Wearable Orthosis Core Skeleton Layer Tendon Routing
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Solution Overview
Problem
Conventional tendon-driven wearable glove orthoses face issues such as labor-intensive and costly manufacturing, shape changes during operation leading to discomfort and misalignment, and inadequate fit, which limits force transmission and user adaptability.
Innovation Solution
A user wearable orthosis with a support structure that includes a core skeleton layer and additional layers, designed to be adaptable and customizable, featuring a tendon guide system and modular components for improved fit and force transmission, manufactured using 3D printing for precise adaptation to individual users.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If fabric-based materials are used for the powered glove device, then wearing comfort is improved, but structural stability and force transmission capability deteriorate due to buckling and folding under compressive forces
Solution Approach 1:
The patent employs a composite structure combining a flexible base layer (providing comfort) with an integrated rigid skeleton (providing structural stability). The rigid skeleton includes finger bones, palm bones, and metacarpal bones that prevent buckling and folding, enabling high force transmission while maintaining wearing comfort through the flexible outer layer.
2Ease of manufacture
If hardware is sewn onto fabric, then the powered glove device can be assembled, but manufacturing complexity and repair difficulty increase due to the delicate and time-consuming process
Solution Approach 1:
The patent integrates the rigid skeleton directly into the flexible base layer through techniques such as molding, bonding, or co-manufacturing processes. This merging eliminates the need for separate sewing operations to attach hardware, significantly simplifying the manufacturing process while maintaining structural integrity and reducing assembly steps.
Solution Approach 2:
The integrated skeleton structure serves multiple functions simultaneously: providing structural support, guiding tendon movement, transmitting forces, and defining the glove's geometric shape. This multi-functionality reduces the number of separate components needed, thereby simplifying both manufacturing and repair processes.
3Productivity
If standard sizes are used for manufacturing, then production efficiency is improved, but fit precision and user comfort deteriorate due to inability to adapt to individual hand shapes
Solution Approach 1:
The patent incorporates adjustable elements within the standardized glove structure, such as adjustable straps, flexible bone segments, and adaptable tendon routing systems. These dynamic components allow the rigid skeleton to conform to individual hand shapes and sizes while maintaining standard manufacturing dimensions, thereby achieving both production efficiency and precise fit.
Solution Approach 2:
The integrated skeleton allows for localized adaptation where specific regions of the glove (such as finger joints or palm areas) can be customized in stiffness, shape, or positioning while maintaining standard overall dimensions. This local quality adjustment enables precise fit for individual users without requiring complete custom manufacturing of the entire glove.
Data Source
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AI summary
The disclosure relates to a user wearable orthosis comprising a support structure configured to be worn on a hand of a user, wherein the support structure comprises a core skeleton layer configured to guide at least one tendon between an actuation unit and at least one end effector mounted on the hand, and at least one additional layer at least partially covering the core skeleton layer, wherein the at least one additional layer has a stiffness lower than a stiffness of the core skeleton layer. Furthermore, a method of manufacturing a user wearable orthosis is disclosed.