Customized Orthosis with Integrated Heat Interconnects for Adjustable Rigidity
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Solution Overview
Problem
Custom orthoses are labor-intensive and expensive to produce, requiring skilled labor for customization and integration of thermoplastic materials, and existing orthoses lack efficient methods for adjusting rigidity based on body part needs.
Innovation Solution
An orthopedic precast with integrated pathways and interconnects that undergo a phase change from flexible to rigid material upon heating, allowing for customizable rigidity through interwoven thermoplastic materials and non-thermoplastic materials, with pathways for interconnects to activate this transition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom orthoses are formed using traditional molding methods with thermoplastic materials, then the orthosis can be customized to fit the patient's body part, but the production process becomes labor-intensive and expensive requiring skilled labor and complex assembly
Solution Approach 1:
The orthopedic precast is prepared in advance with integrated pathways and interconnects embedded within the material structure before the phase change occurs. This preliminary configuration eliminates the need for complex post-processing assembly steps, as the conductive elements and structural pathways are already positioned correctly within the rigidified material
Solution Approach 2:
The patent combines multiple functions into a single integrated structure: the thermoplastic material serves both as the structural orthosis component and as the medium containing the conductive interconnects. The pathways are merged directly into the material matrix, eliminating separate components and assembly operations
2Adaptability or versatility
If pathways are integrated into the orthosis for activation of thermoplastic material, then customizable rigidity can be achieved in specific regions, but the production process becomes even more complex and expensive
Solution Approach 1:
The orthopedic precast incorporates pathways and interconnects at specific local regions where rigidity adjustment is needed, rather than uniformly throughout the entire structure. This allows selective activation of thermoplastic material only in areas requiring customized rigidity, maintaining simplicity in regions where standard flexibility suffices
Solution Approach 2:
The patent utilizes phase transition of thermoplastic material from flexible to rigid state through controlled heating via integrated interconnects. This enables dynamic adjustment of rigidity in specific regions by activating phase change only where pathways are present, providing adaptability without requiring complex mechanical adjustment mechanisms
3Reliability
If multiple straps are used to secure the orthosis, then adequate fixation can be achieved, but the device becomes more complex and time-consuming to adjust
Solution Approach 1:
The patent merges the fixation function into the orthosis structure itself through the rigidified thermoplastic material that naturally conforms to and secures the body part. The integrated structure eliminates the need for separate straps and fasteners, as the customized rigid form factor provides inherent stabilization and retention
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
Enables efficient, cost-effective production of customized orthoses with adjustable rigidity, providing improved fit and comfort by conforming to body parts without the need for complex assembly and adjustment.
Implementation Method 1
thermoplastic material within the wearable to undergo a phase change from a flexible-to-rigid material
Implementation Method 2
when activated, causes thermoplastic material within the wearable to undergo a phase change
Data Source
AI summary
One embodiment relates to an orthopedic precast that, upon an application of heat of a prescribed level while the orthopedic precast is worn adjacent to a targeted body part of the patient, transitions into an orthosis that conforms with the body part. The orthopedic precast includes a first portion and an interconnect. The first portion is formed of interwoven strands of a first thermoplastic material having a first melting temperature. These interwoven strands forming a pathway within the first portion. The interconnect is positioned within the pathway, wherein the interconnect is configured to receive power and radiate heat based on current flowing through the interconnect. Responsive to the interconnect supplying radiating heat of at least the first melting temperature, the first thermoplastic material partially melts and, upon subsequent cooling, the first portion transitions from flexible material into a rigid structure of the orthosis.