Knitted Orthopaedic Brace with Integrated Tunnel Zone
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Solution Overview
Problem
Existing joint braces face issues with mechanical property alteration due to welding or sewing of functional elements, leading to reduced durability and comfort, and lack adequate fit and compression for rehabilitated muscle and joints.
Innovation Solution
A knitted article with integrated tunnel and flat-knitted zones, allowing functional elements like tensioning cables to be inserted without altering mechanical properties, combined with localized padding for comfort and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding or sewing techniques are used to apply functional elements to the textile base, then functional elements can be securely attached, but the mechanical properties of the brace are altered and durability is reduced
Solution Approach 1:
The containment pocket is integrated directly into the knitted textile structure during the knitting process itself, eliminating the need for separate welding or sewing operations. The pocket forms as an inherent part of the fabric's tubular structure, maintaining uniform mechanical properties throughout the brace while providing secure functional element placement.
Solution Approach 2:
The functional element placement is extracted from the post-manufacturing assembly process and incorporated into the textile manufacturing process itself. By forming containment pockets during knitting, the patent removes the need for separate attachment operations that would alter mechanical properties.
2Strength
If welding techniques are used to apply functional elements, then secure attachment is achieved, but the operating life of the brace is reduced due to altered mechanical behavior
Solution Approach 1:
The containment pocket structure is merged with the base textile structure through integrated knitting, creating a unified construction without weak seams or altered zones. This homogeneous structure maintains consistent mechanical behavior throughout the brace's service life, preventing premature failure at attachment points.
3Ease of operation
If conventional fabric construction is used, then wearability and comfort are provided, but adequate fit and compression on traumatized muscle and joint bands cannot be ensured
Solution Approach 1:
The patent creates localized containment pockets within the knitted structure that provide targeted compression and support at specific anatomical locations while maintaining the overall flexibility and comfort of the fabric. The pockets are strategically positioned to apply pressure where needed without compromising general wearability.
4Object-affected harmful factors
If pockets and paddings are applied by welding or sewing, then functional elements are contained and cushioned, but the mechanical behavior of the brace is altered in the zones where they are applied
Solution Approach 1:
The containment pocket and padding structures are merged into a single integrated knitted construction. The padding is incorporated during the knitting process itself, creating a homogeneous structure that provides impact protection without requiring separate welding or sewing operations that would create mechanical discontinuities.
Data Source
AI summary
A knitted article, in particular for an orthopaedic brace, including at least one flat-knitted zone and at least one tunnel zone suitable for the integration of functional elements, such as tensioning cables, comprises a lower layer consisting of several rows of knitted stitches obtained by knitting a first flat-knitted thread, and an upper layer consisting of several rows of knitted stitches obtained by knitting a second flat-knitted thread. The flat-knitted zone consists of lower and upper layer connected to each other. In particular, the first and second flat-knitted threads are the same type of flat-knitted thread. In addition, the tunnel zone consists of lower layer and upper layer detached from each other to define a containment pocket to allow functional elements to pass and be kept in place.