Compression brace material with arcuate slits

[0002] This is a continuation-in-part of prior U.S. patent application Ser. No. 09/846,332, filed May 2, 2001, now U.S. Pat. No. 6,508,776 priority from the filing date of which is hereby claimed under 35 U.S.C. § 120.

[0003] This invention generally relates to orthopedic supports and, more specifically, to a composite material for use in making elastic compression braces having improved compression support, body heat retention, and breathability during use.

[0004] Elastic compression braces are available in many forms. Commonly such braces are composed of soft, elastic material so that when worn, they provide a certain amount of support for an injured joint. These types of braces, often purchased without a prescription or the need for skilled professional fitting, have been used for a number of years and have been commonly available as braces for the knee, ankle, thigh, wrist, elbow, chest, or lower back. These resilient, pliable compression braces can be worn for sprains and strains, arthritis, tendonitis, bursitis, inflammation, or to reduce discomfort during post-operative use or to treat post-trauma discomfort.

[0005] The elastic compression braces are often made from synthetic rubber (e.g., polychloroprene). This particular material is desirable because of its combination of favorable properties useful in elastic compression braces. Polychloroprene rubber has good elasticity and a relatively high density, thereby providing good compression support and resistance to shear forces.

[0006] Polychloroprene rubber is a closed cell material and therefore does not dissipate heat very well during use. Its closed cell characteristics can be useful in retaining heat during use by reflecting emitted heat back into the bones and joints of the affected area. This localized concentration of heat can aid venous flow, help reduce edema, and make the soft tissues less susceptible to injury.

[0007] Although use of polychloroprene rubber in elastic compression braces can concentrate heat, the natural tendency of the closed cell material to prevent heat dissipation may cause problems for the user. When worn, the polychloroprene material braces are stretched to impart a compression load around the affected body area. This compression fit, combined with the high density of the material and the lack of air circulation and dissipation through the material, can result in heat discomfort and perspiration and may lead to heat rashes. Prolonged use of such braces can cause the user to perspire constantly, resulting in discomfort to such a degree that the user often stops wearing the brace prematurely. In effect, the material itself dictates the length of time that the orthopedic brace can be worn. It is not uncommon for users to stop wearing such braces after about one to two hours. In an effort to provide better breathability, certain prior polychloroprene rubber braces have been manufactured with perforations or holes punched through the entire depth of the material. However, these braces may not retain sufficient structural integrity to serve as an effective compression brace for the wearer because neoprene material is removed from these braces.

[0008] Thus, there is a need for an elastic compression brace having sufficient structural strength and integrity to offer a sufficient level of compression support, while also dissipating heat during use to reduce or avoid undue perspiration and heat discomfort, especially during prolonged use.

[0009] The present invention provides a flexible, resilient composite material for use in forming elastic compression braces for surrounding and supporting a body part by compression. The composite material includes a center elastic layer, an inner fabric layer, and an outer fabric layer. The elastic center layer is preferably composed of closed cell material in sheet form, having on one side thereof a plurality of grooves or channels formed therein to intersect each other to define a gridwork. The pattern of channels provides passageways along the width and length of the center layer to enable heat and moisture dissipation for the body part being supported.

[0010] The center layer also may have a plurality of cuts extending through the entire depth of the layer and distributed across the surface area of the layer, with the center layer still having sufficient structural strength and integrity to provide orthopedic compression support.

[0011] The composite material may also include an inner layer of flexible, resiliently elastic, porous fabric material bonded to the grooved side of the center layer. The outer fabric layer may also be composed of a flexible, resiliently elastic, porous material bonded to the non-grooved side of the center layer.

[0012] In an embodiment of the invention, the plurality of cuts extending through the center layer are arcuate slits, for example, circular slits extending between about 180 degrees and 270 degrees, the arcuate slits defining an array of tabs that are hingedly attached to the center layer, such that stretching the composite material produces gaps in the center layer, thereby creating an air flow path between the inner and outer layers.

[0013] The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:

[0014] FIG. 1 is a side elevation view semi-schematically illustrating a knee brace made from an orthopedic material according to principles of the present invention;

[0015] FIG. 2 is a semi-schematic perspective view of the knee brace shown in FIG. 1;

[0016] FIG. 3 is a cross-sectional view schematically illustrating components of a composite orthopedic material of the present invention.

[0017] FIG. 4 is a frontal plan view illustrating a section of a punctured center layer of the composite material of the present invention;

[0018] FIG. 5 is a back plan view illustrating a section of the punctured center layer shown in FIG. 4;

[0019] FIG. 6 is a perspective view illustrating an elbow brace made from the composite material of the present invention;

[0020] FIG. 7 is a perspective view illustrating a wrist brace made from the composite material of the present invention;

[0021] FIG. 8 is a side view illustrating an ankle brace made from the composite material of the present invention;

[0022] FIG. 9 is a view similar to FIG. 4, illustrating another pattern of channels formed in the center layer of the composite material;

[0023] FIG. 10 is a plan view of a center layer according to another embodiment of the present invention;

[0024] FIG. 11 is a plan view of the center layer shown in FIG. 10 with the center layer stretched lengthwise, as indicated with the large arrows;

[0025] FIG. 12 is a plan view of a center layer according to another embodiment of the present invention;

[0026] FIG. 13 is a cross-sectional view of the center layer shown in FIG. 12, taken along line 13—13;

[0027] FIG. 14 is a cross-sectional view of the center layer shown in FIG. 13, shown with inner and outer layers attached to the center layer; and

[0028] FIG. 15 is a cross-sectional view similar to FIG. 14, showing the composite material stretched lengthwise, as indicated with the large arrows.

[0029] FIGS. 1 and 2 illustrate a knee brace 20 made from an orthopedic material according to principles of this invention. The orthopedic material is illustrated in FIGS. 3, 4, and 5. The knee brace is a soft orthopedic brace made from a flexible, resilient composite 100 shown in flat form in FIGS. 3, 4, and 5. The flat form composite material is cut to shape and sewn or otherwise assembled to form a tubular knee brace 20, illustrated in FIGS. 1 and 2.

[0030] Referring to FIGS. 1 and 2, a piece of composite material 100 in flat sheet form is folded over on itself. The overlapping long edges on the opposite side of the fold are fastened by a long, upright seam 50. The material in the flat is cut in a shape so that when stitched along seam 50, as shown in FIGS. 1 and 2, an angular knee support of generally tubular form is produced having an open top 60 and an open bottom 70. Peripheral stitching 80 at the upper edge and similar peripheral stitching 90 at the bottom edge provide finished edges for the completed knee support.

[0031] The components which comprise the composite 100 are best understood by referring to FIGS. 3, 4, and 5. FIG. 3 shows a cross-sectional view illustrating the components of the composite 100 of the present invention. The composite material includes a flexible and foldable center elastic layer 110, an inner fabric layer 130, and an outer fabric layer 120. The center elastic layer 110 is preferably from a closed cell foam material in sheet configuration. One preferred elastic closed cell material is polychloroprene rubber, commonly known as neoprene rubber. Preferred neoprene materials are articles of commerce. Another suitable material for center layer 110 is styrene butadiene rubber (SBR). These materials are available in a wide density range so it is not difficult to find material of a desired density that provides the desired level of support and provides good orthopedic compression during use. Ideally such material for the purposes of the present invention is from 1.5 mm to 8 mm thick. However, other thicknesses may be used. Also, other elastic closed cell materials may be used to form layer 110.

[0032] The center elastic layer 110 has formed therein on one side thereof a plurality of intersecting grooves or channels 140. In non-limiting example, one embodiment of the present invention shows the pattern of intersecting channels 140 is formed by placing neoprene sheet material down on a metal mesh and then placing a weighted heat source on top of the flat sheet material. The pressure and heat cause the mesh to depress into the sheet material to permanently take the shape of the metal mesh on the underside where the grid pattern of the metal mesh is pressing into the sheet material. In addition or alternatively, the mesh may be preheated.

[0033] In another embodiment of the present invention, a pattern of intersecting channels 140 is formed on both surfaces of the sheet material. This can be accomplished in one manner by sandwiching the center layer 110 between top and bottom metal grids and heat pressing both grids against center layer 110, causing both grids to depress into the surfaces of the sheet material. The grid pattern may be identical on both sides of the center layer 110, or may be of different configurations.

[0034] In the embodiment shown in FIGS. 3 and 4, the plurality of intersecting channels 140 formed in center elastic layer 110 define a generally rectangular or square-shaped pattern or grid. It is to be appreciated that the pattern can be of any other shape (e.g., diamonds (see FIG. 9), triangles, ovals, circles, etc.) as long as the channels 140 intersect each other so as to provide a continuous or interconnected passageway across the sheet material and along the length of the material.

[0035] The center elastic layer 110 may be punctured to form a multiplicity of punctures or cuts 150 through the layer. Cuts 150 are not shown in FIG. 3 for simplicity but are shown in FIGS. 4 and 5. FIG. 4 is a frontal plan view showing a section of punctured center layer 110. FIG. 5 is a back plan view showing a section of the punctured center layer 110 shown in FIG. 4. The multiplicity of cuts 150 are dispersed across the surface of center elastic layer 110 and extend through the entire depth of the layer so that fluids, including perspiration and air, can pass through the cuts 150 from one side of the layer to the other, especially when the layer is stretched.

[0036] In one embodiment of the present invention, cuts 150 are located only in registry with the channel portions 140. In another embodiment, cuts 150 are located not only within the channels 140, but also in the ungrooved/channeled portion of elastic layer 110. In a further embodiment (See FIG. 9), the cuts 150′ are located only at the intersections of the channels 140′. The multiplicity of cuts 150 may be of uniform pattern and spaced apart uniformly about the center elastic layer 110. Ideally, the multiplicity of cuts 150 should not be so large or the cuts must be spaced so close together that the overall structural integrity of the neoprene material is reduced beyond the ability of the material to provide sufficient orthopedic compression support during use.

[0037] The multiplicity of cuts 150 may define a cut pattern. FIGS. 4 and 5 show that the cut pattern has three “legs” that radiate from a common point. It is to be appreciated, however, that the cut pattern may be any shape, such as a straight line, a curved line, a cross, or a five-legged pattern, without departing from the scope of the present invention. It is to be further appreciated that preferably the puncture does not actually remove any significant material, if any, from center elastic layer 110 or channels 140; rather, the puncture simply extends through the channels. Thus, the puncture does not form a hole or passage through the neoprene material unless the material is stretched.

[0038] The pattern for the multiplicity of cuts 150 may be formed in center elastic layer 110 by a number of methods. One such method of forming a cut pattern in the neoprene material is by a roller having a cylindrical outer surface with projecting punches in the desired cut pattern so that rolling the roller over the flat surface of the neoprene material punches out cuts in the desired pattern.

[0039] Referring back to FIG. 3, composite material 100 also includes a soft, flexible, resilient, porous inner fabric layer 130. Inner layer 130 may be a knitted flexible and foldable, stretchable cloth fabric material which is porous to air and water because of the pores inherently formed by the knitted fabric. Composite material 100 also includes a flexible and elastic, porous outer fabric layer 120, which also may be made from a stretchable knitted fabric of the same or different type from layer 130. The inner and outer fabric layers 130 and 120, respectively, may also be made from other stretchable knitted fabrics including nylon, Dacron or other synthetic fibers.

[0040] After the center elastic layer 1110 is altered with a plurality of intersecting channels 140 on one side thereof and punctured with a cut pattern 150, inner fabric layer 130 is bonded to the grooved face of center layer 110, while outer fabric layer 120 is bonded to the non-grooved face of center layer 110. Inner fabric layer 130 may be adhered to the center layer 110 using an adhesive technique that prevents the glue or other adhesive from being placed in channels 140. As such, the adhesive does not close or obstruct channels 140. Outer fabric layer 120 is also glued or otherwise adhered or bonded to center layer 110. The adhesive bonds the entire contacting surface areas of the center layer 110 and the adjoining inner and outer fabric layers 130 and 120, respectively. It is to be noted that the adhesive does not disrupt the porosity of the center layer 110 and the inner or outer layers 130 and 120.

[0041] Returning to FIGS. 1 and 2, knee brace 20 is intended to be worn with the grooved/channeled side facing the body of the wearer. This provides the advantageous result of retaining heat against the body while allowing knee brace 20 to be breathable. Furthermore, because knee brace 20 is made from the composite material, it has sufficient porosity that internal heat build-up during use is essentially avoided. Knee brace 20 also provides good compression around a body part supported by knee brace 20 in its stretched condition. The elastic center layer retains substantially all of its ability to apply a compression load on the body portion being braced because material is not actually removed from the neoprene center layer, as in some conventional braces. Additionally, knee brace 20 is of sufficient density due to the neoprene, SBR, or other selected material to provide the compression necessary to serve as a useful knee brace. The inner and outer layers 130 and 120 also provide additional compressive strength to knee brace 20.

[0042] Knee brace 20 also provides good breathability. When knee brace 20 is in use, it stretches in a bi-directional manner, thereby creating a pumping action to allow air to flow through the channels 140 of knee brace 20. This carries body sweat through channels 140 and out the ends of knee brace 20. Knee brace 20 also allows fresh, cool air to pass inwardly through knee brace 20 to reach the body. Correspondingly, a certain amount of heat is able to pass from inside knee brace 20 to the outside through the plurality of cuts 150, which open up as the brace is stretched during use.

[0043] In accordance with a further aspect of the present invention, silicone 152, in the form of a gel or beads, may be applied along the inside of knee brace 20 lengthwise of the brace, perhaps on opposite sides of the brace. Additionally or alternatively, the silicone beads 154 may be placed circumferentially around the inside of the brace, perhaps near the ends of the brace. The silicone may be applied in a stripe of some width, in a narrow line or band, or in other patterns. Moreover, the stripe or line of silicone may be straight or curved. This silicone material causes the brace to stay in place on the body due to the friction between the silicone and the body. The silicone does not, however, cause discomfort or undue rubbing against the body.

[0044] In one embodiment, the silicone may be applied to the interior of knee brace 20 after the brace has been fully constructed. In another embodiment, the silicone is applied to the inside of inner fabric layer 130 of knee brace 20 and then the inner layer 130 is applied to the inside surface of center layer 110. As those skilled in the art will appreciate, other materials, in addition to silicone, may be employed to cause the brace to stay in place on the body without departing from the scope of the present invention.

[0045] FIGS. 6 through 8 illustrate further uses of the composite material 100 in compression braces. FIG. 6 shows an elbow brace 160 in which composite material 100 is folded and seamed along its length. The brace may have an intermediate seam 170 to form a generally L-shaped tubular elastomeric brace. The top and bottom edges of the tubular brace have stitched peripheral seams 180 for edge reinforcement. FIG. 7 illustrates a wrist brace 190 made from the composite material 100, in which the material is folded and seamed lengthwise to form a generally straight tubular brace having peripheral stitching 200 at its opposite ends for edge reinforcement. FIG. 8 illustrates an ankle brace 205 made from composite material 100. The ankle brace 205 is formed as a generally L-shaped tubular brace with peripheral stitching 220 at its opposite ends, peripheral stitching 230 around an edge portion of the brace that fits around the heel of the user. The brace may include intermediate stitching 240 fastening adjoining intermediate edges of the L-shaped ankle support.

[0046] These compression braces can be used to provide required levels of anatomical compression support while improving ventilation to the supported area to reduce the discomfort caused by perspiration and over-heating. The improved composite material of this invention thus improves the anatomical support provided by compression braces formed when such materials build up, because the user is able to wear the brace for extended periods rather than having removed the brace prematurely because of heat discomfort.

[0047] FIG. 9 illustrates an alternative embodiment to the present invention wherein the composite material 100′ is formed with an elastic center layer 110′ having intersecting channels formed therein in a diamond pattern. Also, the cuts 150′ are located at the intersection of the channels 140′. The channels 140′ and cuts 150′ may be formed in a same or similar manner as described above with respect to center layer 110. Further, in other respects, the composite material 100′ may be the same or similar to material 100 described above.

[0048] FIG. 10 illustrates a center layer 210 for a third embodiment of a composite material in accordance with the present invention. In this embodiment, the center layer 210 is provided with a plurality of arcuate slits 250 that extend entirely through the thickness of the center layer 210. The arcuate slits 250 are preferably semi-circular or partially-circular slits defining approximately 180 degrees to 270 degrees of a full circle. The arcuate slits 250 define a plurality of tab portions 255 that remain hingedly attached to the center layer 210, but that can open to allow air flow through the center layer 210. The curved geometry of the slits 250 provide a relatively long slit in a relatively short transverse distance on the center layer 210.

[0049] The plurality of arcuate slits 250 are arranged in a rectangular, offset array, as shown in FIG. 10. The center layer 210 is preferably between about 1.5 and about 8 mm thick, and most preferably about 3 mm thick. The arcuate slits 250 have a diameter D that is preferably between about 3 mm and about 10 mm, and most preferably approximately 4 mm. Adjacent offset lines of slits are spaced apart (in both the vertical and the horizontal direction as shown in FIG. 10) by an offset denoted OS, which is preferably between about 3 mm and about 10 mm, and most preferably, about 6 mm. A composite material utilizing the center layer 210 in combination with inner and outer layers 120, 130 (not shown in FIG. 10) discussed above, has been found to produce adequate compressive strength for use in orthopedic applications such as compression braces.

[0050] The slits 250 are produced in the center layer 210 without removing a significant amount of material from the center layer 210, whereby when the center layer is relaxed, or unstretched, the slits 250 are substantially closed.

[0051] FIG. 11 shows the center layer 210 of FIG. 10, with the composite material stretched elastically in the lengthwise direction (i.e., left and right in FIG. 11). Crescent-shaped air flow channels 250′ are opened in the stretched panel 210. It will be appreciated that the curvature of the arcuate slits 250 produce a relatively large flow area for air and moisture to pass across the center layer 210. This is due in part to the geometry of the tab portions 255, which are hingedly connected to the center layer 210 along one edge, which partially isolates the tab portions 255 from the stretching stresses in the center layer 210. The tab portions 255 therefore do not stretch as much as the surround portion of the material opposite the tab portions 255, producing a larger air flow channel 250′.

[0052] When the center layer 210 is relaxed, i.e., when the stretching forces are removed, the crescent-shaped air flow channels 250′ close, substantially returning to the slits 250 shown in FIG. 10. In particular, the tab portions 255 move laterally relative to the surrounding material opposite the tab portions 255. This opening and closing motion of the tab portions 255 produce a pumping action within the air flow channel 250′ enhancing the flow of air through the center layer 210. It will be appreciated that when a soft compressive brace is worn, such as the knee brace shown in FIGS. 1 and 2, movement of the wearer will result in elastic flexure of the brace. Such flexure of a brace made from the composite material described above will therefore produce an air pumping action improving air flow across the brace. Moreover, when the wearer is relatively still less heat is generated by the wearer, and less air flow will be produced by the pumping action through the air channels 255′.

[0053] A center layer 310 for a fourth embodiment of the present invention is shown in FIG. 12, wherein a center layer 310 substantially identical to the center layer 210 shown in FIG. 11 is provided with a plurality of elongate, shallow grooves or channels 340 that extend laterally across the inner face of the center layer 310. As discussed in detail above, the network of intersecting grooves 340 provide channels that promote air flow adjacent the wearer's skin, along the inner face of the composite material. As seen most clearly in FIG. 13, which shows a cross-sectional view of the center layer, the slits 350 are preferably positioned directly adjacent or intersecting the grooves 340 so that air and vapor is directed towards the slits 350, or conversely air entering from the slits is directed towards into the grooves 340.

[0054] FIGS. 14 and 15 show a cross section of a composite material 300 utilizing the center layer 310. The composite material 300 includes an elastic inner fabric layer 330, preferably a knitted synthetic fiber layer, that is adhered to the inner surface of the center layer 310. An elastic outer fabric layer 320 is adhered to the outer surface of the center layer 310. The inner and outer layers 330, 320 are adhered to the center layer in a manner that will permit at least some of the arcuate slits 350 to open when the composite material is stretched.

[0055] The inner and outer layers 330, 320 are porous such that air and vapor can pass through the inner layer 330, through the arcuate slits 350 (when the slits are open) and through the outer layer 320 to vent gasses away from the wearer, and in the opposite direction to provide cooling air beneath the composite material. FIG. 15 shows the composite material 300 stretched laterally, i.e., left to right in FIG. 15. The slits 350 are in an open position due to the stretching of the fabric. FIG. 14 shows the composite material 300 in an unstretched configuration, wherein the slits 350 are substantially closed. It will be appreciated by comparing FIG. 15 with FIG. 14 that sequential flexing and unflexing (stretching and unstretching) of the composite material will produce the pumping action discussed above, to facilitate the passage of air through the composite material.

[0056] Although the slits of the preferred embodiment are semicircular (i.e., 180-270 degrees of a circular arc), any number of other shapes are possible, and contemplated herein. For example, slits producing elongate tab portions with curved free ends and hingedly attached back ends may be utilized.

[0057] While the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.