Modular Knee Brace Structure for Adjustable Fit and Pressure Distribution

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Solution Overview

Problem

Existing orthopedic devices fail to provide effective knee braces that are adjustable in both custom-fit and off-the-shelf braces to achieve superior functional performance characteristics while being comfortable to the wearer when worn, and lack features for accommodating a variety of leg geometries and providing even pressure distribution.

Innovation Solution

A versatile orthopedic device with frame components made from materials like aluminum alloy, allowing cold-forming to conform to individual anatomies, and a modular design with adjustable struts and pads for customizable fit and pressure distribution, including a strap kit for securing the device to the leg.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a knee brace is designed with a fixed geometry to provide stable support, then stability is improved, but it cannot accommodate variations in leg geometry over time

Engineering Contradiction:

ImprovestabilityVSAvoidaccommodation of leg geometry variations

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The knee brace incorporates adjustable components including movable pads that can be repositioned along the frame, adjustable straps with multiple attachment points, and modular elements that can be reconfigured. This dynamic adjustability allows the brace to adapt to changing leg geometries while maintaining stable support and proper alignment.

Inventive Principle:

Principle #15Dynamics

2Manufacturing precision

If a custom-fit knee brace is made to closely conform to the exact geometry of a leg, then fit precision is improved, but it requires complex manufacturing and cannot accommodate future geometry changes

Engineering Contradiction:

Improvefit precisionVSAvoidmanufacturing complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The knee brace is divided into modular segments including separate frame components, adjustable pads, and independent strap systems. This segmentation allows each component to be manufactured using standard processes while providing precise fit through the combination and adjustment of multiple simpler parts rather than requiring complex custom manufacturing of the entire device.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The brace incorporates adjustable components including movable pads that can be repositioned along the frame, adjustable straps with multiple attachment points, and modular elements that can be reconfigured. This dynamic adjustability allows the brace to adapt to changing leg geometries while maintaining stable support and proper alignment.

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If an off-the-shelf knee brace is designed to accommodate a variety of leg geometries, then versatility is improved, but it cannot provide a precise fit for any particular individual

Engineering Contradiction:

Improveaccommodation of various leg geometriesVSAvoidfit precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #15Dynamics

4Stability of the object's composition

If a knee brace uses heavy, bulky apparatus to provide support, then stability is improved, but comfort and ventilation are reduced

Engineering Contradiction:

ImprovestabilityVSAvoiddiscomfort and poor ventilation

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The knee brace utilizes a lightweight frame construction with strategic placement of padding and support elements rather than heavy bulky materials throughout. The design incorporates ventilation channels and breathable materials in contact areas, providing stability through efficient structural design rather than mass, thereby reducing discomfort and improving ventilation.

Inventive Principle:

Principle #30Flexible shells and thin films

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 device provides a comfortable, secure fit and even pressure distribution, accommodating various leg geometries, and is adaptable for different knee conditions, enhancing stability and reducing discomfort.

Implementation Method 1

frame components made from materials like aluminum alloy, allowing cold-forming to conform to individual anatomies

Methodology Applied

Scientific EffectCold-forming: Cold-forming

Data Source

PatentEP3166547B1Versatile orthopedic device

Publication Date: 2025.12.17 OSSUR ICELAND EHF

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Figure 2A~3A
Figure 3B

AI summary

A versatile orthopedic device (10) is arranged to convert between ligament and osteoarthritis treatment, and to accommodate a variety of leg anatomies. The orthopedic device is preferably configured as a double-upright brace indicating struts (16, 17), frame component sections (24, 26) and associated hinges (20, 24) preferably intended to be along both medial and lateral sides of a wearer's leg. A strap kit (48) with an unloading strap system may be added to the orthopedic device for conversion into an orthopedic device for osteoarthritis relief.