Joint brace with limb-conforming arcuately adjustable cuffs

[0002] This application is a continuation-in-part of U.S. patent application Ser. No. 09/578,125, filed May 24, 2000 now U.S. Pat. No. 6,464,657.

[0003] Not Applicable

[0004] This invention relates in general to anatomical support braces, and in particular to an exteriorly positionable anatomical brace having tensionably tightenable cuffs situated about respective limb structures on either side of a uniting pivoting joint such as a knee joint to thereby provide adjustable limb-conforming arcuate tightening pressure about the respective limb structures and resulting stability to the supported joint.

[0005] Both injury and disease can affect the health, well-being, and operability of various joints of the human body. Chief among such joints are the knee and elbow where disease such as osteo-arthritis can curtail normal activity or where an injury such as a sports-related abuse or impact can prevent or severely limit continued activity. One manner of treating such joint conditions and/or preventing or reducing the severity of sports related injuries is to fit the wearer with an appropriate brace whereby a pivotal support member is positioned adjacent the affected joint and held in place usually by cuffs situated around limb structure sites above and below the supported joint. As is apparent, the cuffs are responsible for stabilizing the support member and therefore must be well secured to their associated limbs. To accomplish such securement, previous designs offered either soft cuffs which afforded no stability, or rigid custom-made cuffs, which are non-adjustable. Further, present cuffs are typically provided with one or more straps that are tightened around each limb structure and retained by buckles, hook-and-loop connections, or the like while the cuff itself generally is substantially permanently preformed to a particular arcuate radius. As is evident, however, such present-day construction is generally deficient in that cuff tightening, and therefore brace stabilization, is limited by the strength of the user in manipulating the straps, buckles, etc., as well as in the flexibility and tensionability of the cuff structure itself. In view of these limitations, it is apparent that a need is present for an exteriorly positionable anatomical brace wherein the tightness of cuffs can be adjusted for effective brace engagement. Accordingly, the primary object of the present invention is to provide an anatomical brace where limb-structure embracing cuffs thereof are arcuately adjustable for tightenable configuration to adjacent limb structures.

[0006] Another object of the present invention is to provide an anatomical brace where arcuate adjustment configurations of the cuffs are maintained upon brace removal.

[0007] Yet another object of the present invention is to provide an anatomical brace where cuff adjustment of arcuate configurations can be accomplished after brace placement on the involved limb.

[0008] These and other objects of the present invention will become apparent throughout the description thereof which now follows.

[0009] The present invention is an exteriorly positionable anatomical brace for stabilizing a uniting pivoting joint such as a knee joint disposed between a first and second limb structure of a living being. The brace comprises an upper frame member and a lower frame member joined together by a pivoting joint member, with each such frame member having secured thereon a respective cuff for encompassing a portion of each limb structure above and below the joint. Retention of the brace in place at the joint site is preferably accomplished with respective upper and lower securement members each wrapping around a respective limb structure in alignment with and not encompassed by the cuff. Each cuff is an arcuate, tensionable, flexibly-bendable wall structure, which non-limitedly can be constructed of a polymer plastic material, having integral therewith at least one elongate tensioner in arcuately related juxtaposition with the cuff such that shortening the tensioner (like tendons in the hand, causes a bending of the tensioner which also bends the cuff. The tensioner includes an exteriorly accessible adjuster for incrementally drawing the lateral end of the tensioner medially for arcuately tightening the cuff or, oppositely, for incrementally releasing the lateral end and arcuately loosening the cuff. Once set, the adjuster maintains the chosen arcuate configuration when the brace is removed, thereby assuring a proper fit without repeated adjustment each time the brace is donned. Such cuff adjustability coupled with respective securement members respectively retains each cuff in place to provide superior and maximized anchored brace stability. In addition, thereafter the cuff may be easily re-adjusted for comfort and/or change in anatomic size.

[0010] An illustrative and presently preferred embodiment of the invention is shown in the accompanying drawings in which:

[0011] FIG. 1 is a perspective lateral view of a knee brace with upper and lower cuffs of respective upper and lower frame members in place on a user's leg shown in phantom;

[0012] FIG. 2 is a perspective medial view of the knee brace of FIG. 1 in place on the leg;

[0013] FIG. 3 is a lateral perspective view of the upper cuff and upper frame member only of FIG. 1 in disassociated relationship illustrating the end of the cuff and the securement system of the present invention;

[0014] FIG. 4 is a medial perspective view of the upper cuff and upper frame member;

[0015] FIG. 5 is a rear perspective view of the upper cuff and upper frame member of FIG. 1 in place on a leg and illustrating the securement system of the present invention;

[0016] FIG. 6 is an interior perspective view of a portion of the upper cuff of FIG. 1;

[0017] FIG. 7ais an interior side elevation view of the upper cuff of FIG. 4;

[0018] FIG. 7bis a schematic interior side elevation view of the cuff of FIG. 7ashowing tensioning thereof;

[0019] FIG. 7cis a top plan view along line 7c-7cof FIG. 7a;

[0020] FIG. 8 is an inner perspective view of the joint assembly and respective portions of joined upper and lower frame members of FIG. 1;

[0021] FIG. 9 is an exploded perspective view of the joint assembly and frame members of FIG. 8;

[0022] FIGS. 10aand 10bare perspective views of the inner and outer sides of the joint assembly of FIG. 8; and

[0023] FIG. 11 is an exploded perspective view of the joint assembly of FIG. 10a.

[0024] Referring first to FIGS. 1-5, a knee brace 10 is shown (FIG. 1) in place on a leg 12 of a human being. The brace 10 has an upper frame member 14 and a lower frame member 16, with each such frame member 14, 16 having secured thereon a respective cuff 18, 20 for disposition about the limb structures above and below the knee joint 22. Each cuff 18, 20 is an arcuate wall structure, which non-limitedly can be fabricated of a polymer plastic, for juxtapositioning with the respective limb structures as shown. Snap-in protective patella cups 24 can be included as shown for specific impact absorption that may occur at the patella of the knee joint 22.

[0025] The knee brace 10 is retained in place on the leg 12 with respective upper and lower securement members 26, 28 each respectively wrapping around an adjacent rear portion of the leg 12. While FIGS. 2-5 show only the upper securement member 26, it is to be understood that the following description thereof applies equally to the lower securement member 28. Thus, the securement member 26 includes a medial piece 30 and a lateral piece 32 each attached at outside edges 36, 38 thereof to an elastomeric central piece 34 disposed behind the medial and lateral pieces 30, 32. Respective inside edges 40, 42 of the medial and lateral pieces 30, 32 are provided with eyelets 44 through which is intertwined a length of non-elastomeric lace 46 in substantially the same manner as a shoe is laced to thereby permit the drawing of each inside edge 40, 42 toward each other. As would be recognized by the skilled artisan, hook-and-loop connectors (e.g. VELCRO) or other appropriate engagers can be employed in place of the length of lace 46. Finally, the elastomeric central piece 34 is secured along a generally central vertical length 48 thereof to a liner section 50 to thereby permit elasticized movement of the medial and lateral pieces 30, 32.

[0026] As illustrated in particular in FIGS. 3 and 4, the lateral piece 32 (FIG. 3) is releasably secured respectively to the upper cuff 18 and the upper frame member 14, and the medial piece 30 (FIG. 4) is releasably secured to the upper frame member 14 and the medial condyle 52, all by way of respective quick-release tab members 54 situated within respective slots 56. As shown, each tab member 54 is provided with a finger-receiving pressure button 58 which, when depressed, permits removal of the tab member 54 from the slot 56. In operation, the brace 10 is placed at the limb site of a user and positioned about the involved limb structures. Upon first placement of the brace 10, the lace 46 is tightened to appropriate tightness while the central piece 34 increases surface area on the leg 12 to disperse pressure and prevent pull from the leg 12 such that the cuff 18 is properly maintained in place. Once such lacing is accomplished the first time, re-lacing although permissible, is not required during subsequent brace use. Specifically, when a user wishes to remove the brace, the user simply presses inwardly on the pressure buttons 58 of only laterally, or, preferably, only medially, situated tab members 54 to release these tab members 54 from their respective slots 56 and remove the brace 10 from the leg 12. It is important to note that the above-described tab-member release does not require increased tension on the leg and therefore is both safe and comfortable. Subsequent re-positioning of the brace 10 merely requires placement thereof as previously situated and re-connection of the earlier disengaged tab members 54 into respective slots 56. This re-connection requires no contact with, or re-adjustment of, the lace 46 or the central piece 34, and thereby assures proper brace placement without awkward, and very possibly incorrect, orientation of the brace 10. Because the medial connection involves connection to the medial condyle 52 which is, of course, at the hinge point of the upper and lower frame members 14, 16, a closer positioning of the securement member 26 to the body joint is permitted, thereby improving joint support. While the lateral condyle 60 in the embodiment here shown does not bear a connector member, it is to be understood that such construction could be provided if desired.

[0027] Construction of the cuffs 18, 20 is illustrated in FIGS. 6-7c. Both the upper cuff 18 and lower cuff 20 are substantially identical in construction except for overall size since, of course, the lower cuff 20 encompasses a smaller-diameter limb portion below the knee joint 22. As shown particularly in FIGS. 6 and 7awith respect to the upper cuff 18, whose following description also applies to the lower cuff 20, the cuff 18 has two tensioning strip members 62, integral therewith and disposed within respective non-continuous sleeves 64, 66 that are structurally a part of the cuff 18. Each cuff defines a longitudinal axis 65, and each sleeve 64, 66 has a lateral end 67 and a medial end 69, as shown in FIG. 7a. The sleeves 64, 66 of each cuff 18 converge toward each other from the lateral end 67 toward the medial end 69 of the sleeves 64, 66. Each strip member 62, which preferably is fabricated of titanium, stainless steel, or similar material possessing similar tensioning properties, continues medially into a cuff mount 68 that functions to secure the cuff 18 to the upper frame member 14. Finally, a respective exteriorly-accessible threaded screw 70 extends into each strip member 62 for adjusting tension in each strip member 62 and simultaneously adjusting the arc defined by the upper cuff 18. Thus, clockwise turning of the screw 70 incrementally draws the lateral end of the strip member 62 medially for arcuately tightening the cuff 18, while counter clockwise turning of the screw 70 incrementally releases the lateral end of the strip member 62 for arcuately loosening the cuff 18. Operationally, the brace 10 is fitted to a user by encompassing the cuffs about the respective limb structures above and below the knee joint 22 as seen in FIG. 1. Once the upper cuff 18 is situated about the limb structure, the screws 70 are threadingly advanced to thereby cause movement of the lateral end of the cuff 18, as illustrated in FIGS. 7band 7c, against the limb structure as the strip members 62 are forced to bend toward the encompassed limb structure. Continued screw advancement increases tightening of the cuff 18 against the encompassed limb structure to thereby accomplish superior anchoring and fit of the brace 10 and consequent stabilization of the knee joint 22. As earlier noted, the lower cuff 20 is constructed in the same manner as the upper cuff 18 and therefore encompasses and embraces the limb structure below the knee joint 22 in like fashion. Although preferably the strip members 62 are fabricated as shown, those skilled in the art will recognize that they can additionally be fabricated as cables or other elongate elements.

[0028] Referring to FIGS. 8-11, the pivoting assembly 72 uniting the upper and lower frame members 14, 16 is illustrated. The assembly 72 includes an upper housing 74 and a lower housing 76 that fit, respectively, into a complementarity shaped opening 78 of the upper frame member 14 and a complementarity shaped opening 80 of the lower frame member 16. However, it is contemplated that the housing 74 and 76 could be integrally formed with the frame members. Once so positioned, respective caps 82, 84 are held in place with conventional set screws 86 passing respectively through apertures 88a, 88band 90a, 90b. The lateral condyle 60 resides between the assembly 72 and the knee joint 22. Both the upper and lower housings 74, 76 have two respective openings 92a, 92band 94a, 94beach having respective sidewalls 96 shaped to nest a spherical shape. Disposed between two openings 92b, 94aof the housings 74, 76 is a forward arm member 98 having generally perpendicularly angled first and second ends 100a, 100bdirectable toward the openings 92b, 94a. In like manner, a rearward arm member 102 having generally perpendicularly angled first and second ends 104a, 104bis disposed between two openings 92a, 94bof the housings 74, 76 such that the ends 104a, 104bare directable toward the openings 92a, 94b. A cable assembly 106 includes a cable 108 extending from the upper housing 74 to an upper edge portion 110 through an aperture 112 of the rearward arm member 102, and is provided with a conventional set screw 114 at one end thereof for extending or shortening the length of the cable 108 disposed between the rearward arm member 102 and upper housing 74. Such length adjustment is accomplished with an Allen wrench inserted into the enterable channel 116 leading to the set screw 114. Because the upper housing 74 resides within the upper frame member 14, the cable 108 functions as a joint extension limiter to determine the travel distance of the upper frame member 14 from the joint and thus the pivotal distance of the upper and lower frame members 14, 16 in relation to each other. An opening 126 can be provided in the cap 82 such that the progressive placement of the cable 108 can be observed exteriorly and such placement can be made identical for both the lateral and medial sides. Two additional benefits are provided by the cable 108 in that, first, infinite pivot-distance adjustability, as opposed to prior-art pre-sized stop members, allows great flexibility in leg extension, and, second, the cable itself has a dampening, or minimal stretch, effect that results in a softer extension stop and a consequent reduced risk of joint trauma.

[0029] As earlier described, the sidewalls 96 of the openings 92a, 92band 94a, 94bare shaped to nest spherical forms. As clearly illustrated in FIG. 11, spherical sockets 118a, 118b, 118c, 118dare disposed in these openings 92a, 92band 94a, 94bin the constructed assembly 72, and each such socket accepts one respective perpendicularly angled end of forward and rearward arm members 98, 102. Each angled end 100a, 100b, 104a, 104bhas an aperture 120 there through which mates with a transverse aperture 122 of each socket 118a, 118b, 118c, 118dsuch that respective pins 124 can pass through such mated apertures and retain the angled ends 100a, 100b, 104a, 104bwithin the sockets 118a, 118b, 118c, 118d. Because of the spherical interface between each socket 118a, 118b, 118c, 118dand each sidewall 96, multi planar movement of the upper and lower frame members 14, 16 in relation to each other can be accomplished. In particular, the different pivot points thus provided allow different pivot ratios as needed for both lateral and medial sides to thereby simulate actual knee joint movement. This is, of course, in contrast to parallel planar hinges as found in the prior art where the knee joint and limb structures of a user are forced to adapt to knee brace construction instead of the knee brace adapting to the needs of the user. The present knee brace 10, because of the multi planar and potentially differing pivot ratios and consequent multi planar movement capabilities of the lower frame member 16 in relation to the upper frame member 14, provides automatic tibia alignment and automatic anatomical changes over time by accommodating anatomical differences among users. These properties accomplish all-important positive three-point positioning at the quadriceps muscle, the gastrocnemius (calf) muscle, and the knee joint itself. In this manner, stabilization and support of a uniting pivoting joint occurs economically, through an “off-the-shelf” brace, and, simultaneously, most effectively through continual self-alignment capabilities combined with sound limb-structure stability.

[0030] While an illustrative and presently preferred embodiment of the invention has been described in detail herein, it is to be understood that the inventive concepts may be otherwise variously embodied and employed and that the appended claims are intended to be construed to include such variations except insofar as limited by the prior art.