figure 1
Picture showing the
Koolpak Instant Ice Pack
5
Video
Figure 2
Video discussing some
advantages or the pack with
a First Aider and regular
consumer.

Strengths and Weaknesses Comparison cont.
Easy 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.
Aesthetics
The 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.
Cost
Inexpensive 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)
Function
It 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.
The 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.
Ingredients
The 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.
The 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)
Function
Used 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.
The outer pack cannot be easily punctured as it is made of
hard plastic, therefore not let any of the contents out.
Ingredients
The contents is made up of non-toxic gel which does not
harm the environment and does not spill easily.
The 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.
Key
Positive
Negative
Comparison
Conclusion
Elements to Carry
Forward
Figure 1 Pictures
showing the Milk &
More Gel Ice Pack
Figure 2 Pictures
showing the Addis
Gel Ice Pack
6
VideoFigure 3
Video detailing the comparison between
the Koolpak Instant Ice Pack, the Gel Ice
Pack and the Solid Ice Pack.

Secondary Research - Koolpak Original Instant
Ice Pack (Figure 1)
Function
The 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 does
not 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
The 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.
Ingredients
The 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
Suitability
Easy to wrap
around injuries as it
is long and easily
manipulated it is
also coated with a
soft material so is
comfortable to the
as well as trying to hold with one hand. It has no ability to
be able to be attached to a person also.
Aesthetics
There are large diagrams showing instructions of use on
the reverse so that anyone can use it.
Cost
They 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 Products
Primary 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 attached
Clasp easily broken and is
difficult to attach and undo. Only one
size.
Strong
Difficult 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 extent
Worn 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.
Key
Positive
Negative
Comparison
Conclusion
Elements to Carry
Forward
Figure 1 Picture
showing the
Koolpak Original
Instant Ice Pack
7
Video
Figure 2 YouTube Video
demonstrating the Koolpak
Original Instant Ice Pack

Slap on Strap
Easy 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 Strap
Fits to any size, doesn’t
become loose and comfortable to wear.
It is very durable and does not
break easily.
Velcro Hi-Vis Strap
Easy to attach and take off,
adjustable and is
strong, reusable and durable.
Sometimes uncomfortable if
worn incorrectly.
Shoe Velcro Strap
Secure, easy to use and undo.
Adjustable and durable.
May become loose if not
secured correctly.
Blood Pressure Cuff Strap
Large 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 Strap
Ergonomically 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 Materials
Hot Water Bottle
Durable 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 Cover
Soft 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 Foam
Soft 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.
Key
Positive
Negative
Comparison
Conclusion
Elements to Carry
Forward
8

Introduction
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 Issues
Source of Raw materials
The 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.
Polyethylene
Polyethylene 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.
Urea 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, followed
by India, Russia and
the USA, however
Only a small percen-
tage goes to instant
ice pack manufacture, over 80% is used as fertilisers for
agricultural crops.
Water
The 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
Production
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.
Transport
There 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 Materials
The 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 1
Map showing world crude oil production 1980-
2010
Figure 2
Flow diagram
showing the
manufacturing of
Urea
Figure 3
Picture showing a Urea factory connected to a Ammonia
factory
Urea
Factory
Ammonia Factory
Crude Oil -
Urea -
Water -
Polyethylen
e -
Figure 4
Map showing the
sources,
transportation and
production of the
materials used in
the Instant Ice Pack
9

Environmental Ethical Debate
Overall 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
Ammonia factory, however there are some changes that
could be made to reduce its impact.
Social Issues
Safety
The 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 conditions
In 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
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 Manufacturing
Companies 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 Debate
In 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
Moral Implications cont.
10
Figure 1
Picture showing
granulated Urea
The Guardian Article - Cambodia Garment Case
Study

Economic Implications
Employment
The 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 Manufacturing
The 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 Money
As 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.
11
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 Debate
There 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.
Sustainabilit
y
Strength /
Durability
Safety
Manufacturin
g
Transport
Recyclabili
ty
Cost of
Productio
n
Ergonomic
s
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 -
Satisfactor
y -
Good -
Excellent -
Moral Implications Sources
http://www.essentialchemicalindustry.org/chemicals/urea.html
http://www.essentialchemicalindustry.org/polymers/polyethene.ht
ml
http://www.theguardian.com/global-
development/2013/dec/16/cambodia-garment-workers-low-
wages-poor-conditions
http://www.nestle.com/asset-
library/documents/library/documents/corporate_social_responsibil
ity/nestle-csv-summary-report-2013-en.pdf
http://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.
Video
Figure 1
Video
showing a
BBC news
report about
Nestlé youth
employment
strategies

Design 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 Weaknesses
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.
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 Product
Key
Function, Infection Prevention and Control, Safety, Ergonomics, Materials, Storage, Technical Details, Aesthetics,
Comfort, Afterlife
Specifications
Function
F1 - 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 effectively
Infection Prevention and Control
IPC1 - My product must be hygienic as it is used for clinical treatment so it should not easily spread disease
IPC2 - 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 wipes
Safety
S1 - My product must not harm the user when being used so that additional injury is not caused
S2 - 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 environment
S3 - My product must no cause freeze burns if directly applied to skin as this is extremely dangerous and painful
Ergonomics
E1 - 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 emergency
Materials
M1 - The inner contents must include a water pouch and Urea chemicals as this causes the pack to cool down instantly
M2 - 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 skin
M3 - My product should use reasonably sustainable resources that are readily available and can be locally sourced
without global shipping needed
Storage
St1 - 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 easily
St2 - 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 difficulty
Technical Details
T1 - 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 ease
T2 - 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 kits
Aesthetics
A1 - My product must look clean and clinical so that dirt, or any imperfections, can be easily seen on the pack
A2 - 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 law
A3 - My product should have the appropriate branding for whichever service provider and/or consumer it is being sold to if
required
Comfort
C1 - My product should be comfortable to the user when being used and must not worsen an injury that it is treating
Afterlife
12

Development 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 number
Ideas to take forward
Ideas to dismiss
Development
Function, Infection Prevention and Control, Safety,
Ergonomics, Materials, Storage, Technical Details,
Aesthetics, Comfort, Afterlife
Weakness 1
Figure 1
Images showing a paper model of idea 1.1
including a simple test to see how easily it
wraps around an arm.
13
1.1.1 1.1.2
1.1.3My 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

Development of Improvement cont.
14
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.
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.

15
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).
1.5.1
Another 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).
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 and
shape 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.
Vide
o

Figure 1 (Left & Above)
Sketches and paper models
of idea 2.1 with the strap
attached to the KoolPak
instant ice pack
16
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.
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
discussing
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

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.
17
2.3
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

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.
Figure 3 (Left)
Sketches detailing the three
versions of the magnetic strap
Figure 4 (Above)
Sketches showing how the
magnetic strap would
automatically connect so that the
strap would stay in place
18
2.4.
2
2.4.1
Similarly 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.
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

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.
Figure 1 (Above)
Metal clip belt using 2 sprung clasps to keep the
male clip in place
Figure 3 (Below)
Apple iWatch magnetic clip to hold the strap in
place
Video showing the mechanism in motion
19
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
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

20
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.
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

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 fabric
2. Polypropylene sheet
3. 3mm foam
4. 6mm foam
These 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.
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
21
3.1
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

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.
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
22
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

In 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
23
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
0
2
4
6
8
10
12
14
16
MinimumTemperature(˚C)
Material
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)

Consumer 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
24
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

In 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 Results
Analysis 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.
25
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 0
Polyester fabric (1 Layer) 2
Polyester fabric (2 Layers) 4
Polyester fabric (3 Layers) 5
Polyethylene sheet 14
Foam (3mm) 6
Foam (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 occur
Figure 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

Weakness 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 Improvements
My 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.
26
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

F522 ice pack (117)

Recommended

Recommended

More Related Content

Viewers also liked

Viewers also liked (8)

Similar to F522 ice pack (117)

Similar to F522 ice pack (117) (20)

More from Amanda_Liepina

More from Amanda_Liepina (15)

Recently uploaded

Recently uploaded (20)

F522 ice pack (117)

Editor's Notes