Lower Leg Orthotic Brace with Hinged Support and Cable Cinching

Solution Overview

Problem

Current orthotics for lower leg and foot ailments like plantar fasciitis and Achilles tendon issues often fail to provide adequate support and passive stretching, leading to discomfort and inadequate healing due to lack of custom fit and effective movement restriction.

Innovation Solution

A custom foot orthotic with a thermoplastic outer shell, closed cell foam liner, and adjustable components, including a hinged lower leg support and cinching mechanism, which secures the foot and leg with a rotatable tightening knob and cable system, allowing for adjustable positioning and reduced pressure on sensitive areas.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a rigid orthotic structure is used to prevent lateral foot movement, then stability and support are improved, but comfort and pressure distribution deteriorate

Engineering Contradiction:

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The orthotic uses a flexible shell that conforms to the foot's contours, providing lateral stability through the shell's curved geometry rather than rigid constraints. The shell's flexibility allows it to distribute pressure evenly across the foot surface, avoiding concentrated pressure points on sensitive areas while maintaining structural support.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The orthotic employs adjustable parameters including the tightness of the flexible shell, the positioning of straps, and the angle of the hinged lower leg support. These adjustable parameters allow customization of the support level and pressure distribution to match individual patient needs, resolving the contradiction between stability and comfort.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If a custom fit orthotic is created to provide effective support, then rehabilitation effectiveness is improved, but device complexity and manufacturing difficulty increase

Engineering Contradiction:

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The orthotic is divided into separate modular components: an upper foot support portion, a lower leg support portion with a hinge joint, and adjustable strapping systems. This segmentation allows each component to be manufactured using standard processes, then assembled to create a custom-fit device, reducing overall manufacturing complexity while maintaining rehabilitation effectiveness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The orthotic incorporates dynamic elements including a hinged connection between the foot and lower leg supports that allows controlled movement, and adjustable strapping systems that can be modified based on patient feedback. This dynamic design enables the device to adapt to individual anatomical variations without requiring completely custom manufacturing of each component.

Inventive Principle:

Principle #15Dynamics

3Stability of the object's composition

If the foot is securely engaged in the foot support, then lateral movement prevention is improved, but the top of the foot remains exposed to the environment

Engineering Contradiction:

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The foot support utilizes a flexible shell that wraps around and secures the foot, preventing lateral movement through the shell's conforming geometry. The same flexible shell material provides coverage for the top of the foot, protecting it from environmental exposure while maintaining the secure engagement needed for stability.

Inventive Principle:

Principle #30Flexible shells and thin films

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 orthotic provides effective support and passive stretching, promoting healing by preventing lateral foot movement and distributing pressure, thus reducing discomfort and aiding in the rehabilitation of soft tissue connective tissues.

Implementation Method 1

a thermoplastic outer shell... custom fit to a foot

Methodology Applied

Scientific EffectThermal heating and molding: Heating

Implementation Method 2

a cinching mechanism having a rotatable tightening knob... and a tightening cable coupled to the rotatable tightening knob

Methodology Applied

Scientific EffectMechanical tension: Tension

Implementation Method 3

a closed cell foam liner within the outer shell

Methodology Applied

Scientific EffectFoam cushioning: Foam

Implementation Method 4

lower leg support hingedly connected to the foot support

Methodology Applied

Scientific EffectHinge rotation: Hinge

Data Source

PatentUS11925572B2Lower leg orthotic brace

Publication Date: 2024.03.12

AI summary

A foot orthotic having a foot support where the foot support includes a thermoplastic outer shell, a closed cell foam liner within the outer shell, and a tongue to secure the user's foot within the foot support. The orthotic also typically has includes a lower leg support that includes a thermoplastic outer shell, a closed cell foam liner within the outer shell, and a strap to secure the orthotic to the user's leg within the lower leg support. A cinching mechanism that typically has a rotatable tightening knob is on the lower leg support, and a tightening cable coupled to the rotatable tightening knob and operably connected to the foot support.