Flex Lock Orthotic Brace Hinge Mechanism
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Solution Overview
Problem
Existing orthotic braces with hinge plates and removable pins are complex to manufacture and use, prone to dust exposure, and risk component loss or unintended movement, which can lead to reinjury during the healing process.
Innovation Solution
A flexible locking mechanism, known as the flex lock, which uses elastomeric material tabs with receiving holes and pull tabs to secure and adjust flexion and extension ranges without tools or removable parts, ensuring secure and easy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a system of holes with removable pins and retaining cover is used to adjust flexion and extension ranges, then the brace can be adjusted to various positions, but the device becomes complex to manufacture and use, and components may be lost or move unintentionally
Solution Approach 1:
The patent removes the complex retaining cover and multiple pin system, extracting only the essential function of limiting range of motion. The simplified design uses a single pin that cannot be lost or inadvertently moved, eliminating the complexity of the previous system while maintaining adjustability through a different mechanism.
Solution Approach 2:
The hinge plate is segmented into multiple holes arranged in specific patterns, allowing the single pin to be positioned at different locations to achieve various flexion and extension limits. This segmentation provides adaptability without requiring multiple pins or a retaining cover.
2Reliability
If a retaining cover is used to secure pins on the hinge plate, then pins are prevented from loss or unintended movement, but the operator must remove and reattach the cover for adjustments, increasing time and complexity
Solution Approach 1:
The retaining cover is completely extracted from the design. Instead of securing pins with a cover that must be removed and reattached, the patent uses a single pinned design where the pin itself serves both as the adjustment mechanism and the securing element, eliminating the time-consuming cover operation.
Solution Approach 2:
The single pin design is self-securing through its interaction with the hinge plate holes and the footpiece assembly. The pin automatically maintains its position without requiring external retention mechanisms, and adjustments are made by simply moving the pin between holes without additional steps.
3Ease of operation
If pins are exposed for adjustment, then the operator can change the range of motion settings, but the hinge plate and inner components are exposed to dust and debris
Solution Approach 1:
The retaining cover that exposed internal components is removed, but the design compensates by using a single pin that can be accessed and adjusted without exposing the entire hinge plate mechanism to contaminants. The simplified structure reduces the surface area exposed to dust and debris.
4Adaptability or versatility
If multiple pins are used to limit both flexion and extension, then comprehensive range of motion control is achieved, but the manufacturing and assembly process becomes more complicated
Solution Approach 1:
Three pins are extracted from the design, leaving only a single pin. The comprehensive range of motion control previously achieved with multiple pins is maintained through the strategic arrangement of holes in the hinge plate, which allows one pin to effectively limit both flexion and extension at various angles.
Solution Approach 2:
The single pin serves multiple functions that previously required four separate pins. By positioning the single pin in different holes on the hinge plate, it can limit flexion at various angles, limit extension at various angles, and provide comprehensive range of motion control, making the pin a multi-functional element.
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 flex lock system provides a cost-effective, user-friendly mechanism for securely locking angular ranges, preventing inadvertent re-setting and reducing the risk of reinjury by eliminating the need for tools and minimizing component loss.
Implementation Method 1
a flexible locking mechanism, known as the flex lock, which uses elastomeric material tabs
Data Source
AI summary
A flex lock system for locking an orthotic brace having a push button for adjusting the range of flexion angles and a push button for adjusting the range of extension angles for the orthotic brace. The flex lock system has a tab having a receiving hole configured to fit around a push button and to prevent the push button from being depressed and adjusting the ranges of flexion or extension improperly. The flex lock system is made of a flexible material that has particular elasticity and compressibility to function as a flex lock as described.