Segmented 3D Orthoses With Elastic Joints for Swelling Relief
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Solution Overview
Problem
Traditional splints and casts face challenges in accommodating swelling, preventing atrophy, and maintaining joint mobility during the healing process, leading to complications such as compartment syndrome, delayed union, and joint stiffness.
Innovation Solution
The development of computer-aided design and digital manufacturing techniques create adaptable exo-skeletal orthoses with semi-dynamic structures that expand or contract in response to swelling and atrophy, incorporating elastic restraints and modular components for controlled pressure application and limited joint mobility, while integrating sensors for real-time monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a cast is made tightly to provide stable support for healing, then stability is improved, but circulation is restricted causing pain and compartment syndrome
Solution Approach 1:
The cast incorporates an expandable structure with multiple expandable segments that can dynamically adjust their volume. The segments are connected by expansion joints that allow the cast to expand outward when swelling occurs, converting a static structure into a dynamic one that adapts to changing anatomical conditions during the healing process.
Solution Approach 2:
The cast is divided into multiple expandable segments separated by expansion joints. This segmentation allows different portions of the cast to expand independently in response to localized swelling, providing both stability and accommodation for tissue changes without compromising overall structural integrity.
2Object-affected harmful factors
If a cast is made loosely to accommodate swelling, then circulation is maintained, but the cast fails to provide stable support for healing
Solution Approach 1:
The expandable cast structure transitions from a loose initial state to a tighter state as swelling subsides. The expansion joints and segments allow the cast to automatically adjust its fit, providing loose accommodation during acute swelling phases and stable support during later healing phases without requiring replacement.
Solution Approach 2:
The cast is designed with built-in expansion capability from the outset, anticipating future swelling. The expansion joints and segmented structure are pre-configured to allow volume increase, eliminating the need for preliminary loose fitting and subsequent replacement with tighter casts.
3Strength
If a cast is applied to immobilize a fracture, then bone healing is promoted, but joint stiffness and muscle atrophy occur due to prolonged immobilization
Solution Approach 1:
The expandable cast allows for controlled adjustment of immobilization intensity. As swelling decreases and healing progresses, the cast can be expanded to reduce compression while maintaining structural support, enabling gradual transition from strict immobilization to controlled mobility, thereby reducing joint stiffness and muscle atrophy.
Solution Approach 2:
The cast design allows for progressive adjustment and eventual removal of compression forces as healing progresses. The expansion mechanism enables the cast to 'discard' its initial high-compression function and transition to a lighter support role, preventing long-term harmful effects of immobilization.
4Ease of operation
If multiple casts are changed to accommodate swelling and atrophy, then patient comfort is improved, but treatment time and inconvenience increase
Solution Approach 1:
The single expandable cast provides continuous adaptation to swelling and atrophy throughout the entire treatment period. The dynamic adjustment capability eliminates the need for multiple cast changes, reducing treatment time and patient inconvenience while maintaining comfort and appropriateness throughout healing.
Solution Approach 2:
The expandable cast design combines multiple functions in a single device: initial loose accommodation of swelling, intermediate stable support, and final comfortable fit after atrophy. This multi-functional design replaces the sequence of multiple specialized casts with one universal adaptable cast.
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
These orthoses effectively manage swelling and atrophy, promote bone healing, prevent joint stiffness, and enhance patient comfort by providing a customizable, adjustable, and medically beneficial interface that reduces the risk of complications and supports the healing process efficiently.
Implementation Method 1
The segments or cells are assembled with elastic mechanical restraints that hold the segments and cells together and further apply external pressure when a covered body surface undergoes swelling
Data Source
AI summary
A conformable body interface is fabricated using a data set representing a three-dimensional, soft tissue body surface. The conformable body interface includes a body scaffold that is divided into two or more longitudinal segments separated by axial joints. Optionally, the body scaffold is further divided into two or more circumferentially split segments separated by circumferential joints. The axial joints are circumferentially constrained by elastic bands, tabs, or similar structures and the circumferential joints are longitudinally constrained by elastic axial tethers or similar structures. In this way, the body interfaces can accommodate swelling and bending of the body surface.