HK1237607B - Knee brace - Google Patents

Description

knee brace

Field of the Invention

The present invention relates generally to the field of articles worn by a person to reduce the likelihood, severity, or progression of physical injury, and more particularly to the field of braces worn on the knee.

Background of the Invention

Flexible knee braces are used by athletes and other people who engage in strenuous physical activity to protect the knee from injury and to prevent the worsening of existing injuries. The knee is one of the most heavily used joints in the body, as it is used for any activity involving walking or running. The knee is also a common target for injury due to the relatively high levels of stress it must withstand. During normal walking, in occupations involving manual labor, and especially during strenuous exercise, the knee can experience abnormal motions caused by rapid changes in direction, fatigue, uneven surfaces, or impact. These abnormal motions can cause sprains or more serious injuries, including dislocation, stretching, or tearing of the tissues that make up the knee.

Several different types of abnormal motion can cause damage to the knee. First, hyperextension of the knee joint can occur, in which the knee flexes in its normal front-to-back manner, but beyond its normal range of motion. A second type of abnormal motion is axial rotation, in which the lower leg twists rotationally around the knee joint about the thigh. A third type of abnormal motion is lateral flexion of the lower leg about the thigh, in which the knee joint flexes from side to side, rather than its normal front-to-back motion. In addition, abnormal motion of the patella (kneecap) can lead to injury, such as chondromalacia patella, which is a softening or degeneration of the lower surface of the patella, and misalignment of the patella, also known as patellar subluxation.

In a variety of specific embodiments, devices for protecting the knee from abnormal motion have been used for many years, and they vary in their ability to protect from different types of abnormal motion. Except protecting the knee from abnormal motion, devices sometimes also provide additional benefits, such as isolating the knee to keep it warm, protecting the knee from impact, or squeezing the knee to reduce discomfort. However, the protection from abnormal motion provided by these devices is usually accompanied by a reduction in normal range of motion or comfort. These devices can also have other undesirable aspects, such as increasing the weight on the leg, the potential for self-injury or injury to others caused by rigid components, being difficult to apply and remove, cost, outward appearance, and irritation or friction to the skin.

For these reasons, there has been a long-standing motivation to discover improved knee braces that can protect the knee from abnormal motion without affecting normal range of motion or comfort, while avoiding the undesirable aspects of prior art devices.

Summary of the Invention

In a first embodiment, a knee brace according to the invention comprises a base and a radial component having a pair of upper and lower tensioning straps, wherein the radial component is permanently fastened to the inner surface of the base.

According to another aspect of the invention, a knee brace according to the invention comprises a base and a radial having paired upper and lower tensioning straps, wherein the radial is permanently fastened to the base by a plurality of stitches passing through the central axis of the base and the radial.

According to another aspect of the present invention, a knee brace according to the present invention comprises a base portion with a pair of upper and lower apertures, and a radial component positioned between the base portion and a person's leg when the brace is worn and having a pair of upper and lower tensioning straps, wherein the tensioning straps extend through the apertures in the base portion when the brace is worn.

In a second embodiment, a knee brace according to the present invention comprises a base portion and a shaped tension member formed from a synthetic fiber that is relatively elastic in all directions, such as the type known as spandex or elastane in the United States or sold under the trademark LYCRA®, although this is not required and other materials may be used. The tension member is permanently fastened to the inner surface of the base portion and has free ends that extend through apertures in the base portion where they can be fastened to the outer surface of the base portion using hook and loop fastening material. In a third embodiment, one or more resilient retainers may also be provided for additional support.

In a fourth embodiment, a knee brace according to the present invention comprises a base, an outer mesh layer, and a multi-part inner radial member comprising a shaped tension member formed from a synthetic fiber that is relatively elastic in all directions, such as a material of the type known in the United States as spandex or elastane, or sold under the trademark LYCRA®, although this is not required and other materials may be used. The shaped tension member has a central portion that is permanently secured to the inner surface of the base and has a strap extending through an aperture in the base to a (free) strap end that can be secured to the outer surface of the base using a hook and loop fastening material. The strap may include an inelastic portion, for example, near the second (free) end.

In a fifth embodiment, a knee brace according to the present invention includes a base, an outer mesh layer, and upper and lower cross straps formed from a synthetic fiber that is relatively elastic in all directions, such as a material of the type known as spandex or elastane in the United States or sold under the trademark LYCRA®, although this is not required and other materials may be used. The cross straps have a first end that is permanently fastened to the inner surface of the base and extend through an aperture in the base to a second (free) end that can be fastened to the outer surface of the base using a hook and loop fastening material. The straps may include an inelastic portion, for example, near the second (free) end.

The inelastic portion of the band can be formed simply by replacing the elastic material with an inelastic material at the desired position of the inelastic portion, for example, extending from a position near the orifice to the free end when worn. Alternatively, the inelastic portion can be formed by sandwiching and/or overlapping the portion of the elastic material with an additional layer of inelastic material band. If overlapped or clamped, one side of the resulting interlayer can be left open to form a bag to accommodate small items, such as keys, access fobs, ID cards or credit cards, smart devices (e.g., fitness trackers) or visible bright objects, such as bright objects, reflectors, flashlights, fluorescent sticks or other lighting devices. In this case, the outer mesh layer is preferably made of a net or other transparent or translucent material to allow the bright object or lighting device to be seen. One or more reflective sheets can also be provided to enhance the wearer's visibility.

Other objects, features and advantages of the present invention will become apparent from the following detailed description when taken in conjunction with the accompanying drawings.

Brief Description of the Drawings

In the attached figure:

FIG1A is a plan view of a prior art knee brace, laid flat to expose the outer surface of the brace;

FIG1B is a plan view of the prior art knee brace of FIG1A , laid flat to expose the inner surface of the brace;

FIG2A is a plan view of a first embodiment of a knee brace according to the present invention, laid flat to expose the outer surface of the brace;

FIG2B is a plan view of the knee brace of FIG2A , laid flat to expose the inner surface of the brace;

FIG3A is a front view of the knee brace of FIG2A-2B applied to a person's leg with the base mounting straps tightened but the radial straps loosened;

FIG3B is a front view of the knee brace of FIG2A-2B applied to a person's leg with the base mounting straps fastened and the radiating straps also fastened;

FIG4A is a side view of the knee brace of FIG2A-2B applied to a person's leg with the base mounting straps tightened but the radial straps loosened;

FIG4B is a side view of the knee brace of FIG2A-2B applied to a person's leg with the base mounting straps fastened and the radiating straps also fastened;

5A is a plan view of a second embodiment of a knee brace according to the present invention having a shaped tensioning member formed from synthetic fibers that are relatively elastic in all directions and durably secured to the inner surface of the base, with the brace laid flat to expose the outer surface of the brace;

FIG5B is a plan view of the knee brace of FIG5A , laid flat to expose the inner surface of the brace;

FIG5C is a plan view of a shaped tensioning member for use with the knee brace of FIG5A-5B;

5D-5E are perspective views of an aperture reinforcement base and backing for the knee brace of FIG. 5A-5B , respectively;

FIG6A is a plan view of a third embodiment of a knee brace according to the present invention having upper and lower cross straps with resilient retainers, with the brace laid flat to expose the outer surface of the brace;

FIG6B is a plan view of the knee brace of FIG6A , laid flat to expose the inner surface of the brace;

7A is a plan view of a fourth embodiment of a knee brace according to the present invention having an outer mesh layer and an inner formed tensioning component having both elastic and inelastic members, with the brace laid flat to expose the outer surface of the brace;

FIG7B is a plan view of the knee brace of FIG7A , laid flat to expose the inner surface of the brace;

FIG7C is a plan view of the knee brace of FIG7A laid flat to expose the outer surface of the brace and with the outer mesh layer removed to reveal the configuration of the internally formed tensioning member that may have both elastic and inelastic members;

FIG7D is a plan view of the outer mesh layer used in the knee brace of FIG7A-7C;

FIG7E illustrates a resilient retention member for use in the knee brace of FIG6A-6B , FIG7A-7C , and FIG8A-8C ;

8A is a plan view of a fifth embodiment of a knee brace according to the present invention having an outer mesh layer and upper and lower cross straps that may have both elastic and inelastic portions, with the knee brace laid flat to expose the outer surface of the brace;

FIG8B is a plan view of the knee brace of FIG8A , laid flat to expose the inner surface of the brace;

FIG8C is a plan view of the knee brace of FIG8A laid flat to expose the outer surface of the brace and with the outer mesh layer removed to reveal the configuration of upper and lower cross straps that may have both elastic and inelastic portions; and

8D is a plan view of an outer mesh layer used in the knee brace of FIGS. 8A-8C .

Detailed description of the invention

Referring to the drawings, Figures 1A and 1B illustrate a prior art knee brace 20 of a design similar to that taught in U.S. Patent No. 5,472,413, the contents of which are hereby incorporated herein by reference. The prior art knee brace 20 includes a base member 22 and a radial member 24, each formed by cutting a planar sheet 26 of elastomeric material into a desired shape. The outer surface 31 of the base member 22 is preferably covered with a fabric 28 carrying a fiber loop, which adheres to the hook material when the fiber loop and hook material are pressed together.

The base 22 of the prior art knee brace 20 has a base center portion 30 extending vertically from an upper edge 36 to a lower edge 38, and has a central axis 40 extending vertically downward along the middle of the base center portion 30. The base 22 includes a first upper mounting strap 32A, a second upper mounting strap 32B, a first lower mounting strap 34A, and a second lower base mounting strap 34B extending from the center portion 30.

1B , which illustrates the inner surface 39 of the base member 22, the first upper mounting strap 32A and the first lower mounting strap 34A terminate in hook-type strap fastening tabs 46 that are adapted to be detachably attached to the loop-bearing fabric 28 on the outer surface 31 of the base member 22. The strap fastening tabs 46 are sewn to the mounting straps using stitching 48.

The base also has a patella opening 52 to receive the patella when the brace is worn, may be formed to include a notch 74 to prevent bunching when the brace is worn, and preferably includes a trim 76, although these features are not required.

As perhaps best shown in FIG1A , which illustrates the outer surface 31 of the base 22, the prior art knee brace 20 includes a radial member 24. The radial member 24 has a radial member center portion 54 extending vertically from an upper edge 56 to a lower edge 58, and has a central axis 60 extending vertically downward along the middle of the radial member center portion 54. The radial member 24 is permanently attached to the outer surface 31 of the base 22 by stitches 72 that extend around the periphery of the radial member center portion 54.

The radial member 24 includes a first upper tensioning strap 62A, a second upper tensioning strap 62B, a first lower tensioning strap 64A, and a second lower tensioning strap 64B extending from the central portion 54. Each of the tensioning straps 62A, 62B, 64A, 64B terminates in a hook-type fastening tab 66 adapted to be detachably attached to the fabric 28 on the outer surface of the base 22 and sewn to the tensioning strap using stitches 68. The radial member 24 also has a patella opening 70 to receive the patella when the brace is worn.

2A and 2B show exterior and interior plan views, respectively, of a flat-lay knee brace 120 according to the present invention. The knee brace 120 comprises a base member 122 and a radial member 124, each formed by cutting a planar sheet 126 of elastomeric material into a desired shape. The outer surface of the base member 122 is preferably covered with a fabric 128 carrying a fiber loop, which adheres to the hook material when the fiber loop and hook material are pressed together.

The base 122 of the knee brace 120 has a base center portion 130 extending vertically from an upper edge 136 to a lower edge 138, and has a central axis 140 extending vertically downward along the middle of the base center portion 130. The base 122 includes a first upper mounting strap 132A, a second upper mounting strap 132B, a first lower mounting strap 134A, and a second lower base mounting strap 134B extending from the center portion 130.

2B , which illustrates the interior surface 139 of the base member 122, the first upper mounting strap 132A and the first lower mounting strap 134A terminate in hook-type strap fastening tabs 146 adapted to be detachably attached to the loop-bearing fabric 128 on the exterior surface 131 of the base member 122. The hook-type strap fastening tabs 146 are sewn to the mounting straps using stitches 148.

4A and 4B , when the base 122 of the knee brace 120 is applied to a person's leg, the first upper mounting strap 132A overlaps the second upper mounting strap 132B at the back of the leg, allowing the hook-type fastening tabs 146 at the ends of the first upper mounting strap 132A to adhere to the loop-of-fiber fabric 128 on the outer surface of the second upper mounting strap 132B to secure the knee brace 120 around the wearer's thigh 142. Similarly, the first lower mounting strap 134A overlaps and adheres to the second lower mounting strap 134B at the back of the leg to secure the knee brace 120 around the wearer's calf 144.

The base 122 also preferably has a patella opening 152 to receive the patella (kneecap) when the brace is worn. The patella opening 152 can be matched to the size of the patella so that the wearer's patella extends through the patella opening 152 when the brace 120 is worn, but this is not required. The patella opening 152 is preferably circular in shape, but this is not required, and other shapes such as diamond, oval, rectangular, or square can also be used. In addition to providing direct patellar stabilization, the patella opening 152 can help position the brace 120 relative to the patella during use.

The base 122 can be formed to include notches 174 between the upper mounting straps 132A, 132B and the lower mounting straps 134A, 134B so that when the knee brace 120 is fitted on the leg, the gaps on each side form an opening at the back of the knee, but this is not required. The notches 174 can help prevent chafing, can provide ventilation, and can help prevent bunching or undue restriction of movement.

The base 122 is preferably formed as a reclosable sleeve made of a sheet of elastic material, as shown in Figures 2A-2B, which provides generalized support and compression to the knee area along with therapeutic warmth, although other materials may be used. The base 122 may also be formed, for example, as a tubular elastic sleeve shaped to fit snugly around the knee and adjacent leg. The base preferably includes a trim 176, but these features are not required.

2B , which illustrates the inner surface 139 of the base 122, the knee brace 120 includes a radial member 124. The radial member 124 has a radial member center portion 154 extending vertically from an upper edge 156 to a lower edge 158, and has a central axis 160 extending vertically downward along the middle of the radial member center portion 154. The center portion 154 of the radial member 124 is permanently attached to the inner surface 139 of the base 122 by a stitch 171 extending along the central axis 160 of the radial member center portion 54.

The radial member 124 includes a first upper tensioning strap 162A, a second upper tensioning strap 162B, a first lower tensioning strap 164A, and a second lower tensioning strap 164B extending from the central portion 154. Each of the tensioning straps 162A, 162B, 164A, 164B terminates in a hook-type fastening tab 166 adapted to be detachably attached to the annulus-bearing fabric 128 on the outer surface of the base 122 and sewn to the tensioning straps using sutures 168. The radial member 124 also has a patella opening 170 to receive the patella when the brace is worn.

While there are some similarities between the prior art knee brace 20 and the knee brace 120 according to the present invention, there are at least three important differences (without limitation). First, the radial member 24 of the prior art knee brace 20 is secured to the outer surface 31 of the base 22. In contrast, the radial member 124 of the knee brace 120 according to the present invention is secured to the inner surface 139 of the base 122.

Second, the radial member 24 of the prior art knee brace 20 is secured to the base 22 by stitches 72 extending around the periphery of the radial member center portion 54. In contrast, the radial member 124 of the knee brace 120 is secured to the base 122 by stitches 171 extending along the central axis 160 of the radial member center portion 154.

Third, the central portion 54 of the radial member 24 and the tensioning straps 62A, 62B, 64A, 64B of the prior art knee brace 20 are on the outer surface 31 of the base 22 during normal use. In contrast, in the knee brace 120, the central portion 154 of the radial member 124 is on the inner surface 139 of the base 122, and the tensioning straps 162A, 162B, 164A, and 164B extend through the apertures 133A, 133B, 135A, 135B to the outer surface 131 of the base 122.

5A-5B are plan views of a second embodiment of a knee brace 220 according to the present invention, with the brace laid flat to expose both the outer and inner surfaces of the brace. The knee brace 220 has a shaped tensioning member 224 (shown in isolation in FIG. 5C ) permanently secured to the inner surface of the base. The knee brace 220 also includes a reinforcement aperture 237 formed with an aperture reinforcement base 237A and an aperture reinforcement backing 237B (shown in isolation in FIG. 5D-5E ).

The knee brace 220 includes a base member 222 and a shaped tension member 224, each formed by cutting a planar sheet 226 of one or more elastomeric materials into a desired shape. The outer surface of the base member 222 is preferably covered with a fabric 228 carrying fiber loops that adhere to the hook material when the loops and hook material are pressed together. The shaped tension member 224 is preferably formed from a synthetic fiber that is relatively elastic in all directions, such as the type known as spandex or elastane in the United States or sold under the trademark LYCRA®, but this is not required and other materials may be used.

The base 222 of the knee brace 220 has a base center portion 230 extending vertically from an upper edge 236 to a lower edge 238, and has a central axis 240 extending vertically downward along the middle of the base center portion 230. The base 222 includes a first upper mounting strap 232A, a second upper mounting strap 232B, a first lower mounting strap 234A, and a second lower base mounting strap 234B extending from the center portion 230. The base 222 also includes a first upper aperture 233A, a second upper aperture 233B, a first lower aperture 235A, and a second lower aperture 235B, all of which are formed as reinforcement apertures 237 in the base 222.

5B , which illustrates the inner surface 239 of the base 222, the first upper mounting strap 232A and the first lower mounting strap 234A terminate in hook-type strap fastening tabs 246 that are adapted to be detachably attached to the loop-bearing fabric 228 on the outer surface 231 of the base 222. The hook-type strap fastening tabs 246 are sewn to the mounting straps using stitches 248.

The knee brace 220 is applied and fastened to a person's leg in a manner similar to the knee brace 120 shown in Figures 3A-3B and 4A-4B. The base 222 also preferably has a patella opening 252 to receive the patella (kneecap) when the brace is worn, and can be formed to include side notches 274 between the upper mounting straps 232A, 232B and the lower mounting straps 234A, 234B. The base preferably includes a trim 276, but these features are not required.

As perhaps best shown in FIG5B , which illustrates the inner surface 239 of the base 222, the knee brace 220 includes a shaped tensioning member 224. As perhaps best shown in FIG5C , the shaped tensioning member 224 has a central portion 254, an upper edge 256, a lower edge 258, a first lateral side 263A, a second lateral side 263B, and a central portion axis 260. The shaped tensioning member 224 also includes a first upper tensioning strap 262A, a second upper tensioning strap 262B, a first lower tensioning strap 264A, and a second lower tensioning strap 264B. The shaped tensioning member 224 terminates in a hook-type fastening tab 266 adapted to be detachably attached to the loop-bearing fabric 228 on the outer surface of the base 222 and sewn to the tensioning straps using stitches 268. The shaped tensioning member 224 may include a patella opening 270 that may be permanently attached to the base 222 via a midline suture 271 that extends along the central axis 260 of the central portion 254 .

6A-6B are plan views of a third embodiment of a knee brace 320 according to the present invention, with the brace laid flat to expose both the outer and inner surfaces of the brace. The knee brace 320 has a resilient retainer and features upper and lower cross elastic straps permanently secured to the inner surface of the base. The knee brace 320 also includes reinforcement apertures 337.

The knee brace 320 includes a base member 322 formed by cutting a planar sheet 326 of one or more elastomeric materials into a desired shape. The outer surface 331 of the base member 322 is preferably covered with a fabric 328 that carries a fiber loop, which adheres to the hook material when the fiber loop and hook material are pressed together. The knee brace 320 also includes an upper cross strap 324 and a lower cross strap 325, which are preferably formed of an elastic material along the length of the strap.

The base 322 of the knee brace 320 has a base center portion 330 extending vertically from an upper edge 336 to a lower edge 338, and has a central axis 340 extending vertically downward along the middle of the base center portion 330. The base 322 includes a first upper mounting strap 332A, a second upper mounting strap 332B, a first lower mounting strap 334A, and a second lower base mounting strap 334B extending from the center portion 330. The base 322 also includes a first upper aperture 333A, a second upper aperture 333B, a first lower aperture 335A, and a second lower aperture 335B, all of which are formed as reinforcement apertures 337 in the base 322.

2B , which illustrates the inner surface 339 of the base 322, the first upper mounting strap 332A and the first lower mounting strap 334A terminate in hook-type strap fastening tabs 346 adapted to be detachably attached to the loop-bearing fabric 328 on the outer surface 331 of the base 322. The hook-type strap fastening tabs 346 are sewn to the mounting straps using stitches 348.

The knee brace 320 is applied and fastened to a person's leg in a manner similar to the knee brace 120 shown in Figures 3A-3B and 4A-4B. The base 322 also preferably has a patella opening 352 to receive the patella (kneecap) when the brace is worn, and can be formed to include a notch 374 between the upper mounting straps 332A, 332B and the lower mounting straps 334A, 334B. The base preferably includes a trim 376, but these features are not required.

As perhaps best shown in FIG6B , which illustrates the inner surface 339 of the base 322, the knee brace 320 includes an upper cross strap 324 with a center portion 354 and a lower cross strap 325 with a center portion 355. The cross straps have a central axis 360. The upper cross strap 324 includes a first upper cross tensioning strap 362A and a second upper cross tensioning strap 362B. The lower cross strap 325 includes a first lower cross tensioning strap 364A and a second lower cross tensioning strap 364B. The tensioning straps terminate in hook-type Velcro fastening tabs 366 adapted to be detachably attached to the annulus fiber-bearing fabric 328 on the outer surface of the base 322 and sewn to the tensioning straps using sutures 368. The base 322 may include a patella support 370. The upper and lower cross straps 324, 325 may be permanently attached to the base 322 by stitches 371 extending along the central axis 360 and by stitches 363A, 363B, 365A, 365B at the fixed ends of the cross straps.

The base 320 may include additional lateral support, such as one or more resilient retainers 382 (shown in FIG. 7E ) placed in pockets 381 formed using additional sheets secured to the base by resilient retainer channel stitches 380 .

7A-7B are plan views of a fourth embodiment of a knee brace 420 according to the present invention, with the brace laid flat to expose both the outer and inner surfaces of the brace. Similar to the knee brace 220 of FIG5A-5B , the knee brace 420 has a shaped tensioning member 424 (shown in isolation in FIG7C ) formed from synthetic fibers that are relatively elastic in all directions and permanently secured to the inner surface of the base. The knee brace 420 also includes reinforcement apertures 437 and an outer mesh layer 480 (shown in isolation in FIG7D ).

The knee brace 420 includes a base member 422 and a shaped tension member 424, each formed by cutting a planar sheet 226 of one or more elastomeric materials into a desired shape. The outer surface of the base member 422 is preferably covered with a fabric 428 carrying a fiber loop that adheres to the hook material when the fiber loop and hook material are pressed together. The shaped tension member 424 is preferably formed from a synthetic fiber that is relatively elastic in all directions, such as the type known as spandex or elastane in the United States or sold under the trademark LYCRA®, but this is not required and other materials may be used.

The base 422 of the knee brace 420 has a base center portion 430 extending vertically from an upper edge 436 to a lower edge 438, and has a central axis 440 extending vertically downward along the middle of the base center portion 430. The base 422 includes a first upper mounting strap 432A, a second upper mounting strap 432B, a first lower mounting strap 434A, and a second lower base mounting strap 434B extending from the center portion 430. The base 422 also includes a first upper aperture 433A, a second upper aperture 433B, a first lower aperture 435A, and a second lower aperture 435B, all of which are formed as reinforcement apertures 437 in the base 422.

7B , which illustrates the inner surface 439 of the base 422, the first upper mounting strap 432A and the first lower mounting strap 434A terminate in hook-type strap fastening tabs 446 that are adapted to be detachably attached to the loop-bearing fabric 428 on the outer surface 431 of the base 422. The hook-type strap fastening tabs 446 are sewn to the mounting straps using stitches 448 and may include one or more light features 449, such as reflectors, lights, glow-in-the-dark materials, or bright colors.

The knee brace 420 is applied and fastened to a person's leg in a manner similar to the knee brace 120 shown in Figures 3A-3B and 4A-4B. The base 422 also preferably has a patella opening 452 to accommodate the patella (kneecap) when the knee brace is worn. The base 422 can be formed to include a notch 474 between the upper mounting straps 432A, 432B and the lower mounting straps 434A, 434B. The base 422 can be formed using multiple sheets or by using a simple cut with stitching 453 to contour the base to fit more closely to the leg.

As perhaps best shown in FIG7B , which illustrates the inner surface 439 of the base 422, the knee brace 420 includes a shaped tensioning member 424 having a central portion 454, an upper edge 456, a lower edge 458, a first lateral side 463A, a second lateral side 463B, and a central portion axis 460. The shaped tensioning member 424 also includes a first upper tensioning band 462A, a second upper tensioning band 462B, a first lower tensioning band 464A, and a second lower tensioning band 464B. As perhaps best shown in FIG7C , the tensioning bands may include one or more inelastic portions 465.

The shaped tensioning member 424 terminates in a hook-type fastening tab 466 adapted to be detachably attached to the annulus-bearing fabric 428 on the outer surface of the base 422 and sewn to the tensioning band using sutures 468. The shaped tensioning member 424 may include a patella opening 470 and may be permanently attached to the base 422 by a midline suture 471.

As perhaps best shown in FIG7A , the knee brace 420 includes an outer mesh layer 480. As shown in FIG7D , the outer mesh layer 480 has an upper edge 481, a lower edge 482, a central axis 484, a first upper arm 486A, a second upper arm 486B, a first lateral side 487A, a second lateral side 487B, a first lower arm 488A, and a second lower arm 488B. The outer mesh layer 480 is permanently secured to a first upper tensioning strap near the first strap end, a second upper tensioning strap near the second strap end, a first lower tensioning strap near the third strap end, and a second lower tensioning strap near the fourth strap end. The outer mesh layer 480 may not otherwise be attached to the base 422.

8A-8B are plan views of a fifth embodiment of a knee brace 520 according to the present invention, with the brace laid flat to expose both the outer and inner surfaces of the brace. Similar to the knee brace 320 of FIG6A-6B , the knee brace 520 has upper and lower cross elastic straps permanently secured to the inner surface of the base. The knee brace 520 also includes reinforcement apertures 537 and resilient retainers 582, and features an outer mesh layer 580 (shown in isolation in FIG8D ).

The knee brace 520 includes a base member 522 formed by cutting a planar sheet 526 of one or more elastomeric materials into a desired shape. The outer surface of the base member 522 is preferably covered with a fabric 528 that carries a fiber loop, which adheres to the hook material when the fiber loop and hook material are pressed together. The knee brace 520 also includes an upper cross strap 524 and a lower cross strap 525, which are preferably formed of an elastic material along the length of the strap.

The base 522 of the knee brace 520 has a base center portion 530 extending vertically from an upper edge 536 to a lower edge 538, and has a central axis 540 extending vertically downward along the middle of the base center portion 530. The base 522 includes a first upper mounting strap 532A, a second upper mounting strap 532B, a first lower mounting strap 534A, and a second lower base mounting strap 534B extending from the center portion 530. The base 522 also includes a first upper aperture 533A, a second upper aperture 533B, a first lower aperture 535A, and a second lower aperture 535B, all of which are formed as reinforcement apertures 537 in the base 522.

8B , which illustrates the inner surface 539 of the base 522, the first upper mounting strap 532A and the first lower mounting strap 534A terminate in hook-type strap fastening tabs 546 that are adapted to be detachably attached to the loop-bearing fabric 528 on the outer surface 531 of the base 522. The hook-type strap fastening tabs 546 are sewn to the mounting straps using stitches 548.

The knee brace 520 is applied and fastened to a person's leg in a manner similar to the knee brace 120 shown in Figures 3A-3B and 4A-4B. The base 522 also preferably has a patella opening 552 to accommodate the patella (kneecap) when the brace is worn. The base 522 can be formed to include a notch 574 between the upper mounting straps 532A, 532B and the lower mounting straps 534A, 534B.

As perhaps best shown in FIG. 2B , which illustrates the inner surface 539 of the base 522, the knee brace 520 includes an upper cross strap 524 with a center portion 554 and a lower cross strap 525 with a center portion 555. The cross straps have a central axis 560. The upper cross strap 524 includes a first upper cross tensioning strap 562A and a second upper cross tensioning strap 562B. The lower cross strap 525 includes a first lower cross tensioning strap 564A and a second lower cross tensioning strap 564B. The tensioning straps terminate in hook-type Velcro fasteners 566 adapted to be detachably attached to the annulus fiber-bearing fabric 528 on the outer surface of the base 522 and sewn to the tensioning straps using sutures 568. The base 522 may include a patella support 570. The upper and lower cross straps 524, 525 may be permanently attached to the base 522 by a centerline stitch 571 extending along the central axis 560 and by stitches 563A, 563B, 565A, 565B at the fixed ends of the cross straps.

The base 520 may include additional lateral support, such as one or more resilient retainers 582 placed in pockets 581 formed using additional sheets secured to the base by resilient retainer channel stitches 580 .

As perhaps best shown in FIG8A , the knee brace 520 includes an outer mesh layer 590. As shown in FIG8D , the outer mesh layer 590 has an upper edge 591, a lower edge 592, a central axis 594, a first upper arm 596A, a second upper arm 596B, a first lateral side 597A, a second lateral side 597B, a first lower arm 598A, and a second lower arm 598B. The outer mesh layer 590 is permanently secured to a first upper tensioning strap near the first strap end, a second upper tensioning strap near the second strap end, a first lower tensioning strap near the third strap end, and a second lower tensioning strap near the fourth strap end. The outer mesh layer 590 may not otherwise be attached to the base 522.

There are various possibilities for alternative embodiments of the knee brace according to the invention.

While in a preferred embodiment, the knee brace includes a base formed as a reclosable sleeve made from a sheet of elastic material, this is not required. For example, the base can also be formed from a tubular elastic sleeve that is shaped to fit snugly around the knee and adjacent leg. The base need not include a patella opening, and the patella opening (if present) can have a variety of shapes, such as circular, square, rectangular, oval, diamond, trapezoidal, or any substantially equivalent shape. All such alternative embodiments will be referred to herein as a base.

Although in a preferred embodiment the lateral sides of the base terminate in an upper and lower fastening strap respectively with the side notches between them, this is not essential. For example, the sides of the base or portions thereof may be straight.

While in a preferred embodiment, the base can be detachably fastened around the wearer's legs using a type of hook and loop material that adheres when pressed together, this is not required. For example, other fasteners (such as buttons, clasps, buckles, pins, zippers, straps, buttons, or other substantially equivalent items) can be substituted for the hook and loop type fastener material.

Although in a preferred embodiment, the various components are permanently fastened together using sutures, this is not required. For example, other means (such as glue, heat bonding or other substantially equivalent means) may be used.

One or more vertical support members may be provided on one or both sides of the base of the knee brace to provide support and protect the knee from abnormal movement, but this is not required. The vertical support members may be formed, for example, by placing resilient retention members within elongated side pockets. The resilient retention members may comprise a flat spiral core of stainless steel or other flexible material of conventional construction commonly used in various types of braces.

For example, elongated side pockets can be formed between the vertical stitching seams that secure the side pocket covering strips to the base. The side pocket covering strips can be made of the same elastic sheet material as the base, but this is not required. Trims can be fastened to the edges of the side pocket covering strips, but this is not required.

The exact number, location, and configuration of the vertical support members, if provided, may vary. For example, there may be a single elongated side pocket forming only one vertical support member, or there may be one or more elongated side pockets on each side of the knee, each with a resilient retainer therein. The elongated side pockets may be openable at one end to allow removal of the resilient retainer so that the protector can be washed, or so that different resilient retainers can be inserted to adjust the amount and type of support provided. The vertical support members may comprise mechanical hinges, plastic rods, metal rods, narrow strips of reinforced sheet material, or other substantially equivalent items, or combinations of these various alternatives.

Advantageously, the outer surface of the front portion of the knee brace according to the present invention does not bear any structure and can be smooth except for any stitching that secures the radial component to the inner side of the base. For example, the smooth outer surface can be maintained to provide an attractive and clean appearance that will not hinder or impede movement during use. Alternatively, other structures (such as thick knee pads used in contact sports such as football or industries such as concrete or floor tile work, or smooth materials used in sports such as volleyball) can be positioned on the outer surface for specific applications.

It is to be understood that the present invention is not limited to the embodiments set forth herein as illustrated, but encompasses all such forms thereof falling within the scope of the following claims.

Claims (3)

1. A knee brace, comprising: (a) A base that can be worn close to the knee and adjacent parts of the leg, the base including a first upper opening, a second upper opening, a first lower opening and a second lower opening, and having an outer surface and an inner surface when worn; (b) An upper crossband, permanently secured to the inner surface of the base, formed of a longitudinally elastic material, and comprising a first upper crossband and a second upper crossband. (c) A lower crossband, permanently secured to the inner surface of the base, formed of a longitudinally elastic material, and comprising a first lower crossband and a second lower crossband. The first upper cross tension band extends through the first upper opening to the first free end, the second upper cross tension band extends through the second upper opening to the second end, the first lower cross tension band extends through the first lower opening to the third end, and the second lower cross tension band extends through the second lower opening to the fourth end. Furthermore, when the protective gear is worn, the first free end, the second end, the third end, and the fourth end can be detachably attached to the outer surface of the base. 2. The knee brace according to claim 1, wherein the knee brace further comprises an outer mesh layer permanently fastened to at least one of the first upper cross tension band, the second upper cross tension band, the first lower cross tension band, and the second lower cross tension band. 3. The knee brace according to claim 2, wherein the outer mesh layer is permanently fastened to the first upper tension band near the first free band end, the second upper tension band near the second band end, the first lower tension band near the third band end, and the second lower tension band near the fourth band end.