Orthosis Support Device Segmentation Snap-Connection

Solution Overview

Problem

Existing orthosis stabilisation elements are complex and costly to produce, limiting their accessibility and functionality.

Innovation Solution

A support device for orthoses comprising two stabilisation elements connected via snap-in connections, allowing for simpler and more economical production while maintaining or improving functionality and stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If stabilisation elements are formed as non-planar shell-shaped braces encompassing the body part, then functional stability and support are improved, but manufacturing complexity and cost increase significantly

Engineering Contradiction:

Improvefunctional stabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The stabilisation element is divided into multiple planar segments that can be separately manufactured and then assembled. Each segment is produced independently using simple injection moulding, avoiding the need for complex thermoforming of entire shell structures. The segments are connected through coupling elements to form the complete stabilisation element.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Coupling elements serve as intermediaries to connect the planar segments, enabling the assembly of complex three-dimensional structures from simple two-dimensional components. These coupling elements facilitate the transformation of multiple flat segments into a unified shell-shaped stabilisation element without requiring complex manufacturing processes.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Shape

If stabilisation elements are produced using thermoforming from flat blanks, then functional shape is achieved, but material input and personnel input increase

Engineering Contradiction:

Improvespatial end shapeVSAvoidmaterial and personnel input

Core Design Contradiction:

ShapeVSProductivity

Solution Approach 1:

The stabilisation element is divided into multiple planar segments that can be separately manufactured and then assembled. Each segment is produced independently using simple injection moulding, avoiding the need for complex thermoforming of entire shell structures. The segments are connected through coupling elements to form the complete stabilisation element.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The traditional thermoforming mechanical process is replaced with injection moulding technology. This substitution enables automated production of planar segments with precise geometric accuracy, reducing both material waste and manual intervention requirements compared to conventional deep drawing and thermoforming methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If snap-in connections are used to connect stabilisation elements, then ease of assembly is improved, but connection strength may be reduced

Engineering Contradiction:

Improveease of assemblyVSAvoidconnection strength

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The coupling elements are designed with pre-formed geometric connection features (protrusions and recesses) that guide the assembly process. These preliminary structural arrangements ensure proper alignment and engagement of the snap-in connections, maintaining assembly ease while ensuring adequate connection strength through precise geometric interlocking.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20250127644A1Multi-part support device for an orthosis

Publication Date: 2025.04.24 BAUERFEIND GMBH & CO

AI summary

The present invention relates to orthopaedic products, in particular orthoses and support devices for orthoses. The invention provides an improved support device for an orthosis, a method of producing the same and an orthosis containing a support device according to the invention.