Resiliently Deformable Hinge for Ankle Orthosis

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Solution Overview

Problem

Existing ankle foot orthoses with hinges are bulky, cause discomfort due to limited shock absorption and movement resistance, and are not customizable to individual patient needs.

Innovation Solution

A joint orthosis with a resiliently deformable hinge that includes a resiliently deformable portion configured to control ankle movement, providing shock absorption and customizable fit through 3D printing with varying material compositions and geometries.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a distinct hinge is used to provide greater ankle immobilization, then the degree of immobilization is improved, but the bulkiness and comfort are worsened

Engineering Contradiction:

Improveankle immobilizationVSAvoidcomfort when worn under shoe

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent replaces the traditional rigid hinge with a flexible printed circuit board that can bend and deform elastically. This flexible structure provides the necessary immobilization control while being thin and conformable, allowing it to be worn comfortably under shoes without the bulkiness of conventional hinges.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent changes the physical state and properties of the hinge material from rigid to flexible by using a printed circuit board with controlled elasticity. The flexible PCB can be engineered with specific bend radii, thicknesses, and material properties to achieve the desired balance between immobilization control and comfort.

Inventive Principle:

Principle #35Parameter changes

2Strength

If a distinct hinge with rivet and strengthening material is used, then the structural strength is improved, but the bulkiness and comfort are worsened

Engineering Contradiction:

Improvestructural strength around hingeVSAvoidcomfort when worn under shoe

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The flexible printed circuit board itself provides structural strength through its layered construction and material properties without requiring additional strengthening materials. The PCB's inherent rigidity in the planar direction combined with flexibility in the bending direction eliminates the need for rivets and external strengthening components.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The flexible PCB is constructed as a composite structure with multiple layers including conductive traces, dielectric materials, and flexible substrates. This composite construction provides the necessary structural strength and durability while maintaining flexibility and thin profile for comfortable wear.

Inventive Principle:

Principle #40Composite materials

3Reliability

If a flexible stabilizing ankle brace with pair of hinges is used, then the ankle support is improved, but the bulkiness and comfort are worsened

Engineering Contradiction:

Improveankle supportVSAvoidcomfort when worn under shoe

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent uses a flexible printed circuit board that can be engineered to provide the necessary ankle support through its elastic deformation characteristics. The flexible nature of the PCB allows it to conform to the ankle shape and provide support without the bulkiness of traditional hinge mechanisms.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The flexible PCB provides dynamic support that adapts to ankle movement through elastic deformation. Rather than rigid constraints, the flexible structure allows controlled movement while maintaining support, improving comfort while preserving functional reliability.

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 deformable hinge offers improved comfort and mobility by absorbing shock and resisting unwanted ankle movements, while being customizable to individual patient anatomy and reducing bulkiness.

Implementation Method 1

the resiliently deformable portion 3 is configured to resiliently deform in response to at least the ankle movement in the at least one direction, to resist further ankle movement in the at least one direction

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentEP3856096B1Joint orthosis with resiliently deformable hinge

Publication Date: 2026.04.01 UNIVERSITY OF DERBY

Figure 1~3B
Figure 4A
Figure 4B

AI summary

A joint orthosis such as an ankle foot orthosis for controlling joint movement is disclosed, and a method of manufacture. The joint orthosis comprises: a hinge for controlling joint movement in at least one direction; wherein the hinge comprises at least one resiliently deformable portion, and wherein the resiliently deformable portion is configured to resiliently deform in response to at least the joint movement in the at least one direction, to resist further joint movement in the at least one direction.