LOAD DISTRIBUTION DEVICE FOR PREVENTING ORTHOSIS MIGRATION

1 ) A load distribution device for use with an orthosis and an orthosis attachment system, wherein the orthosis attachment system attaches the orthosis to a wearer of the orthosis:

wherein the load distribution device prevents at least one of migration of the orthosis and detrimental localized load force concentrations of the orthosis attachment system;

wherein the load distribution device comprises a rigid or semi-rigid structural support body having a curvilinear surface that substantially approximates or matches a surface of a mating body part in a first direction, wherein the curvilinear surface also substantially approximates or matches the surface of the mating body part in a second direction that is orthogonal to the first direction; and

wherein the load distribution device is connected to the orthosis attachment system or is shaped to attach to the orthosis attachment system.

2 ) The load distribution device of claim 1 , wherein the load distribution device further applies a force in a direction to improve biomechanics of a joint of the wearer of the orthosis.

3 ) The load distribution device of claim 1 , wherein the orthosis is a dynamic orthosis.

4 ) The load distribution device of claim 1 , wherein the curvilinear surface is determined based on a three-dimensional scan of the mating body part.

5 ) The load distribution device of claim 1 , wherein the load distribution device is made using three-dimensional (“3D”) printing or additive manufacturing.

6 ) The load distribution device of claim 1 , wherein the load distribution device is fabricated from at least one of: a rigid or semi-rigid thermoplastic, nylon, polypropylene, polyethylene, acrylonitrile butadiene styrene, polylactic acid, polyethylene terephthalate, polyethylene terephthalate glycol, and polyurethane.

7 ) The load distribution device of claim 1 , wherein the load distribution device is fabricated using a mold of the load distribution device in order to create a cast of the load distribution device made of at least one of carbon fiber, a composite material, and fiberglass material.

8 ) The load distribution device of claim 1 , wherein a surface area of the load distribution device contacting the mating body part is greater than a migration force divided by a coefficient of friction between an inner surface of the load distribution device and the mating body part times a pressure imparted by the load distribution device on the mating body part due to a tension provided by the orthosis attachment system.

9 ) The load distribution device of claim 1 , wherein a surface area of the load distribution device contacting the mating body part is one of: greater than 20 cm 2 , greater than 50 cm 2 , greater than 90 cm 2 , greater than 100 mm 2 , and greater than 120 cm 2 .

10 ) The load distribution device of claim 1 , wherein a surface of the load distribution device contacting the mating body part comprises a high-friction material to minimize migration or translation between the mating body part and the load distribution device.

11 ) The load distribution device of claim 10 , wherein the high-friction material is silicone.

12 ) A method for preventing migration of an orthosis, preventing detrimental localized load force concentrations of an orthosis attachment system, or both, comprising:

three-dimensionally scanning a surface of a mating body part;

digitally designing a load distribution device that connects to the orthosis attachment system;

fabricating using three-dimensional printing or additive manufacturing the load distribution device, wherein the load distribution device comprises a rigid or semi-rigid structure providing a curvilinear surface that substantially conforms to a surface of the mating body part in a first direction and the surface of the mating body part in a second direction that is orthogonal to the first direction; and

attaching the load distribution device to a wearer using the orthosis attachment system.

13 ) The load distribution device of claim 12 , wherein the load distribution device further applies a force in a direction to improve biomechanics of a joint of the wearer.

14 ) The method of claim 12 , wherein the orthosis is a dynamic orthosis.

15 ) A load distribution device connected to an orthosis attachment system, the load distribution device comprising:

a rigid or semi-rigid structure providing a curvilinear surface that substantially approximates or conforms to a surface of a mating body part in a first direction and substantially approximates or conforms to the surface of the mating body part in a second direction that is orthogonal to the first direction; and

a moment arm generated by an offsetting wedge located between the orthosis attachment system and the load distribution device.

16 ) A load distribution device connected to an orthosis attachment system, the load distribution device comprising:

a rigid or semi-rigid structure providing a curvilinear surface that substantially approximates or conforms to a surface of a mating body part in a first direction and that substantially approximates or conforms to the surface of the mating body part in a second direction that is orthogonal to the first direction;

wherein one end of the orthosis attachment system attaches to the load distribution device at a first location that is at least one of horizontally and vertically offset from a second location that attaches to a second end of the orthosis attachment system; and

wherein the offset attachment locations on the load distribution device impart one or more moments of rotation to the load distribution device.

17 ) The load distribution device of claim 1 , wherein the wearer is a human or an animal.