Modular Off-Load High Leg-Foot Brace Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing orthopedic footwear designs, such as those disclosed in U.S. Pat. No. 8,230,619, suffer from discomfort due to the upper portion bending between the heel and calcaneus during ambulation, requiring specific models based on therapy or pathology, and lack customization options.
Innovation Solution
An off-load high leg-foot brace featuring a soft sole with a stiffening plate, a removable rigid body, a thermoformable upper, and a modular intermediate sole, allowing for customization and adjustment to the patient's foot shape and pathology, with interchangeable components for optimal fit and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the upper is directly and firmly connected to the bottom sole, then the structure is simple and stable, but the upper bends during ambulation causing discomfort
Solution Approach 1:
The orthopedic footwear is divided into separate modules: a bottom sole assembly, an intermediate insole assembly with rigid insert, and an upper assembly. These modules are connected through removable fastening elements, allowing the upper to be detached and replaced without removing the entire footwear. This segmentation enables the upper to be independently adjusted or replaced to eliminate bending discomfort while maintaining structural stability through the rigid insert and proper assembly connection.
Solution Approach 2:
The connection between the upper and bottom sole is made dynamic through removable fastening elements (such as Velcro straps, buckles, or snap fasteners) rather than permanent attachment. This allows the upper to be easily removed and replaced with different uppers having different stiffness characteristics, enabling adaptation to varying comfort requirements during ambulation while maintaining structural integrity when assembled.
2Adaptability or versatility
If specific models are purchased for different therapy or pathology, then the fit and therapy effectiveness is optimized, but the device complexity and cost increase
Solution Approach 1:
The orthopedic footwear employs a universal bottom sole assembly with rigid insert that can accommodate multiple different upper assemblies. The standardized interface and fastening system allow a single bottom assembly to work with various uppers designed for different therapeutic needs (e.g., different stiffness levels, opening configurations, or support characteristics). This enables one base model to serve multiple therapy purposes, reducing the need for multiple specialized models while maintaining therapy effectiveness.
Solution Approach 2:
By separating the footwear into modular components (bottom sole, rigid insert, upper), the design allows customization through component selection rather than requiring entirely different models for each pathology. The rigid insert provides universal structural support, while different uppers can be selected based on specific therapeutic requirements, simplifying the overall product line while maintaining adaptability.
3Ease of operation
If the upper padding is added for comfort, then patient comfort is improved, but the upper bends during movement causing discomfort
Solution Approach 1:
The rigid insert is positioned locally in the plantar region (sole area) where structural support is most needed to prevent bending, while the upper portions (vamp, quarter, tongue) can incorporate padding for comfort. This localized application of rigidity allows the critical load-bearing area to remain stable while other areas provide cushioning, resolving the conflict between comfort padding and overall upper rigidity.
Solution Approach 2:
The footwear combines different material properties within the same structure: the rigid insert provides structural stability and prevents bending, while the upper padding materials (foam, fabric, leather) provide comfort and cushioning. This composite construction allows simultaneous achievement of both rigidity where needed and comfort where applicable, eliminating the trade-off between padding and upper stability.
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 brace provides customizable support and comfort by allowing easy replacement of the upper and bottom components, accommodating varying pathology and medical conditions, thereby reducing discomfort and stress on the foot during ambulation.
Implementation Method 1
a stiffening plate made of a hard is indeformable material that is associated with the sole and fixed thereon
Implementation Method 2
the upper of the brace of the invention is made of a material that can be thermoformed and cut according to the shape of the foot and to the injuries of the patient
Data Source
AI summary
A brace includes a bottom having a sole made of a soft material with a tread intended to come in contact with the ground, and a stiffening plate fixed on the sole. A rigid body is provided having a base plate removably connected to the stiffening plate. A monolithic upper is removably connected to the body, and at least one intermediate sole made of a soft material is disposed on the base plate of the body.