Knitted Orthosis Precast with Thermoplastic Shell
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Solution Overview
Problem
Current orthopedic braces require time-consuming adjustments and customization, with existing methods for producing custom ankle foot orthoses being inefficient and costly due to their manual and labor-intensive nature.
Innovation Solution
A knitted orthopedic precast system comprising a shell portion made of thermoplastic material and a flexible portion made of non-thermoplastic material, where the thermoplastic material is partially melted to fuse and rigidify the shell, allowing for efficient customization and production of custom orthoses that conform to the body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manual methods are used to produce custom orthoses, then customization and fit are improved, but production time and cost increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-knitting the orthosis with thermoplastic material in a standardized configuration before customization. The precast orthosis is prepared in advance with integrated shell and flexible portions, eliminating the need for manual assembly during customization. This pre-preparation significantly reduces production time while maintaining the ability to customize fit through heat molding and stretching processes.
Solution Approach 2:
The patent utilizes parameter changes by transforming the thermoplastic material from a flexible state to a rigid state through controlled heating and cooling. The shell portion is heated to a specific temperature range to become pliable, allowing it to be molded to the patient's anatomy, then cooled to set the custom shape. This parameter transformation enables efficient customization without manual labor-intensive processes.
2Reliability
If multiple straps are used to secure the orthosis, then stability is improved, but ease of operation deteriorates due to time-consuming adjustments
Solution Approach 1:
The patent merges the shell portion and flexible portion into a single integrated precast orthosis structure. The shell provides rigid support and stability, while the flexible portion made of elastic material provides secure attachment to the body. This combination eliminates the need for multiple separate straps and manual adjustments, as the elastic flexible portion automatically adapts to body movements while maintaining stability.
Solution Approach 2:
The patent applies dynamics by using an elastic flexible portion that can dynamically adapt to body movements and changes in body shape. The elastic material allows the orthosis to maintain stability during movement while automatically adjusting to the patient's anatomy, eliminating the need for manual strap adjustments. The dynamic properties of the elastic material ensure continuous stability without requiring user intervention.
3Ease of operation
If resilient material is used in orthosis sock, then ease of wear is improved, but support adequacy deteriorates
Solution Approach 1:
The patent uses composite materials by combining thermoplastic material for the shell portion with elastic material for the flexible portion. The thermoplastic shell provides rigid structural support and stability, while the elastic flexible portion ensures ease of wear and comfortable fit. This composite structure integrates the advantages of both material types, achieving adequate support without compromising ease of wear.
Solution Approach 2:
The patent segments the orthosis into two distinct functional portions: a rigid shell portion for support and a flexible elastic portion for ease of wear and attachment. The shell portion comprises at least 30% of the orthosis and provides structural integrity, while the flexible portion comprises at most 70% and ensures comfortable fit and ease of wear. This segmentation allows each portion to optimize its specific function without compromising the other.
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
This method enables the efficient production of custom orthoses that provide adequate support and stability, reducing the time and cost associated with traditional methods while allowing for easy adjustment and wear, improving patient comfort and reducing the risk of mispositioning during movement.
Implementation Method 1
a shell portion that includes a knitted strand of at least a first thermoplastic material that melts at a first melting point
Implementation Method 2
Heating the precast to at least the first melting point to partially melt and thereby fuse and rigidify the shell portion
Implementation Method 3
Heating the precast to at least the first melting point
Data Source
AI summary
An orthopedic precast comprises a knitted shell portion and a knitted flexible portion. The precast is positioned about a limb or other mold, and heat or other hardening agent is used to harden the shell portion, while retaining flexibility in the flexible portion. Contemplated hardening agents include light, heat, and chemical polymerizing agents. In some embodiments the shell portion includes threads or yarns comprising a thermoplastic, which is then hardened by heating the thermoplastic sufficiently to at least partially melt, and thereby fuse together some of the threads or yarns, and then cooling to ambient temperature. In other embodiments, the precast is contained in a bag or other airtight container, along with a self-heating composition that is triggered to release heat upon contact with oxygen. In still other embodiments, the precast includes a prepolymer of other polymerizable composition, which is polymerized by effective application of light, heat, and/or chemical agent(s).