Modular Orthopedic Support with Lattice Structure

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Solution Overview

Problem

Existing pre-fabricated orthopedic braces lack moldability, customization, and comfort, leading to reduced dexterity and increased inventory needs, while trapping heat and moisture against the skin, necessitating improved orthopedic supports for joint immobilization.

Innovation Solution

A modular orthopedic support system with a lattice structure that includes apertures and fillable channels, allowing for the attachment of interchangeable accessories and personalization, using a liquid resin to form a rigid structure for customizable immobilization and accessory integration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If pre-fabricated braces are used, then manufacturing complexity is reduced, but moldability and customization capability deteriorate

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidmoldability and customization

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The orthopedic support is divided into multiple modular components including a lattice structure module, immobilization module, and accessory module that can be independently manufactured and then assembled together, enabling both ease of manufacture and customization

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system transitions from static pre-fabricated braces to a dynamic assembly process where components are attached to a lattice structure that can be customized for each patient's specific needs while maintaining manufacturing efficiency

Inventive Principle:

Principle #15Dynamics

2Reliability

If traditional casts and braces are used, then joint immobilization is achieved, but heat and moisture trapping against the skin worsens

Engineering Contradiction:

Improveimmobilization effectivenessVSAvoidheat and moisture accumulation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The lattice structure is designed with an open porous framework that allows air circulation and moisture evaporation through its interconnected struts and spaces, reducing heat and moisture trapping while maintaining structural integrity for reliable immobilization

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The system combines the rigid lattice structure for immobilization with breathable materials that have thermal and moisture management properties, creating a composite structure that provides both reliable support and comfort

Inventive Principle:

Principle #40Composite materials

3Quantity of substance

If pre-fabricated products are used, then inventory variety increases, but dexterity and fit customization deteriorate

Engineering Contradiction:

Improveinventory varietyVSAvoiddexterity and fit customization

Core Design Contradiction:

Quantity of substanceVSEase of operation

Solution Approach 1:

A universal lattice structure design serves as a platform that can accommodate various accessory modules for different joints and patient needs, reducing inventory requirements while maintaining the ability to customize fit and function for each patient

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20250205073A1Attachment System for Orthopedic Supports

Publication Date: 2025.06.26 CAST21 INC

AI summary

The present disclosure provides attachment systems to a a parent device, namely, a latticed orthopedic support, and accessory devices for a variety of achievements.