Custom-Selectable Hinge Stops for Orthopedic Braces
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Solution Overview
Problem
Existing orthopedic and orthotic hinge assemblies require special tools for adjusting range-of-motion, limiting user convenience and flexibility in customizing hinge stops for individual patient needs.
Innovation Solution
A dual-axis ROM hinge assembly with exchangeable, custom-selectable hinge stops that can be easily removed and repositioned without tools, allowing for adjustable range-of-motion control by engaging with intermeshing gear teeth and stop surfaces, and secured using a stop retention post.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If extractable inserts are secured using small screws or hardware requiring special tools, then the hinge stop can be firmly secured to control angular movement, but the ease of operation deteriorates as users need special tools for adjustment
Solution Approach 1:
The patent replaces the traditional screw-based mechanical fastening system with a friction-fit system using a friction member and friction surface. The friction member is received by the friction fit mechanism, eliminating the need for screws, wrenches, or screwdrivers while maintaining secure attachment of the hinge stop to the hinge assembly.
Solution Approach 2:
The friction-fit mechanism enables users to install, adjust, and remove hinge stops without external tools or assistance. The self-contained friction-based system allows the user to simply insert, position, and remove the friction member as needed, making the device self-servicing and eliminating dependency on specialized tools.
2Device complexity
If fixed hinge stops are used in prior art hinge assemblies, then the structural simplicity is maintained, but the adaptability deteriorates as the range of motion cannot be customized for individual patient needs
Solution Approach 1:
The patent transforms the static, fixed hinge stop into a dynamic, adjustable component. The hinge stop can be repositioned along the hinge bar at different locations, and the friction-fit mechanism allows for easy modification of the range of motion settings. This enables the hinge assembly to adapt to different patient needs while maintaining structural simplicity.
Solution Approach 2:
The hinge assembly is segmented into modular components: the hinge bar with gear teeth, the hinge stop with friction member, and the friction-fit mechanism. This segmentation allows the hinge stop to be independently adjusted and repositioned without affecting the overall hinge structure, enabling customization while preserving structural integrity.
3Reliability
If extractable inserts require special tools for removal and exchange, then the secure attachment is ensured, but the productivity deteriorates due to time-consuming adjustment procedures
Solution Approach 1:
The patent replaces the multi-step screw-based attachment system with a single-action friction-fit system. The hinge stop can be quickly inserted and secured by simply engaging the friction member with the friction fit mechanism, eliminating the time-consuming process of screwing and unscrewing fasteners while maintaining secure attachment.
Data Source
AI summary
A brace incorporates an elongated strut having rigid hinge bars interconnected by an adjustable dual-axis ROM hinge. An exchangeable hinge stop is removably positioned within the ROM hinge, and designed to engage the hinge bars at a predetermined flexion/extension limit, thereby restricting pivoting movement of the strut and custom limiting a range of extension or flexion of the body part. A stop retention post cooperates with a flex member to hold the hinge stop in position relative to the first and second hinge bars. Lifting the flex member outwardly away from the hinge plate allows the hinge stop to be removed from the ROM hinge and exchanged.