Walking Boot Chafe Assembly for Rotating Strap Tightening
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Solution Overview
Problem
Existing walking boots fail to securely tighten around the lower leg due to non-rotatable strap attachments, lack flexibility, and require improved push-button release valves for inflation.
Innovation Solution
A walking brace with a U-shaped malleable stay overmolded into a footbed and uprights, allowing for manual bending and rotation, combined with a push-button release valve and inflatable cavities for customizable fit and pressure adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a rigid plastic chafe with non-rotatable strap attachment is used, then the structural integrity is maintained, but the strap cannot easily tighten onto the anatomy
Solution Approach 1:
The chafe is designed to rotate about a transverse axis, transforming from a static rigid structure to a dynamic component that can adapt its orientation. This rotation capability allows the strap to tighten properly onto the anatomy while maintaining structural integrity through the defined rotation axis and attachment mechanism to the boot upright
Solution Approach 2:
The chafe is divided into functional segments: a rotation axis portion that provides the pivot point, a body portion that maintains structural integrity, and a strap attachment feature. This segmentation allows each part to fulfill its specific function - rotation for tightening, rigid body for strength, and attachment for securing the strap
2Adaptability or versatility
If a non-flexible chafe structure is used, then manufacturing simplicity is maintained, but the chafe cannot accommodate extra bulk such as bandages
Solution Approach 1:
The chafe incorporates flexible portions that can bend and deform to accommodate variations in leg anatomy and extra bulk such as bandages. These flexible sections are strategically placed to allow adaptation without compromising the overall structural integrity or requiring complex manufacturing processes
Solution Approach 2:
The chafe includes flexible portions made from materials that can bend and conform to different shapes, allowing the rigid chafe body to adapt to extra bulk like bandages while maintaining manufacturability through standard molding or fabrication techniques
3Reliability
If a standard push-button release valve is used, then the inflation mechanism is simple, but the valve may be accidentally activated or damaged
Solution Approach 1:
A protective rim is provided around the push-button release valve that prevents accidental activation by surrounding the button and requiring deliberate action to press. The rim also protects the valve from damage while maintaining the simple inflation mechanism, as it is integrated into the existing valve structure rather than adding a separate protective device
Data Source
AI summary
A walking brace is provided. The walking brace includes a U-shaped malleable stay configured to hold a manually-bent shape. The walking brace includes an integral portion. The integral portion includes a footbed, a first upright disposed at a first side of the footbed and a second upright disposed on a second side of the footbed. The integral portion is overmolded onto the U-shaped malleable stay such that the U-shaped malleable stay extends through each of the footbed, the first upright and the second upright. Other walking braces are provided wherein the integral portion includes a pocket configured to receive the U-shaped malleable stay at an underside of the integral portion such that the U-shaped malleable stay extends through each of the footbed, the first upright and the second upright. A method of manufacturing a walking brace is also provided.