Modular Foot Plate for Ankle-Foot Orthosis with Adjustable Pivot
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Solution Overview
Problem
Existing jointed ankle-foot orthoses (AFOs) are customized as one assembled device, requiring complex and time-consuming processes for adjustment and replacement of parts, with standard ankle joints limiting height adjustments.
Innovation Solution
A modular jointed AFO system with a releasably mounted foot plate and adjustable ankle joint, allowing for retrofitting and reuse of parts, and a customizable orthotic upright made from thermoplastic carbon composite that can be thermoformed for personalized fit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If jointed AFOs are made as one assembled and customized device, then the device provides a precise fit and structural compensation, but the customization process becomes complicated and time-consuming
Solution Approach 1:
The AFO is divided into separate modular components including interchangeable foot plates, uprights, and ankle joints. Each component can be independently selected and assembled, eliminating the need for complex custom fabrication while maintaining precise fit through modular interlocking mechanisms and adjustable connection points.
2Ease of manufacture
If ankle joints are produced in standard lengths, then manufacturing is simplified, but the height dimension relating to the distance between the heel and ankle joint axis cannot be precisely incorporated
Solution Approach 1:
The foot plate incorporates adjustable connection points or telescopic elements that allow the distance between the heel and ankle joint axis to be dynamically adjusted after assembly. This enables standard-length ankle joints to accommodate varying patient anatomies through post-assembly adjustment rather than requiring custom manufacturing.
3Reliability
If the AFO is fully customized and assembled, then it provides optimal patient-specific support, but any adjustments or replacement of elements afterwards become rather complicated
Solution Approach 1:
The AFO employs clearly defined modular segments with standardized interfaces between foot plates, uprights, and ankle joints. Each segment can be independently removed and replaced through simple connection mechanisms, allowing easy maintenance and adjustment while preserving the overall customized configuration.
Solution Approach 2:
Multiple components share universal connection interfaces and mounting patterns, allowing any foot plate or upright to be interchanged with others in the system. This universality simplifies replacement procedures while maintaining the patient-specific customization achieved through selective component assembly.
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
The modular system simplifies the customization and maintenance of AFOs, enabling easier replacement of worn parts and adjustment of height, while the customizable upright reduces production time and ensures a precise fit.
Implementation Method 1
heating the covered part of the upright to a temperature above a deformation temperature
Implementation Method 2
contour the upright to the model until cooled to settling temperature of the thermoplastic carbon composite
Data Source
Figure 1
Figure 2a~2d
Figure 3a~3c
AI summary
Foot plate (10) for a jointed ankle-foot orthosis (AFO) (100) comprising an ankle joint (30) with a first arm (32) and a second arm (34) pivotably joined at a pivot point (36), said foot plate comprising at least one aperture (12) adapted to receive the first arm and where the foot plate is adapted to be releasably mounted to the ankle joint by fastening means (20) interlocking the first arm in the aperture in a final position (40) defined by a distance (d) between the foot plate and the pivot point.