Adjustable Knee Brace Hinge for Joint Unloading and Custom Fit
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Solution Overview
Problem
Existing knee braces for osteoarthritis are ineffective in unloading weight from the knee joint, failing to provide significant pain relief and requiring invasive procedures, and custom-fit medical devices suffer from human error and inefficiency in measurement and manufacturing.
Innovation Solution
A knee brace with adjustable tensioning mechanisms, customizable through 3D scanning and machine learning, redistributes weight from the knee joint using a rigid or semi-rigid frame and hinges, providing extension assistance and unloading forces via adjustable tension elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional measurement methods are used for knee brace fitting, then the manufacturing process is simple, but the fit precision is poor due to human error
Solution Approach 1:
The patent replaces traditional mechanical measurement methods (manual measurement tools and human assessment) with optical scanning technology (laser or structured light scanners) to capture 3D surface geometry of the knee joint. This substitution eliminates human error in measurement while maintaining relatively simple manufacturing processes through digital modeling and automated brace fabrication.
2Adaptability or versatility
If fixed tension mechanisms are used in knee braces, then the device structure is simple, but the adaptability to different patients and conditions is poor
Solution Approach 1:
The patent implements dynamic tension adjustment mechanisms that allow the brace to transition from fixed to adjustable tension states. This includes features like adjustable straps, ratchet mechanisms, or elastic elements with variable stiffness that enable customization of tension levels based on patient-specific needs, activity level, and treatment phase, while maintaining structural simplicity through modular design.
3Reliability
If uniform brace design is used, then the manufacturing cost is low, but the effectiveness in relieving patellofemoral pain is reduced
Solution Approach 1:
The patent applies local quality by customizing specific regions of the knee brace based on 3D scan data and patient-specific anatomy. This includes varying the rigidity, curvature, and pressure distribution in different zones of the brace to match individual knee geometry and pain locations, particularly targeting the patellofemoral region with customized contouring and tension application points while maintaining cost-effective manufacturing through additive manufacturing or modular assembly.
Data Source
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AI summary
An adjustable tension knee brace for unloading weight from a knee joint, thus reducing pain and improving mobility, comprising: an upper and lower frame connected by an unloading hinge assembly, optionally comprising a sensor and processor allowing for control of brace tension. The brace may include a mechanism capable of adjusting a tensioning element. Electronic motors, sensors, and indicators may be included in the brace to improve brace performance. A method for applying geometric constraints to a starter file and considering specifications outside of fit to achieve an optimized, restorative joint brace or orthotic device. Specifications may include indications of the patient, X-ray, biometric, and/or MRI data, data from doctors, joint geometry, and envelope of motion. After the fitting process, the starter file undergoes exact commands to finish and/or add additional features. With a vertical integration from scanning an object to producing the custom fitted device, the product can be manufactured rapidly and at lower cost, improving access to superior devices at a reasonable price.