Dynamic Tension System for Orthopedic Braces
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Solution Overview
Problem
Conventional orthopedic braces lack a dynamic tensioning system that can automatically distribute equal lateral tightening forces and prevent overtightening, making it cumbersome and inaccurate to secure the brace effectively, especially for PCL injuries where dynamic load is crucial.
Innovation Solution
A dynamic tension system with an adjustment mechanism that includes a cable, a spool with teeth, and a pawl mechanism to prevent overtightening, along with a torque-limiting tool to control tension, allowing for easy adjustment and even distribution of force across the brace.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional straps are used to secure the brace, then the brace can be attached to the user's leg, but manually tightening each strap is cumbersome and time-consuming
Solution Approach 1:
Multiple straps are merged into a single lace that passes through multiple slots on opposite sides of the brace. By pulling both ends of the lace simultaneously, all straps are tightened together in one action rather than individually, resolving the contradiction between ease of operation and time consumption.
Solution Approach 2:
The single lace serves multiple functions by passing through multiple slots and securing multiple straps. One lace component performs the work of multiple separate straps, allowing uniform tensioning across all attachment points simultaneously.
2Manufacturing precision
If conventional lacing systems are used, then the brace can be secured to the user, but it is difficult to ensure even distribution of tension along the lace
Solution Approach 1:
The lace is threaded symmetrically through slots positioned at equal intervals and orientations on opposite sides of the brace. This symmetrical arrangement ensures that tension is distributed evenly along the entire length of the lace, creating equipotential tension distribution and preventing localized over-tightening.
3Measurement precision
If multiple separate straps are used, then each strap can be adjusted individually, but it is difficult to gauge the general fit of the brace
Solution Approach 1:
A single lace with two free ends replaces multiple separate straps, providing a unified adjustment mechanism. The user can assess the overall fit by evaluating the tension in one lace rather than coordinating multiple independent straps, simplifying fit assessment while maintaining adjustability.
4Manufacturing precision
If the lace is threaded through multiple slots, then the brace can be secured, but higher tension near the ends causes the brace to be tighter in certain areas
Solution Approach 1:
The symmetrical slot arrangement and equal lace routing ensure that tension is distributed uniformly throughout the lace length. The geometry of the lacing path is designed so that no single section bears disproportionate load, eliminating localized over-tightening while maintaining secure attachment.
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 system ensures comfortable and effective tensioning by preventing overtightening, allowing for precise adjustment of the brace's fit and support, enhancing the stability and comfort of orthopedic devices like knee braces.
Implementation Method 1
A spring engages the pawl and biases the pawl toward the plurality of teeth.
Implementation Method 2
A pawl is pivotable relative to and is arranged to engage the plurality of teeth
Implementation Method 3
a torque-limiting tool to a spool of the adjustment mechanism arranged to limit winding of the cable from passing a predetermined level of tension
Data Source
AI summary
A dynamic tension system connects to an orthopedic device having a frame and a hinge connected to the frame. The dynamic tension system includes a cable, an adjustment mechanism connected to the cable and arranged to incrementally wind or release the cable, and a tension control device connected to the adjustment mechanism and arranged to limit the adjustment mechanism from winding of the cable past a predetermined tension level.