Orthopedic Support Laminate with Integral Straps
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Solution Overview
Problem
Existing orthopedic supports lack materials that provide increased comfort and breathability without sacrificing mobility or bulkiness, and require more efficient and economical strapping systems for securement and easy adjustment.
Innovation Solution
An orthopedic support featuring a flexible laminate material with a stretch fleece inner layer, stretch unbroken loop outer layer, and polyurethane foam in between, along with unique strapping configurations and optional spacer materials for enhanced comfort and breathability, allowing for secure and adjustable fitting on various limbs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional laminate materials are used in orthopedic supports, then structural support is provided, but comfort and breathability are compromised
Solution Approach 1:
The patent employs a multi-layer laminate construction combining neoprene foam (for structural support and compression), mesh fabric (for breathability and moisture wicking), and elasticized outer fabric (for durability and fit). This composite material approach allows each layer to contribute its specific properties, achieving both structural reliability and comfort simultaneously.
Solution Approach 2:
The laminate structure provides different material properties at different locations and layers. The inner neoprene layer provides compression and support where needed, while the mesh layer provides breathability in contact with the skin, and the outer layer provides durability. This localized differentiation of material properties resolves the contradiction between support and comfort.
2Reliability
If complex strapping configurations are used to secure orthopedic supports, then securement is improved, but assembly time and manufacturing complexity increase
Solution Approach 1:
The patent integrates the straps directly into the laminate structure rather than attaching them as separate components. The straps are formed as integral extensions of the laminate material itself, eliminating the need for separate attachment steps and reducing assembly time while maintaining securement reliability.
Solution Approach 2:
The laminate material serves multiple functions: it provides structural support, comfort, and simultaneously forms the straps for securement. This multi-functionality eliminates the need for separate strapping components and simplifies both manufacturing and assembly processes.
3Adaptability or versatility
If multiple separate components are used for strapping, then adjustability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
Multiple strap functions are merged into a single integrated laminate structure. The laminate is designed with built-in strap extensions that provide adjustability through integrated loops and fastening points, eliminating the need for multiple separate strapping components while maintaining adaptability.
Solution Approach 2:
The laminate material serves as both the support structure and the strapping system. By making the straps integral to the laminate, the design achieves adjustability with fewer components, reducing manufacturing complexity and assembly steps.
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 orthopedic support provides improved comfort and moisture-wicking properties, conforming to different limb sizes while securing the support effectively, reducing assembly time and components, and accommodating various orthopedic applications with enhanced breathability and support.
Implementation Method 1
The stretch fleece could be configured in a grid pattern, while the unbroken loop material could include a plurality of eyelets. The laminate material provides improved comfort and moisture-wicking properties
Implementation Method 2
an outer layer of elasticized fabric having a looped structure, and an inner layer of elasticized cotton fabric
Data Source
AI summary
An orthopedic support for supporting a joint of a wearer is provided and includes a sheet of flexible laminate material configured to at least partially enclose the joint. The orthopedic support also includes a spacer material attached to the sheet of material about at least a portion of its outer periphery, and at least one strap integrally defined in the sheet of material and configured to tension and secure the sheet of material about the wearer's joint.