Modular Orthosis with Telescoping Struts for Warfighter Mobility

Solution Overview

Problem

Current injury support systems for warfighters are bulky, heavy, and require complex adjustments, failing to effectively immobilize injured limbs, especially during movement, which increases the risk of re-injury and complicates application in austere environments.

Innovation Solution

A compact, modular orthosis system comprising a footplate, tibial cuff, and extensible struts with quick connectors, allowing for easy assembly and adjustment to distribute load away from the injury site, enabling ambulatory mobility while minimizing undesirable motion and requiring minimal training and tools.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If powered exoskeletons are used to support injured limbs, then mobility is improved, but the device becomes bulky, heavy, and requires complex adjustment

Engineering Contradiction:

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The orthosis is divided into separate modular components including a footplate, tibial cuff, and adjustable struts that can be independently sized and configured. This segmentation allows each component to be adjusted separately to fit the user's anatomy without requiring complex overall system adjustment.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The struts incorporate telescoping mechanisms with multiple length positions that allow dynamic adjustment to accommodate different user sizes and injury conditions. This dynamic adjustability provides mobility support for various anatomies without requiring a completely different device for each user.

Inventive Principle:

Principle #15Dynamics

2Ease of manufacture

If formable splints and braces are used to immobilize injured limbs, then application is simplified, but they cannot fully immobilize the limb during movement

Engineering Contradiction:

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The footplate is contoured to match the anatomical shape of the foot and lower leg, providing optimal contact and immobilization. The curved design distributes pressure evenly while maintaining rigid immobilization of the injured area during movement.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The struts are designed with telescoping sections that can be adjusted to the precise length needed for each user, ensuring that the immobilization structure fits perfectly and maintains effectiveness during dynamic movement rather than being a one-size-fits-all static design.

Inventive Principle:

Principle #15Dynamics

3Reliability

If vacuum splints are used to immobilize injured limbs, then immobilization is achieved, but the device becomes very heavy and renders the casualty non-ambulatory

Engineering Contradiction:

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The rigid footplate provides sufficient immobilization for the injured area without requiring the complete vacuum sealing and enclosure of a full vacuum splint. This partial approach achieves the necessary immobilization reliability while dramatically reducing the overall device weight to enable ambulation.

Inventive Principle:

Principle #16Partial or excessive action

4Reliability

If plaster or fiberglass casts are used to immobilize injured limbs, then effective immobilization is achieved, but application requires advanced skills, copious pack volume, and significantly more time

Engineering Contradiction:

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The orthosis components are pre-fabricated with predetermined shapes and sizes, eliminating the need for on-site molding and shaping operations. The footplate and cuff are manufactured in advance with standard anatomical contours, allowing rapid assembly without requiring advanced casting skills or significant application time.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The cast is replaced by separate pre-formed components (footplate, cuff, struts) that can be quickly assembled together. This segmentation eliminates the time-consuming single-step casting process while maintaining immobilization effectiveness through the rigid assembled structure.

Inventive Principle:

Principle #1Segmentation

5Reliability

If pinned fixators are used to immobilize injured limbs, then effective immobilization is achieved, but application requires advanced training, specialized tools, and puncturing the skin

Engineering Contradiction:

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The soft cuff acts as an intermediary between the rigid footplate and the user's body, distributing contact pressures and eliminating the need for direct skin contact or puncturing. This intermediary layer simplifies application by removing the need for sterile techniques and specialized insertion tools while maintaining immobilization effectiveness.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS20230277356A1Orthosis system

Publication Date: 2023.09.07

AI summary

Disclosed is an orthosis device particularly well-suited for use in the field. The orthosis system includes a tibial cuff, at least one strut, an optional off-loading cuff, and a foot plate. The struts connect the tibial cuff to the footplate. Optional couplers may be used to facilitate these connections and may be in the form of quick disconnects or cam locks. The footplate may further spring plate having energy return properties to aid mobility. The systems may be modular, is compact, and easily stowed and carried.