Orthopedic Knee Brace Hinge Assembly for Post-Rivet ROM Adjustment
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Solution Overview
Problem
Existing orthopedic knee braces with fixedly connected angle adjustment components cannot be assembled or replaced after the riveting process, limiting flexibility and convenience in adjusting the range of motion.
Innovation Solution
A hinge design with separable upper and lower hinge plates connected via snap-fit mechanisms, allowing angle adjustment components to be mounted before or after riveting, featuring flexible arms and limiting pins for adjustable rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the angle adjustment component is fixedly connected to the hinge upper plate during the riveting process, then the structural strength and stability are improved, but the ease of assembly and replacement deteriorates
Solution Approach 1:
The hinge is divided into separate components: the hinge body (including upper and lower hinge plates) and the angle adjustment component. This segmentation allows the angle adjustment component to be independently assembled onto the hinge body after riveting, rather than being permanently fixed during the riveting process. The separate assembly enables easier manufacturing and replacement while maintaining structural integrity through the connection mechanism between the hinge plates and the angle adjustment component.
2Reliability
If the angle adjustment component is fixedly connected during riveting, then the reliability of the connection is improved, but the adaptability and flexibility deteriorates
Solution Approach 1:
The hinge design incorporates dynamic adjustability through the angle adjustment component, which can be modified after assembly. The connection mechanism between the upper and lower hinge plates allows for adjustable range of motion settings while maintaining reliable structural connection. This dynamic capability enables the hinge to adapt to different angle requirements without compromising connection reliability.
3Productivity
If the hinge plates are assembled together before angle adjustment, then the manufacturing process is simplified, but the ease of operation and adjustment deteriorates
Solution Approach 1:
The hinge plates are pre-assembled through the riveting process to establish the basic structural framework, which improves manufacturing efficiency. Subsequently, the angle adjustment component is assembled onto the pre-assembled hinge body, allowing for easy adjustment of the range of motion. This two-stage process combines the benefits of simplified manufacturing with maintained operational flexibility.
Data Source
AI summary
A hinge for orthopedic knee braces with adjustable range of rotation, comprises: a first hinge plate (1a), a second hinge plate (1b), two support arms (3) disposed left and right; one or more angle adjustment components (4); wherein a space (10) is defined between the first hinge plate (1a) and the second hinge plate (1b); the heads (3a) of the two support arms (3) are located within the space (10), each head (3a) of each support arm (3) is rotatable and the heads (3a) mesh with each other; each angle adjustment components (4) comprises a retainer frame (41) and a plurality of limiting pins (42), the retainer frame (41) is connected to the second hinge plate (1b) and located above the second hinge plate (1b). In the hinge of the present invention, the angle adjustment components can be mounted on the second hinge plate either before or after the riveting process.