Hinge Brace Dial-Cam Mechanism for Precise Motion Limits

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Solution Overview

Problem

Existing hinge braces for managing joint injuries suffer from bulkiness, complexity in adjustment, risk of losing components, and large angular changes, making them inconvenient and ineffective for smaller patients or anatomical joints.

Innovation Solution

A hinge brace system with internal gears, cams, and pins, featuring a dial assembly that allows precise adjustment of flexion and extension limits through a dial mechanism, ensuring the brace can be locked at specific angles without needing removal for adjustments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If post-operation style braces are used to protect the joint, then the joint is immobilized effectively, but the brace becomes bulky and difficult to maneuver

Engineering Contradiction:

Improvejoint immobilizationVSAvoidbrace size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent implements nesting by placing the cam mechanism inside the gear housing, and the pin inside the cam. This nested arrangement allows the brace to maintain effective joint immobilization while significantly reducing the overall volume and bulkiness of the device, making it suitable for smaller patients or anatomical joints.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Adaptability or versatility

If pin style braces are used to allow partial ranges of motion, then the brace provides flexibility, but the adjustment mechanism becomes complicated and risks losing the pin

Engineering Contradiction:

Improverange of motion adjustmentVSAvoidadjustment mechanism

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the adjustment mechanism into a unified gear-cam-pin system where the dial assembly, cam, and pin work together as an integrated unit. The cam is received within the gear, and the pin is received within the cam, creating a compact adjustment mechanism that eliminates the risk of losing separate pins while maintaining flexible range of motion adjustment capabilities.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If stop style braces are used to prevent unwanted flexion and extension, then the joint is protected, but the brace must be removed for adjustments which is time consuming

Engineering Contradiction:

Improvejoint protectionVSAvoidadjustment time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent implements a dynamic adjustment mechanism where the dial assembly can rotate the cam to different positions while the brace remains on the patient. The cam rotates about the gear housing, allowing the limit markings to be adjusted to different angles without removing the brace, thus maintaining joint protection while eliminating adjustment time loss.

Inventive Principle:

Principle #15Dynamics

4Adaptability or versatility

If traditional hinge braces are used with large angular changes, then the brace provides sufficient range of motion, but the angular increments are too large (10-20 degrees or greater) for precise control

Engineering Contradiction:

Improverange of motionVSAvoidangular control

Core Design Contradiction:

Adaptability or versatilityVSMeasurement precision

Solution Approach 1:

The patent replaces traditional mechanical adjustment mechanisms with a dial-cam-gear system that provides fine angular control. The dial assembly rotates the cam in small increments, and the cam's interaction with the gear teeth translates this into precise angular adjustments of the limit markings, enabling control much finer than the 10-20 degree increments of traditional braces.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 provides a compact, user-friendly, and reliable way to manage joint motion, allowing precise control over angular limits, reducing the risk of component loss, and enhancing usability for smaller patients.

Implementation Method 1

a cam, and a pin associated with each of the first upright and second upright... The gear, cam, and pin are internal to a gear housing... The dial flange configured to rotatably step the cam, causing the cam to step the gear about the gear housing

Methodology Applied

Scientific EffectCam mechanism: Cam

Implementation Method 2

a first upright including gear teeth on an end internal to a joint of the hinge brace system, a second upright including gear teeth on an end internal to the joint of the hinge brace system, the gear teeth of the second upright meshed with the gear teeth of the first upright

Methodology Applied

Scientific EffectGear mechanism: Gear

Data Source

PatentUS12357484B2Hinge brace

Publication Date: 2025.07.15 SCHILLIG JEREMIAH

AI summary

A hinge brace system including a first upright, a second upright, a gear, a cam, and a pin associated with each of the first upright and second upright, and a dial assembly opposite the gear housing. The dial assembly includes a dial base and a dial flange, the dial flange configured to rotatably step the cam, causing the gear to step about the gear housing. The gear further includes a limit marking, the limit marking extruding from the gear into a slot of the upright and preventing the upright from travelling beyond a desired angle, the angle preventing rotation of the hinge brace system in at least one of extension and flexion.