Heat-Moldable Rigid Ankle Brace with Multi-Layer Housing
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Solution Overview
Problem
Conventional orthopedic casts, splints, and braces are difficult to form into complex shapes and custom fit to the body, leading to discomfort and reduced compliance due to their mechanical construction and limited moldability.
Innovation Solution
A moldable, rigid ankle brace with a multi-layer housing that includes a heat-moldable middle layer made from a low-temperature, high-modulus composite material, allowing for customization and comfort through a process of heating and molding to the specific shape of the ankle, combined with a closure mechanism for secure fitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional casting materials (fiberglass, plaster) are heated to high temperatures for molding, then the material becomes sufficiently malleable to be formed about the body, but the material may burn the patient or practitioner
Solution Approach 1:
The patent changes the temperature parameter at which the material becomes malleable. The thermoplastic polymer material becomes sufficiently soft and moldable at lower temperatures (below 160°F) compared to conventional fiberglass or plaster materials that require higher temperatures. This parameter change allows the material to be formed about the body without causing burns to the patient or practitioner.
Solution Approach 2:
The patent utilizes phase transition of the thermoplastic polymer material. The material transitions from a rigid state at room temperature to a soft, moldable state when heated to a specific temperature range, and then returns to a rigid state upon cooling. This phase transition occurs at lower temperatures than conventional casting materials, enabling safe custom fitting without burn risk.
2Strength
If braces are made rigid to prevent injury to weakened body parts, then they provide necessary support, but they become difficult to form into custom shapes and fit to the body
Solution Approach 1:
The patent applies dynamics by making the brace material's rigidity changeable. The thermoplastic polymer material is rigid at room temperature for structural integrity, but becomes soft and moldable when heated to a specific temperature range. This dynamic property allows the brace to be easily formed into custom shapes during manufacturing, then maintains rigidity for injury prevention during use.
3Shape
If multiple pieces are attached together to form complex shapes for braces, then the complex anatomy can be accommodated, but the support becomes weaker
Solution Approach 1:
The patent applies segmentation by providing a kit with multiple separate thermoplastic polymer components (e.g., ankle brace portion, foot plate, shin guard). These segmented pieces can be individually molded to fit specific anatomical regions and then attached together using adhesives or mechanical connections. This segmentation allows complex geometry to accommodate varied anatomy while maintaining support integrity through proper design of connection interfaces.
4Strength
If conventional braces use mechanical mechanisms and connections for construction, then they provide structural support, but they are difficult to custom fit to the body
Solution Approach 1:
The patent applies parameter changes by utilizing the temperature-dependent properties of thermoplastic polymer materials. The material transitions from rigid to moldable when heated, allowing the brace to be custom fitted to the patient's anatomy. After cooling, the material returns to its rigid state, maintaining structural support. This parameter change enables both custom fitting and structural integrity without requiring complex mechanical mechanisms.
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 solution enables a quick, custom-fitted ankle brace that reduces the number of visits needed for orthosis, provides comfort, and offers quick relief, while being adaptable to changes in ankle anatomy, thus improving patient compliance and reducing costs.
Implementation Method 1
heating the product at a relatively low temperature, placing the heated product about a body part, and applying pressure to custom form the product
Implementation Method 2
applying pressure to custom form the product
Data Source
AI summary
A moldable rigid ankle brace is disclosed. The rigid stabilizing ankle brace includes a heat-moldable multi-layer housing having an opening for receiving a user's ankle, a footplate attached to the housing, and a closure mechanism. The multi-layer housing includes a middle layer, which is substantially stiff at a temperature below about 130° F. and moldable at temperatures between about 130° F. and 275° F. A method of stabilizing an ankle is also disclosed. The method may include providing a rigid stabilizing ankle brace, having a heat-moldable multi-layer housing having an opening for receiving a user's ankle, and a footplate removably attached to said housing, heating the ankle brace to between about 130° F. to about 275° F., and applying said heated ankle brace to the ankle of a patient in need thereof.