Polyolefin Elastomer Foam Ankle Foot Orthosis

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional ankle foot orthoses (AFOs) and traditional leather gauntlets lack adjustability, durability, and comfort, providing inadequate support and control for patients with conditions like ankle instability and arthritis, and require extensive manufacturing time.

Innovation Solution

An ankle foot orthosis composed of a closed cell polyethylene foam inner lining bonded to a polyolefin elastomeric material outer layer, offering tri-planar control and a customizable design with adjustable closure mechanisms, enhanced durability, and improved comfort through a combination of materials and manufacturing processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If traditional leather gauntlet design is used, then comfort and flexibility are improved, but durability and ease of cleaning deteriorate

Engineering Contradiction:

ImprovecomfortVSAvoiddurability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The AFO combines closed cell polyethylene foam (providing comfort and flexibility) with polyolefin elastomeric material (providing durability and water resistance). This composite construction resolves the contradiction by integrating materials with complementary properties, allowing the device to be both comfortable and durable while being easy to clean.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The polyolefin elastomeric outer layer acts as a flexible shell that provides durability and water resistance while allowing the foam core to provide comfort. This flexible shell structure resolves the contradiction between comfort and durability by protecting the soft inner material while maintaining flexibility.

Inventive Principle:

Principle #30Flexible shells and thin films

2Ease of operation

If traditional leather gauntlet design is used, then comfort is improved, but ease of cleaning and hygiene deteriorate

Engineering Contradiction:

ImprovecomfortVSAvoidease of cleaning

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The combination of closed cell foam and polyolefin elastomeric material creates a surface that is both comfortable against the skin and resistant to water and stains, making it easy to clean. The polyolefin outer layer specifically addresses the cleaning issue while the foam layer maintains comfort.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The polyolefin elastomeric outer layer serves as a protective film that is water-resistant and easy to wipe clean, while the closed cell foam core provides comfort. This layered approach resolves the contradiction between comfort and ease of cleaning.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If rigid plastic AFO design is used, then support and control are improved, but comfort and flexibility deteriorate

Engineering Contradiction:

ImprovesupportVSAvoidcomfort

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The closed cell polyethylene foam core provides cushioning and comfort, while the polyolefin elastomeric outer layer provides structural support and control. This composite structure resolves the contradiction between support and comfort by distributing functions across different material layers.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Different regions of the AFO have different material properties - the foam core provides local cushioning where needed, while the polyolefin shell provides local support and control. This local differentiation of material quality resolves the contradiction between comfort and support.

Inventive Principle:

Principle #3Local quality

4Ease of operation

If custom leather AFO is manufactured, then fit and comfort are improved, but manufacturing time and complexity increase

Engineering Contradiction:

ImprovefitVSAvoidmanufacturing time

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The AFO components are pre-formed using molds, with the foam core and polyolefin shell created separately before assembly. This preliminary formation of components reduces manufacturing time while maintaining custom fit through the molding process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The AFO is divided into separate components (foam core, polyolefin shell, closure mechanisms) that can be manufactured independently and then assembled. This segmentation allows for more efficient manufacturing of individual parts while maintaining overall custom fit.

Inventive Principle:

Principle #1Segmentation

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 solution provides a comfortable, adjustable, and durable AFO that offers improved support and control for the ankle-foot structure, addressing the limitations of traditional devices by being hygienic, waterproof, and easily cleaned, while accommodating a range of neurological and orthopedic pathologies.

Implementation Method 1

a closed cell polyethylene foam inner lining bonded to a polyolefin elastomeric material

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS10092436B2Ankle foot orthosis (AFO) and method of making the same

Publication Date: 2018.10.09 BRACEMASTERS INTERNATIONAL LLC

AI summary

A custom or pre-fabricated ankle foot orthosis provides tri-planar control of the ankle foot structure. The ankle foot orthosis includes a brace body made from a polyolefin elastomeric material, foam material and a closure mechanism.