Orthopedic Support with Knitted Receiving Channels for Targeted Compression
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Solution Overview
Problem
Generic orthopedic support means with elastic design face challenges in achieving effective compression, correction, and stabilization functions due to undesired movement sequences, and solutions like attaching drawstrings result in increased thickness and manufacturing costs, compromising comfort and aesthetics.
Innovation Solution
Incorporating a non-elastic support band within a receiving channel formed by knitting threads and weft/warp threads in the knitted fabric, which reduces elasticity in specific areas, allowing for targeted compression and support without adding thickness or discomfort, and enabling a single-stage production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the main body is designed to be elastic to enable easy putting on and body movement, then ease of operation is improved, but the orthopedic support and stabilization function deteriorates due to unfavorable movement sequences
Solution Approach 1:
The support means is divided into elastic non-compression areas and inelastic compression areas. The inelastic areas are segmented into discrete regions where support bands are inserted into receiving channels within the knitted fabric structure, creating localized zones of reduced elasticity that provide stabilization without compromising overall flexibility
Solution Approach 2:
Different regions of the support means are assigned different elastic properties. The knitted fabric provides elasticity in most areas for comfort and movement, while specific local regions contain inelastic support bands within receiving channels to provide targeted compression and stabilization where orthopedic support is needed
2Reliability
If drawstrings are attached to limit elasticity in specific areas, then the orthopedic support function is improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The support bands and receiving channels are integrated directly into the knitted fabric structure during the manufacturing process. The receiving channels are formed as part of the knitting pattern, and support bands are inserted into these channels before the fabric is completed, combining what would otherwise be separate components into a unified structure
Solution Approach 2:
The receiving channels are pre-formed during the knitting process before the support bands are inserted. The knitted fabric is constructed with integrated channels that guide and position the support bands, eliminating the need for subsequent attachment operations and reducing manufacturing complexity
3Stress or pressure
If drawstrings are attached to limit elasticity, then compression function is improved, but thickness increases reducing comfort and aesthetics
Solution Approach 1:
The support bands are nested within receiving channels that are integrated into the knitted fabric structure. The support bands are positioned inside the fabric thickness rather than adding to it externally, allowing compression functionality to be achieved without increasing the overall thickness of the support means
Solution Approach 2:
The knitted fabric itself serves as a flexible thin film structure that contains the support bands within its thickness. The receiving channels are formed within the fabric layers, allowing the support bands to provide compression without requiring additional external layers or attachments that would increase overall thickness
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 effectively reduces elasticity in orthopedic support means, enhancing compression and stabilization functions while maintaining comfort and aesthetics, allowing for precise adjustment of support and mobility restriction, particularly beneficial for joint support and compression applications.
Implementation Method 1
The main body is designed to be elastic at least in the area of the elastic partial areas in order to be able to put on the orthopedic support means easily and to be able to move the corresponding part of the body surrounded by the support means
Implementation Method 2
a non-elastic support band, which is not involved in the stitch formation of the knitwear, is inserted into the receiving channel, preferably stretched
Data Source
Figure 1a~1b
Figure 2
Figure 3
AI summary
The supporting unit e.g. knee brace (10), has a receiving channel provided between an inner side and an outer side of a main body (20) and extending through an elastic portion of the main body. The receiving channel is limited towards the inner side and the outer side of the body by a knitting yarn and a weft yarn of a knitted fiber. Inelastic support bands (40a-40c) are inserted into the receiving channel and are not engaged to knitting formation of the knitting yarn of the main body. An independent claim is also included for a method for manufacturing an orthopedic supporting unit.