Brace System With Multi-Pulley Torque Mechanism
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Solution Overview
Problem
Existing knee braces often inhibit natural joint motion and are not designed to provide stability and reduce muscle load, especially when carrying heavy loads, and can be uncomfortable due to alignment issues and restrictive design.
Innovation Solution
A brace system that applies flexion and/or extension torque to joints while allowing normal motion, featuring a hinge assembly with intermediate links and pulleys, and tension-bearing elements that can be configured to apply torque and measure joint angles, allowing for adjustable fit and reduced sensitivity to alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a one degree of freedom (DOF) hinge is used in existing braces, then the brace structure is simplified, but the brace becomes sensitive to alignment with the knee joint, causing uncomfortable or dangerous loads and migration
Solution Approach 1:
The hinge assembly is divided into multiple independent components: a first hinge for sagittal plane motion, a second hinge for coronal plane motion, and a third hinge for axial rotation. This segmentation allows each hinge to handle specific degrees of freedom independently, reducing alignment sensitivity while maintaining structural simplicity.
Solution Approach 2:
The hinge assembly transitions from a fixed one-DOF structure to a dynamic multi-DOF system that adapts to the complex three-dimensional motion of the knee joint. The multiple hinges enable the brace to dynamically accommodate variations in joint movement patterns without requiring precise alignment.
2Stability of the object's composition
If a rigid structure spans between medial and lateral hinges to enforce fixed width, then the brace maintains structural stability, but the brace becomes wider than necessary and requires custom fitting
Solution Approach 1:
The distance between medial and lateral hinges is made adjustable through telescoping mechanisms or sliding connections, allowing the brace width to be dynamically adjusted to match different user anatomies. This eliminates the need for custom fitting while maintaining structural stability during use.
Solution Approach 2:
The brace design incorporates adjustable parameters including hinge spacing, strap lengths, and fastening positions. These parameters can be modified to accommodate various leg sizes and shapes, replacing the need for rigid fixed-width structures and custom fitting procedures.
3Stability of the object's composition
If the brace restricts twisting of the foreleg to maintain stability, then the brace provides better support, but it restricts normal DOF of the leg and increases likelihood of chafing and migration
Solution Approach 1:
The hinge assembly is segmented into components that independently handle different degrees of freedom: sagittal motion, coronal motion, and axial rotation. This segmentation allows the brace to provide stability in weight-bearing directions while permitting natural twisting motions during swing phase, reducing chafing and migration.
Solution Approach 2:
The brace incorporates adjustable resistance mechanisms that can be tuned to provide appropriate stability during stance phase while allowing greater freedom during swing phase. This dynamic parameter adjustment maintains support when needed without restricting natural motion unnecessarily.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The brace system provides stability and reduces muscle load, allows natural joint motion, and fits various sizes without custom fitting, minimizing discomfort and migration, while enabling torque application beyond 180 degrees for enhanced functionality.
Implementation Method 1
The brace system may further include two or more pulleys positioned between the upper portion and the lower portion. The brace system may further include a tension-bearing element substantially encircling each of the pulleys that may be anchored to the lower portion.
Implementation Method 2
In an alternative configuration, the tension-bearing element may be wrapped around the pulleys in a counterclockwise direction. In this configuration, the tension-bearing element may apply a flexion torque to the brace system.
Data Source
AI summary
The present disclosure provides a brace system including an upper portion and a lower portion. The brace system may also include a first pulley rotatably coupling the upper portion to a first intermediate link positioned between the upper portion and the lower portion. The brace system may also include a second pulley rotatably coupling the first intermediate link to a second intermediate link positioned between the upper portion and the lower portion. The brace system may also include a third pulley rotatably coupling the second intermediate link to the lower portion. Further, the brace system may include at least one tension-bearing element substantially encircling each of the first pulley, the second pulley, and the third pulley.