Multi-Component Orthopedic Frame with Composite Segmentation

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Solution Overview

Problem

Existing orthopedic knee braces are often bulky, heavy, and fail to accommodate dynamic leg dimensions and geometrical variations, leading to discomfort and reduced effectiveness.

Innovation Solution

A multi-component frame with a continuous concave cross-section made from malleable metal, enhanced with fiber-reinforced layers and padding, allowing for customizable fit and distribution of pressure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional rigid frame structures are used in knee braces, then structural strength is maintained, but weight and bulk increase, reducing comfort and usability

Engineering Contradiction:

Improvestructural strengthVSAvoidbrace weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The frame is constructed using composite materials including fiber-reinforced polymers and metal alloys, combining the strength of metals with the lightweight properties of polymers to achieve high strength-to-weight ratio

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The frame is divided into multiple segments that can be independently adjusted and configured, allowing optimization of each section for its specific function while reducing overall weight compared to a monolithic structure

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If flat frame components are used, then manufacturing is simple, but the brace fails to accommodate geometrical variations and dynamic dimensions of the leg

Engineering Contradiction:

Improveframe manufacturing simplicityVSAvoidaccommodation of leg geometry variations

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The frame incorporates adjustable and reconfigurable elements that can adapt to different leg geometries and dimensions, transforming a static structure into a dynamic one that responds to user-specific anatomical variations

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

Different sections of the frame are designed with varying properties and configurations to accommodate specific anatomical regions, with each segment optimized for its local function while maintaining overall structural integrity

Inventive Principle:

Principle #3Local quality

3Strength

If bulky strap support structures are added to the frame, then strap attachment strength is improved, but the brace profile increases and comfort is reduced

Engineering Contradiction:

Improvestrap attachment strengthVSAvoidbrace profile and bulk

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The strap attachment mechanisms are integrated directly into the frame structure rather than being separate add-on components, combining the structural frame with the attachment functions to eliminate unnecessary bulk

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Strap attachment features are nested within or along the contours of the frame structure, with straps routing through recesses or along the frame profile rather than requiring external protruding supports

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS20250144265A1Multi-component frame for use in an orthopedic device

Publication Date: 2025.05.08 OSSUR ICELAND EHF

AI summary

A multi-component frame includes a first component made from a rigid structural material and a second component connected to at least an end portion the first component. The first component is constructed from a metal or metal alloy, and the second component is constructed from a material different from the first component. The first and second components form at least part of a length of the multi-component frame.