Orthopedic Brace Subshells for Adjustable Fit and Pressure Distribution

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Solution Overview

Problem

Conventional knee braces are often heavy, bulky, and lack adjustment features, leading to discomfort and poor fit, failing to provide consistent support and pressure distribution for various leg geometries.

Innovation Solution

The orthopedic device features a rigid frame with adjustable subshell components and strapping systems that allow for customizable fit, including flexible subshells with living hinges and anchoring members, enabling precise adjustment and distribution of pressure across the leg.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional knee braces are designed with heavy, bulky structures, then they provide increased stability and support to the knee, but they fail to provide ventilation and evenly distribute pressure on the leg

Engineering Contradiction:

Improveknee stabilityVSAvoidpressure distribution and ventilation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The brace is divided into separate functional components: a rigid frame structure for stability, flexible subshells for pressure distribution, and ventilation channels for airflow. This segmentation allows each component to optimize its specific function without compromising the others.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Flexible subshells are introduced as intermediary elements between the rigid frame and the leg. These subshells conform to the leg's geometry, distribute pressure evenly, and allow ventilation while maintaining structural support.

Inventive Principle:

Principle #30Flexible shells and thin films

2Adaptability or versatility

If off-the-shelf braces are designed to accommodate various leg geometries, then they can be used by different users, but they cannot provide a precise fit for individual leg geometries

Engineering Contradiction:

Improveaccommodation of various leg geometriesVSAvoidfit precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The brace incorporates adjustable components including movable anchoring members, repositionable subshells, and configurable strapping systems. These dynamic elements allow the brace to adapt to different leg geometries while maintaining a precise, customized fit for each user.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The brace design integrates multiple adjustment mechanisms and configurable components that enable a single brace model to serve multiple leg geometries. The universal design allows customization through adjustment rather than requiring different models for different users.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If custom-fit braces are made to closely conform to the exact geometry of a leg, then they provide superior fit and comfort, but they require frequent adjustments when leg geometry changes over time

Engineering Contradiction:

Improvefit precisionVSAvoidaccommodation of geometry changes

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The brace features dynamic adjustment capabilities with movable components that can be repositioned as leg geometry changes. This includes adjustable anchoring members, reconfigurable strapping systems, and flexible subshells that can adapt to changing anatomical conditions while maintaining precise fit.

Inventive Principle:

Principle #15Dynamics

4Reliability

If knee braces are designed with heavy materials for durability and support, then they provide reliable knee stabilization, but they become uncomfortable and detract from the user's endeavor

Engineering Contradiction:

Improveknee supportVSAvoiduser comfort

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

Flexible subshells replace portions of heavy rigid structures while maintaining support functionality. These thinner, more compliant elements reduce overall weight and bulk while providing necessary support and improving comfort during user activity.

Inventive Principle:

Principle #30Flexible shells and thin films

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 provides a comfortable, secure, and adjustable orthopedic device that effectively supports the knee by accommodating various leg geometries, enhancing stability and reducing the risk of injury through improved fit and pressure distribution.

Implementation Method 1

a flexible subshell secured to the frame, and having a first end extending laterally beyond the first side portion so as to flex relative to the first frame side portion. The subshell has a contoured edge extending beyond the peripheral contour so as to flex relative to the frame peripheral contour.

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS9345607B2Configurable subshell components in orthopedic devices

Publication Date: 2016.05.24 OSSUR HF

AI summary

A coupling device for an orthopedic brace includes an anchoring member for securing to a frame and protruding therefrom, and a subshell arranged to connect to the frame by the anchoring member. The subshell has a locking element for selectively positioning the subshell on the frame at a plurality of locations. The subshell may include an end portion or contoured edge extending beyond a portion of the frame so as to flex relative to the frame.