Dynamic Rotary Orthotic Control System Using Composite Struts
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Solution Overview
Problem
Existing ankle foot orthotic devices face issues with material inconsistency, fatigue, and mechanical limitations, such as wear and noise from moving parts, which affect their ability to provide consistent motion control and adapt to individual patient needs.
Innovation Solution
A Dynamic Rotary Orthotic Control System (DROCS) featuring a composite strut made of carbon fiber composite materials, with modular components including a footplate, upper and lower tibial cuffs, and adjustable wedges, allowing for customization and adjustment to fit individual patients, providing dynamic motion control and resistance without mechanical pivots or hinges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If mechanical hinges and moving parts are used in orthotic devices, then motion control capability is improved, but device complexity and susceptibility to wear and noise increase
Solution Approach 1:
The patent replaces traditional mechanical hinge systems with a composite material-based flexible joint system. The orthotic device uses strategically placed flexible joints made from composite materials that provide the necessary motion control without mechanical moving parts, thereby eliminating wear and noise while maintaining operational capability
Solution Approach 2:
The patent employs composite materials with varying degrees of flexibility and strength to create the orthotic structure. These composite materials incorporate flexible joints that enable controlled motion through material properties rather than mechanical articulations, resolving the contradiction between motion control and mechanical complexity
2Ease of operation
If rigid mechanical stops are used to control motion, then gait phase control is improved, but motion smoothness deteriorates due to impeded movement
Solution Approach 1:
The patent changes the physical parameters of the joint system by using flexible composite joints with progressively varying stiffness. This allows the device to control gait phases through gradual resistance changes rather than abrupt mechanical stops, maintaining motion smoothness while achieving phase control
Solution Approach 2:
The patent replaces rigid mechanical stop systems with flexible joint systems that use material properties to control motion. The flexible joints provide progressive resistance through deformation rather than abrupt stopping, eliminating motion discontinuity while maintaining gait phase control
3Adaptability or versatility
If hinged designs with multiple materials are used, then motion control versatility is improved, but device weight and bulk increase
Solution Approach 1:
The patent uses composite materials that combine multiple material properties within a unified structure. The composite construction provides varying flexibility and strength zones that deliver motion control versatility without requiring separate heavy material components, thereby reducing overall device weight
Solution Approach 2:
The patent merges multiple functional elements into a unified composite structure. The flexible joints and structural components are integrated into a single composite system rather than being separate mechanical assemblies, reducing device bulk and weight while maintaining motion control versatility
4Strength
If custom fabricated devices with rigid lamination are used, then structural strength is improved, but adaptability to individual patient needs deteriorates
Solution Approach 1:
The patent segments the orthotic device into modular components with standardized connection interfaces. This allows the device to maintain structural strength through precise modular connections while enabling easy customization and adjustment to individual patient needs by reconfiguring or replacing specific modules
Solution Approach 2:
The patent incorporates adjustable and reconfigurable elements within the composite structure. The device can be dynamically adjusted to match individual patient anatomies and gait requirements while maintaining overall structural integrity through the composite material system
Data Source
AI summary
An orthotic device includes a composite strut, a footplate removeably attached to a lower end of the strut, an upper tibial cuff removeably attached to an upper end of the strut and a lower tibial cuff removeably attached to a central portion of said strut. The footplate, upper tibial cuff and lower tibial cuff are formed of a composite material, preferably a carbon fiber composite. Each of the footplate, upper tibial cuff and lower tibial cuff include a support structure molded into the component with threaded holes therein. The upper and lower end of the strut may also include mounting holes therein for bolting the upper tibial cuff and footplate thereto. Mounting structure may also include mounting plates positioned on the rear surface of the strut and one or more tapered wedges mounted between the mounting structure on a rear of the strut, said tapered wedges allowing an angled orientation of the footplate and cuffs in relationship to the surface of the strut to which it is attached.