Thermoformable Orthosis for Calf Compression
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Solution Overview
Problem
Current elastic venous compression orthoses are not adequately tailored to individual patient morphology, leading to suboptimal performance of the muscular pump in the calf, which is crucial for venous return, and are difficult to manufacture in a cost-effective and scalable manner.
Innovation Solution
A compression orthosis with a contentive proximal part made from thermoformable yarn, which is initially flexible and becomes rigid after activation, allowing for precise adaptation to the calf morphology, combined with a conventional compressive distal part, ensuring effective compression and ease of fitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional elastic compression orthoses are used with uniform compression profile, then manufacturing is simple and cost-effective, but the muscular pump performance in the calf is not adequately optimized
Solution Approach 1:
The orthosis incorporates a differentiated compression profile with a first zone (calf region) providing higher compression (20-35 mmHg) to optimize muscular pump performance, and a second zone (thigh region) providing lower compression (10-20 mmHg). This local differentiation of compression intensity addresses the specific physiological needs of the calf muscles while maintaining overall therapeutic effectiveness.
Solution Approach 2:
The orthosis is pre-formed with a specific three-dimensional shape and compression profile before application to the patient. The differentiated compression zones are integrated into the garment structure during manufacturing, eliminating the need for custom tailoring while ensuring optimal muscular pump support from the first application.
2Reliability
If maximum compression is applied at the ankle as in conventional orthoses, then venous pressure counteraction is effective, but calf muscle compression and muscular pump optimization are compromised
Solution Approach 1:
The orthosis applies differentiated compression pressures to different anatomical regions: the calf region receives higher compression (20-35 mmHg) to optimize muscular pump function, while the ankle region receives moderate compression and the thigh region receives lower compression (10-20 mmHg). This local differentiation ensures optimal venous return without compromising calf muscle compression.
Solution Approach 2:
The compression profile is designed to work dynamically with the muscular pump cycle, providing enhanced compression during muscle contraction to facilitate venous emptying, and maintaining appropriate baseline compression during relaxation. The differentiated zones respond differently to muscle movement, optimizing venous return efficiency.
3Stress or pressure
If differentiated compression zones are implemented to optimize muscular pump, then calf compression is improved, but manufacturing complexity increases
Solution Approach 1:
The orthosis is divided into distinct compression zones (calf region with 20-35 mmHg, thigh region with 10-20 mmHg) that can be manufactured as separate knitted sections and then joined. This segmentation allows for optimized compression in each zone while using standard manufacturing techniques for each segment, balancing complexity with effectiveness.
Solution Approach 2:
The orthoxis utilizes composite knitted structures with different yarn compositions and knit densities in different zones to achieve the desired compression profile. The calf region uses tighter knit structures with higher elastic content for 20-35 mmHg compression, while the thigh region uses more open knit structures for 10-20 mmHg compression, creating a differentiated pressure system through material variation rather than complex mechanical structures.
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 orthosis provides enhanced venous return by optimizing calf compression while maintaining ease of use and affordability through a manufacturing process that does not require custom tailoring, accommodating various leg morphologies and ensuring therapeutic pressure distribution.
Implementation Method 1
one of said weft or knit yarns comprising a yarn thermoformable
Implementation Method 2
the stretched textile of the orthosis exerts a compression resulting from the restoring force of the elastic fibers that make up the material
Implementation Method 3
the application of these elastic restoring forces on the perimeter of the contour generates at a given point, according to Laplace's law, a local pressure inversely proportional to the radius of curvature of the contour at this point
Data Source
Figure 1~2
Figure 3~5(d)
AI summary
This orthosis (10) comprises a distal elastic compressive portion (14), extending upwards from the ankle, associated with an adjoining proximal supportive portion (16) that envelops a region of the calf between level (B1) of the junction between the Achilles tendon and the calf muscles and level (D) located below the tibial tuberosity. This proximal supportive portion is a deformable, essentially non-elastic tubular section, made by knitting with thermoformable yarn, and it is knitted continuously with the distal elastic compressive portion.