Custom Ankle Brace With Adjustable Compression For Ligament Stabilization
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Solution Overview
Problem
Current ankle braces fail to adequately compress and stabilize the anterior inferior tibiofibular ligament and posterior inferior tibiofibular ligament during high ankle sprain recovery, leading to prolonged recovery times and increased risk of re-injury, and are often cumbersome, costly, and inefficient for athletic activities.
Innovation Solution
A customizable ankle brace featuring a contoured foot plate with an enclosed calcaneal heel cup and pivotably coupled orthopedic splint, utilizing 3D printing for a custom fit and durable construction, along with an adjustable compression system to promote proper alignment and stability of the tibia and fibula.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional ankle braces are used, then basic ankle support is provided, but they fail to adequately compress and stabilize the anterior inferior tibiofibular ligament and posterior inferior tibiofibular ligament
Solution Approach 1:
The brace is divided into distinct functional components: a lower leg section with compression mechanisms targeting the tibiofibular ligaments, an ankle section with hinged joints for controlled movement, and a foot section with arch support. This segmentation allows each component to address specific stabilization needs without requiring a completely complex redesign of the entire brace structure.
Solution Approach 2:
The brace implements differentiated compression zones with varying pressure levels: higher compression on the proximal tibiofibular ligaments through adjustable straps and padding, moderate compression on the ankle joint, and lower compression on the foot. This local quality approach ensures critical ligamentous structures receive adequate stabilization while maintaining overall comfort and functionality.
2Manufacturing precision
If custom-fit braces are manufactured using traditional methods, then proper fit and support are achieved, but the process is cumbersome and costly
Solution Approach 1:
The brace incorporates multiple adjustable parameters including strap lengths, compression levels, hinge positions, and footbed contours that can be modified post-manufacturing. This allows a standardized base model to be adapted to individual patient needs through simple adjustments rather than requiring complete custom manufacturing for each user.
Solution Approach 2:
The brace features dynamic adjustment mechanisms such as adjustable straps, movable hinges, and flexible padding that can be modified based on swelling, comfort preferences, and recovery progression. This dynamic adaptability replaces the need for static custom-fit manufacturing while maintaining proper fit and support throughout the recovery process.
3Reliability
If rigid stabilization is applied to the ankle, then ligament healing is promoted, but mobility and comfort are reduced
Solution Approach 1:
The brace incorporates hinged joints at the ankle that allow controlled range of motion while maintaining stabilization. The hinges permit dorsiflexion and plantarflexion within safe limits while preventing excessive inversion, eversion, and rotation that could jeopardize ligament healing. This dynamic design balances immobilization needs with functional mobility requirements.
Solution Approach 2:
The brace applies rigid stabilization selectively to the injured tibiofibular ligaments through compression straps and padding, while leaving other ankle regions more flexible to maintain necessary mobility. The foot section includes arch support and heel cup for stability without completely restricting foot movement, allowing patients to perform rehabilitation exercises and daily activities while protecting the injured ligaments.
4Strength
If durable construction materials are used, then the brace withstands athletic activities, but the brace becomes heavier and less comfortable
Solution Approach 1:
The brace utilizes composite construction combining rigid elements (such as plastic or carbon fiber components for structural support and hinge mechanisms) with flexible elements (such as foam padding, elastic straps, and breathable fabric covers). This composite approach provides the necessary strength and durability to withstand athletic activities while keeping the overall weight manageable through strategic material selection and placement.
Solution Approach 2:
The brace is segmented into rigid structural components where strength is critical (lower leg section with compression straps, hinge mechanisms) and flexible components where weight and comfort are prioritized (padding layers, strap materials, footbed). This segmentation allows optimization of each section's material properties to balance durability requirements with weight constraints.
Data Source
AI summary
An ankle brace configured to be worn by a target wearer having a foot, an ankle, a lower leg, and a tibia and a fibula disposed within the lower leg, is disclosed. The ankle brace comprises a foot plate having a foot bed contoured to underlie the foot. The foot bed has a heel cup extending upward from the foot bed and has a relatively greater flexibility than a front foot portion of the foot bed. An orthopedic splint is pivotably coupled to the foot plate and configured to at least partially wrap around the lower leg. The orthopedic splint is disposed in an adjustable pocket, which is configured to adjust compression of the orthopedic splint relative to the lower leg to promote a rehabilitative position of the tibia and the fibula. The foot plate may be fabricated with a computer aided manufacturing process.