Smart Brace Hinge Assembly for Comfortable Motion Sensing
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Solution Overview
Problem
Existing braces lack the ability to gather data related to limb and joint motion while maintaining comfort and a low profile, and often prioritize structural support over data collection.
Innovation Solution
A smart brace with a flexible and rigid hinge assembly that includes sensors to collect motion data, featuring thin, flexible bars in the frontal plane and stiff bars in the sagittal plane, with ends countersunk into gears for a low profile and accurate data collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional rigid hinge assemblies are used to provide structural support, then strength and stability are improved, but comfort and low profile are worsened
Solution Approach 1:
The hinge assembly employs different material properties in different orientations: the bar is made rigid in the sagittal plane (front-to-back) to provide structural support, while being flexible in the frontal plane (side-to-side) to allow natural movement and maintain comfort. This is achieved through specific material selection and cross-sectional geometry design.
Solution Approach 2:
The hinge assembly utilizes composite construction combining rigid materials (such as aluminum or titanium alloys) with flexible elements. The bar may be constructed as a composite structure where a rigid core is surrounded by flexible material, or where rigid and flexible components are joined to create the desired combination of strength and flexibility.
2Strength
If thicker bars are used to provide rigidity in the sagittal plane, then strength is improved, but flexibility in the frontal plane is worsened
Solution Approach 1:
The bar's cross-sectional geometry is specifically designed to create different stiffness characteristics in different directions. The cross-section may be non-circular (rectangular, I-shaped, or other forms) where the dimension providing sagittal plane rigidity is larger, while the dimension providing frontal plane flexibility is smaller. This creates locally optimized properties for each directional requirement.
Solution Approach 2:
The bar may incorporate curved or tapered sections that gradually transition between rigid and flexible regions. Curved geometries can distribute stress more evenly and provide progressive flexibility while maintaining overall structural integrity. The bar may have varying cross-sectional dimensions along its length to optimize both rigidity and flexibility.
3Measurement precision
If sensors and electronic components are added to gather motion data, then measurement precision is improved, but device complexity and profile are worsened
Solution Approach 1:
The sensor and electronic components are nested within the existing hinge assembly structure. The bar serves as a housing for the sensor, with the sensor mounted along the bar's length. The hinge plate and connecting elements provide additional nesting space for electronic components, batteries, and processing units. This nested arrangement minimizes the overall profile increase while accommodating the necessary technology.
Solution Approach 2:
The hinge assembly is designed to accommodate sensors and electronics in the longitudinal dimension (along the bar's length) rather than increasing the cross-sectional profile. By distributing components along the length of the bar and utilizing the internal volume of the hinge structure, the design adds functionality without significantly increasing the medial-lateral or anterior-posterior dimensions that would affect comfort and profile.
4Ease of operation
If the bar is made thin to improve flexibility and low profile, then comfort is improved, but structural strength is worsened
Solution Approach 1:
The bar's cross-sectional geometry is specifically designed to create different stiffness characteristics in different directions. The cross-section may be non-circular (rectangular, I-shaped, or other forms) where the dimension providing sagittal plane rigidity is larger, while the dimension providing frontal plane flexibility is smaller. This creates locally optimized properties for each directional requirement.
Solution Approach 2:
The hinge assembly utilizes composite construction combining rigid materials (such as aluminum or titanium alloys) with flexible elements. The bar may be constructed as a composite structure where a rigid core is surrounded by flexible material, or where rigid and flexible components are joined to create the desired combination of strength and flexibility.
Data Source
AI summary
A smart brace is configured to be worn on a limb over the joint and includes a sensor that gathers data related to motion. The sensor can be included in a hinge assembly of the smart brace. The hinge assembly can include a first gear and a first bar and a second gear and a second bar. The first gear can be meshingly engaged with the second gear such that rotation of one causes corresponding rotation of the other. The first bar and the second bar are configured in size and shape to be flexible in a frontal plane and rigid in a sagittal plane. An end of the first bar and an end of the second bar can be received within corresponding recesses of the first gear and the second gear.