Toe Corrector Gear Adjustment for Stable Angle Correction
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Solution Overview
Problem
Current orthotic devices for correcting foot alignment issues such as bunions and toe deformities are non-adjustable, cumbersome, and provide limited correction efficacy, lacking versatility.
Innovation Solution
A novel toe corrector featuring a fastening bracket, correction bracket, and a rotational adjustment mechanism with an adjustable fastening strap, correction strap, and a gear-based adjustment system allowing horizontal rotation and precise angle adjustment of the correction bracket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a non-adjustable orthotic device is used, then the device structure is simple, but the correction effect is poor and the scope of application is limited
Solution Approach 1:
The patent implements a rotational adjustment mechanism that allows the correction bracket to be adjusted to different angles relative to the fastening bracket. This dynamic adjustment capability enables the device to adapt to different foot deformity conditions and correction requirements, transforming a static non-adjustable device into a dynamic adjustable one, thereby improving correction precision without excessive structural complexity
Solution Approach 2:
The patent changes the angular parameter between the fastening bracket and correction bracket through the rotational adjustment mechanism. By allowing the correction bracket to rotate around the pivot shaft to different angles, the device can accommodate various correction needs for different foot deformities, improving the scope of application and correction effect
2Manufacturing precision
If an adjustable orthotic device is used, then the correction effect is improved, but the device becomes cumbersome to use and operate
Solution Approach 1:
The adjustment mechanism is segmented into distinct functional components: an adjustment knob for user operation, a drive gear for force transmission, a bevel gear for directional change, and a rack for linear displacement conversion. This segmentation allows each component to perform its specific function efficiently, making the overall adjustment process simpler and more intuitive despite the multiple moving parts
Solution Approach 2:
The patent introduces a rack as an intermediary component between the bevel gear and the correction bracket. The bevel gear rotates, driving the rack to move linearly along guide slots, which in turn rotates the correction bracket via the pivot shaft. This intermediary mechanism translates rotational input from the adjustment knob into controlled angular adjustment of the correction bracket, improving ease of operation
3Reliability
If a simple orthotic device is used, then the device is easy to manufacture, but the stability and correction efficacy are insufficient
Solution Approach 1:
The patent incorporates a ratchet mechanism with pawls and ratchet teeth that engages automatically when the adjustment knob is rotated. This mechanism prevents the correction bracket from moving backward or losing its adjusted position, providing positional stability and reliability without requiring complex locking systems or additional adjustment mechanisms
Solution Approach 2:
The patent uses a bevel gear with curved tooth surfaces that mesh with the drive gear. The conical shape of the bevel gear allows for smooth angular transmission and provides inherent mechanical advantage, enhancing the stability of the correction mechanism while maintaining a compact structure that doesn't overly complicate the device
4Adaptability or versatility
If a non-adjustable correction bracket is used, then the device structure is simple, but the versatility and adaptability are poor
Solution Approach 1:
The rotational adjustment mechanism serves multiple functions: it adjusts the correction angle for different deformity types, accommodates various foot sizes through angle variation, and can be used for both preventive and corrective applications. This single mechanism provides universal adaptability across different clinical scenarios without requiring multiple specialized devices
Solution Approach 2:
The correction bracket is designed with dynamic adjustability through the rotational mechanism, allowing it to transition between different angular positions. This dynamic capability enables the device to adapt to various foot anatomies and deformity severities, significantly improving versatility compared to fixed-angle designs
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 rotational adjustment mechanism enables stable and efficient correction of foot alignment issues, providing exceptional stability and avoiding angle loss, with a gear adjustment structure that enhances overall adjustment precision and structural strength.
Implementation Method 1
a drive gear that is coaxial with the adjustment knob is disposed at a lower end of the adjustment knob, the drive gear is in meshing engagement with the adjustment gear
Implementation Method 2
ratchets that are circumferentially disposed are formed on a lower end surface of the drive gear; and pawls that correspond to the ratchets are disposed at a bottom of the gearbox housing, and the ratchets are engaged with the pawls to form a ratchet mechanism
Implementation Method 3
a spring contact strip that is elastically connected to the central shaft is formed on the central shaft
Implementation Method 4
a pivot shaft is disposed at an end of the correction bracket, the pivot shaft is received between the two articulated connection arms, and is in articulated joint with the two articulated connection arms
Data Source
AI summary
A toe corrector includes a fastening bracket extending longitudinally, correction bracket extending longitudinally, and rotational adjustment mechanism for adjusting the correction bracket. An adjustable fastening strap for fastening the fastening bracket to a medial side of a foot is disposed on the fastening bracket. An adjustable correction strap for fastening the correction bracket to the medial side of the foot is disposed on the correction bracket. The rotational adjustment mechanism includes an adjustment knob disposed on the fastening bracket and adjustment gear, where a drive gear coaxial with the adjustment knob is disposed at a lower end of the adjustment knob, and is in meshing engagement with the adjustment gear that is connected to the correction bracket, the adjustment knob and the adjustment gear are constructed to enable the fastening bracket to be in articulated joint with the correction bracket that is horizontally rotatable relative to the fastening bracket.