Exoskeleton Leg Suspension With Supra-Malleolar Alignment

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Solution Overview

Problem

Existing exoskeleton systems struggle with maintaining secure alignment and suspension of devices worn on the leg, particularly at the knee joint, leading to discomfort and potential displacement due to gravity and movement.

Innovation Solution

A fit system for exoskeletons that includes a supra-malleolar strap positioned above the ankle, coupled with rigid braces and adjustable straps, ensuring alignment and suspension without relying on shoe integration, and incorporating adjustable joints and couplers for anatomical fit.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If existing exoskeleton systems use traditional suspension methods relying on shoe integration or knee joint positioning, then device alignment may be achieved, but device displacement occurs due to gravity and movement, causing discomfort and potential displacement

Engineering Contradiction:

Improvedevice alignmentVSAvoiduser comfort

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The suspension system is divided into multiple independent strap segments (thigh strap, knee strap, lower leg strap) that can be adjusted individually. Each strap segment targets a specific anatomical region to distribute the device weight and prevent displacement without requiring shoe integration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The straps are pre-positioned at anatomical landmarks (supra-malleolar region, knee joint area, thigh) to establish proper device alignment before movement begins. This preliminary positioning ensures the device remains suspended correctly throughout subsequent movements and gravitational forces.

Inventive Principle:

Principle #10Preliminary action

2Stability of the object's composition

If rigid braces are used to maintain device alignment, then structural stability is improved, but adaptability to different anatomical shapes is reduced

Engineering Contradiction:

Improvedevice alignmentVSAvoidanatomical fit

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The suspension system uses adjustable straps with movable fastening mechanisms that allow dynamic adaptation to different leg circumferences and anatomical variations. The straps can be tightened or loosened to accommodate various user sizes while maintaining stable device alignment through the rigid brace structure.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The strap length and tension parameters can be modified to fit different anatomical shapes. By changing these parameters, the system adapts to various leg sizes and contours while the rigid braces maintain the overall structural stability and device alignment.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If shoe integration is used for suspension, then device stability is achieved, but versatility in footwear choice is lost

Engineering Contradiction:

Improvedevice stabilityVSAvoidfootwear choice

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The suspension function is extracted from the shoe and relocated to the exoskeleton device itself through the strap system. By taking out the suspension requirement from the footwear, users gain versatility in shoe selection while the device maintains stability through its own integrated strap-based suspension mechanism.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The strap-based suspension system serves multiple functions: it suspends the device, positions it anatomically, and secures it without requiring any specific footwear. This universal approach allows the same suspension mechanism to work with any type of footwear or even without shoes in certain applications.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Adaptability or versatility

If adjustable joints and couplers are incorporated for anatomical fit, then adaptability is improved, but device complexity increases

Engineering Contradiction:

Improveanatomical fitVSAvoidsystem structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The adjustment mechanism is segmented into multiple independent strap systems rather than one complex adjustable joint. Each strap (thigh, knee, lower leg) can be adjusted separately using simple fastening mechanisms, achieving anatomical fit without requiring complex integrated adjustment systems.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12454047B2Fit and suspension systems and methods for a mobile robot

Publication Date: 2025.10.28 ROAM ROBOTICS INC

AI summary

An exoskeleton system comprising a leg actuator unit that is configured to be coupled to a leg of a user. The leg actuator unit includes: an upper arm and a lower arm that are rotatably coupled via a rotatable joint, the rotatable joint configured to be positioned at a knee of the user with the upper arm coupled about an upper-leg portion of the user above the knee and with the lower arm coupled about a lower-leg portion of the user below the knee. The upper arm is configured to be coupled to the upper-leg portion above the knee via a first set of couplers that includes a first upper-leg coupler, the lower arm is configured to be coupled to the lower-leg portion below the knee via a second set of couplers that includes one or more lower-leg couplers associated with a lower-leg brace, and an actuator extends between the upper arm and lower arm, the actuator configurable to move the upper arm and lower arm.