Orthopedic Brace Subshell Design for Ventilation and Fit

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Solution Overview

Problem

Conventional knee braces are often heavy, bulky, and lack ventilation and adjustment features, leading to discomfort and poor fit, which can reduce their effectiveness in providing stability and support.

Innovation Solution

The design incorporates flexible and ventilated subshells with pressure-relieving perimeter edge portions and reinforcement elements, allowing for a customizable fit and improved air circulation, while maintaining structural integrity and durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional knee braces are designed with heavy, bulky structures to provide stability and support, then the structural integrity is improved, but the weight and comfort deteriorate

Engineering Contradiction:

Improvestructural integrityVSAvoidbrace weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent employs flexible subshells made from lightweight materials that conform to the leg's contours, providing structural support and stability without the need for heavy rigid frames. The subshells maintain their shape and support properties while being significantly lighter than conventional brace structures.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent utilizes composite materials combining rigid and flexible properties in the subshell construction. This allows the brace to maintain structural integrity and stability while reducing overall weight, as the composite structure provides strength where needed without requiring bulk throughout the entire device.

Inventive Principle:

Principle #40Composite materials

2Strength

If conventional knee braces use rigid structures to provide stability, then the support is improved, but the ventilation and comfort deteriorate

Engineering Contradiction:

Improvesupport stabilityVSAvoidventilation deficiency

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent incorporates porous or perforated subshell structures that allow air circulation and ventilation while maintaining the structural support function. The porous design enables breathability and comfort without compromising the stability-providing capabilities of the brace structure.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The flexible subshell design allows the structure to conform closely to the leg's surface, creating a form-fitting interface that improves ventilation by allowing air flow along the leg while maintaining structural support and stability.

Inventive Principle:

Principle #30Flexible shells and thin films

3Adaptability or versatility

If off-the-shelf braces are designed to accommodate various leg geometries, then the versatility is improved, but the fit precision deteriorates

Engineering Contradiction:

Improveaccommodation rangeVSAvoidfit precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent employs adjustable components and flexible subshells that can adapt to different leg geometries through dynamic adjustment mechanisms. This allows off-the-shelf braces to achieve custom-fit precision by enabling the user to adjust the brace to match their specific leg shape and size requirements.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent incorporates adjustable parameters such as flexible subshell configurations and modular components that can be modified to match different leg geometries. This allows a single brace design to achieve precise fit across multiple users with varying leg shapes and sizes.

Inventive Principle:

Principle #35Parameter changes

4Manufacturing precision

If custom-fit braces are made to closely conform to leg geometry, then the fit precision is improved, but the adaptability to geometry changes deteriorates

Engineering Contradiction:

Improvefit precisionVSAvoidgeometry change accommodation

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent incorporates dynamic adjustment features in custom-fit braces, allowing the precisely fitted subshells to be adjusted if leg geometry changes over time. This maintains the initial custom-fit precision while providing adaptability for future geometry changes through adjustable components.

Inventive Principle:

Principle #15Dynamics

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 solution results in a lighter, more comfortable, and adjustable knee brace that provides better stability and support, enhancing the wearer's freedom and flexibility, with improved suspension and breathability.

Implementation Method 1

a resilient first shell body defining front and rear surfaces... The edge portion has greater flexibility than the first shell body

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS9039644B2Orthopedic component for use with an orthopedic brace

Publication Date: 2015.05.26 OSSUR HF

AI summary

An orthopedic component for use in orthopedic device includes a rigid frame and a flexible subshell connected to and extending flexibly outwardly from the rigid frame. The subshell may have a shell body and a perimeter edge portion defining a lip extending outwardly from a surface of a shell body and defining a clearance between the shell body and the lip. The subshell may include a plurality of slots and ventilated padding is used in combination with the slots. A tightenable fastener may be adjustably secured to the rigid frame and extend through an opening on the subshell, wherein the first side portion of the subshell is adjustable in location relative to the rigid frame.