Unidirectional actuated exoskeleton device
Inventors
Mooney, Luke • Duval, Jean-Francois
Assignees
Publication Number
US-11304827-B2
Publication Date
2022-04-19
Expiration Date
2037-10-12
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Abstract
The present invention is directed to an autonomous exoskeleton device that includes one or more actuators, one or more controllers, one or more sensors with one or more unidirectional transmissions. The present invention provides a mechanical joint in parallel with a biological joint. The exoskeleton device preferably includes and electric motor and winch, chain, belt, cam transmission or other mechanism for providing unidirectional force to assist rotation about the biologic joint. Moreover, a controller, a motor angle sensor, joint angle sensor and/or force sensor may be used for additional control and monitoring of the device. The motor may be any type of motor, but is preferably brushless in configuration where its diameter is larger than its length to provide a compact and lightweight exoskeleton device.
Core Innovation
The invention provides an autonomous exoskeleton device employing one or more actuators, controllers, and sensors with at least one unidirectional transmission. It features a mechanical joint operating in parallel with a biological joint, using mechanisms such as a winch, chain, belt, or cam to provide unidirectional force supporting rotation about the user’s joint. The system is designed for integration with a composite footplate, which is incorporated directly into the sole of the footwear and tailored to interact both with the user’s body and the exoskeleton actuator.
A key technical challenge addressed by this invention is the need for an exoskeleton that combines low mass and high force/torque/power output without sacrificing comfort, efficiency, controllability, or range of motion. Conventional exoskeletons are either too heavy or inadequately powerful, and often struggle to deliver large forces safely and comfortably to the user. The current invention overcomes these problems by using a composite footplate with multi-directional fibers and variable thickness, designed to both transmit actuator force efficiently and accommodate natural flexion at the metatarsal region, while its structure allows plantar flexion, dorsiflexion, eversion, and inversion through dedicated mechanical joints.
The preferred embodiment integrates a brushless electric motor with a drive spool and a flexible drive belt to apply actuation only in the intended direction, optimizing device weight, bulk, and efficiency. Optionally, the composite footplate can include embedded sensors for force, pressure, strain, IMU, humidity, or temperature. The device can be quickly attached or detached from footwear, maintaining minimal interference when inactive, and can be adapted to various joints, such as the ankle or knee, without obstructing the user’s natural movement.
Claims Coverage
There are two independent claims covering two main inventive features regarding the structure and function of the composite foot plate for footwear.
Composite foot plate with variable thickness and multi-axis mechanical joint
The composite foot plate is integrated into the sole of footwear. Key aspects include: - The footplate extends upward only from one lateralmost side surface (or on the lateral side) of the footwear. - It is made of a composite material with fibers in multiple orientations and is flexible at the metatarsal joint region. - The footplate's thickness is varied. - There is a mechanical joint disposed on the footplate, configured and arranged to permit plantar flexion, dorsiflexion, eversion, and inversion of the footplate relative to the user's shank. - The structure includes both an outer sole (between the footplate and ground) and an inner sole (above the footplate).
Mechanical joint with dual axes of rotation for ankle movement
The composite foot plate's mechanical joint comprises: - An ankle dorsiflexion/planar-flexion joint with an axis of rotation configured to be perpendicular to the sagittal plane of the user. - An ankle eversion/inversion joint with an axis of rotation configured to be perpendicular to the axis of the dorsiflexion/planar-flexion joint. - The configuration places the ankle eversion/inversion joint proximal to the sole and the dorsiflexion/planar-flexion joint proximal to the eversion/inversion joint.
The independent claims define a composite footplate, integrated into footwear, with variable thickness, multi-orientation fibers, and a dual-axis mechanical joint to allow comprehensive biomechanical assistance and adaptability.
Stated Advantages
The exoskeleton device is compact, lightweight, inexpensive to manufacture, powerful, and easy to control.
The composite foot plate enables efficient energy transfer while accommodating natural range of motion, flexibility, and comfort.
The structure allows for quick attachment and detachment from footwear, providing convenience and adaptability for the user.
Adaptability to a variety of leg sizes and shapes, with minimal bulk and interference, while preserving comfort.
Documented Applications
Integration into footwear to assist and augment joints such as the ankle and knee, supporting plantar flexion, dorsiflexion, eversion, and inversion movement.
Use in military boots and tactical footwear, providing rigid arch support, protection, and exoskeletal actuation.
Application in devices worn on one or both legs, supporting bilateral use with communication between exoskeleton units for control and telemetry.
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