Low Profile Knee Brace Using Composite Shells
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Solution Overview
Problem
Existing knee braces for treating ACL, PCL, MCL, and LCL instabilities are often bulky, heavy, and uncomfortable, leading to reduced patient compliance and effectiveness in providing support and stability.
Innovation Solution
A low-profile orthotic brace constructed from lightweight materials, featuring a customizable upper leg cuff and a flexible lower cuff connected by rotatable hinges, with bilateral rigid members and straps attached directly to the liner for secure fit and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional rigid knee braces are used to provide structural support and stability, then knee joint support is improved, but weight and bulk increase leading to reduced comfort and compliance
Solution Approach 1:
The patent replaces traditional rigid metal frames with flexible yet strong materials such as carbon fiber and advanced polymers. These materials maintain structural support and stability while dramatically reducing weight and bulk, allowing the brace to be low-profile and comfortable for extended wear.
Solution Approach 2:
The patent utilizes composite materials combining carbon fiber, fiberglass, and advanced polymers to create a brace that offers both structural integrity and weight reduction. These composites provide the necessary strength for knee joint support while being significantly lighter than traditional metal constructions.
2Ease of operation
If traditional rigid knee braces with removable padding and straps are used, then adjustability and fit are improved, but device complexity and bulk increase leading to reduced comfort
Solution Approach 1:
The patent integrates padding, straps, and structural elements into a unified low-profile design. The flexible materials allow the brace to conform to the leg contours while maintaining adjustability through integrated closure systems, eliminating the need for separate removable components and reducing overall complexity.
Solution Approach 2:
The patent employs dynamic, flexible materials that adapt to the wearer's leg shape and movement. The brace maintains adjustability through elastic and flexible components that provide continuous adaptation rather than fixed rigid structures, reducing complexity while preserving ease of operation.
3Strength
If traditional bulky knee braces are used to ensure structural strength, then stability is improved, but wearability and comfort are reduced leading to poor patient compliance
Solution Approach 1:
The patent uses flexible shell structures made from carbon fiber and advanced polymers that provide structural strength without bulk. These thin-film composite structures maintain the necessary rigidity for stability while being thin enough to be low-profile and comfortable for continuous wear.
Solution Approach 2:
The patent employs composite materials that deliver high strength-to-weight ratios, enabling the brace to maintain structural integrity and stability while being lightweight and comfortable. The combination of carbon fiber, fiberglass, and polymers creates a structure that is both strong and wear-friendly.
Data Source
AI summary
Methods of manufacturing a low-profile brace for treating a ligament injury are provided. Among other features, a method of manufacturing includes providing a liner and permanently attaching provided first and second metal components configured to be formed to the shape of a thigh and a calf of the patient; and providing upper and lower lateral rigid members, each having a three-dimensional structure comprising a recessed portion extending along a length of the respective lateral rigid member. The recessed portion includes a substantially y-shaped portion that is: disposed at a proximal end of the lower lateral rigid member or at a distal end of the upper lateral rigid member, and further raised outwardly away from the patient's leg from adjacent portions of the recessed channel that separate the substantially y-shaped portion from a perimeter of the lower or upper lateral rigid member. Related methods of use are also provided.