WO2005117769A1

WO2005117769A1 - Lumbar back brace with mechanically advantaged draw mechanism

Info

Publication number: WO2005117769A1
Application number: PCT/US2004/016986
Authority: WO
Inventors: Geoffrey Garth
Original assignee: Aspen Medical Products
Priority date: 2004-05-27
Filing date: 2004-05-27
Publication date: 2005-12-15

Abstract

A back brace can be fully tightened in a mechanically advantaged manner by drawing on a single cord. A web that produces the mechanical advantage need not be centered on the front or the back, but can instead be positioned off to the side, permitting inclusion of a sacral window (120). The brace can comprise a single panel of fabric, or two or more panels, all of which forms the body of the brace. Although the brace can be fully tightened using the single cord (42), it is contemplated that one or more retaining straps (50A, 50B) can be used to stabilize the upper and lower portions of the brace.

Description

LUMBAR BACK BRACE WITH MECHANICALLY ADVANTAGED DRAW MECHANISM

Field of the Invention. The field of the invention is medical braces for the lumbar and pelvic regions.

Background Lower back braces can be highly effective in redistributing weight, reducing undesirable mobility, and reducing pain experienced by the wearer. Problems arise, however, in that individuals vary widely in shapes and sizes, amounts and distribution of muscle and fat, and so forth. Many different mechanisms are known to accommodate the variances, including the use of multiple segments, sacral windows, and cushioning at the edges. Regardless of which such accommodative mechanisms are chosen, it is important that a lower back brace be sufficiently tight to provide the needed support. This presents yet additional problems, where the wearer is insufficiently strong to properly tighten the brace about his/her waist. Many earlier braces were little more than a strong, elongated piece of elastic or elasticized fabric, with the ends removably securable to the front or opposing side walls of the brace. Velcro™ and other hook and loop mechanisms have been used for that purpose, as have even simpler mechanisms such as belt buckles. All such mechanisms are without mechanical advantage, so that pulling an end two inches tightens the brace by about two inches (actually less if the brace is elastic).

More sophisticated braces use some form of mechanically advantaged tightening. US 6213968 to Heinz et al. (Apr. 2001), for example, teaches a two piece brace in which the pieces are coupled across the lower back and sacrum using a web of cable threaded among a series of pulleys. There are actually four sets of pulleys, two that cooperate to tighten the upper part of the brace, and another two sets of pulleys that cooperate to tighten the lower part of the brace. There are two cables, and tightening of the brace requires a wearer to pull on each of the two cables. Figure 7 shows an alternative, four segment design in which two sets of pulleys are disposed on the left side of the brace, and the other two sets of pulleys are disposed on the right side of the brace. In all instances a wearer must pull on two cables to correctly tighten the brace. l of lO US 6322529 to Chung (Nov. 2001) teaches an alternative embodiment in which the pulleys are replaced by eyelets or posts.

Published US patent application no 2001/0008955 to the present inventor, Geoffrey Garth (July 2001), teaches an entirely different mechanism. There, the mechanical advantage is achieved using a levered buckle on the front of the brace. The above-referenced patents and applications, as well as all other materials discussed herein are incorporated by reference in their entirety.

Despite the reported advantages of the above referenced devices, practical experience has shown that persons actually wearing the braces would prefer simpler tightening mechanisms, which are still mechanically advantaged. Moreover, the devices that position the cable web over the lower lumbar and sacral regions reduce the stability that would otherwise be available using a sacral window. Thus, there is still a need for further improvements.

Summary Of The Invention The present invention provides a systems and methods in which a back brace can be fully tightened in a mechanically advantaged manner by drawing on a single cord.

Preferred embodiments utilize a back and forth web of the cord disposed more or less on one side of the brace, with the cord being drawn across the front and releasably attaching to the other side using a hook and loop or other mechanism. The cord can comprise any suitable material, including nylon or other polymeric material.

The brace can comprise a single panel of fabric, or two or more panels, all of which forms the body of the brace. The front portion of the brace can advantageously comprise overlapping ends that simply overlay one another. The back of the brace preferably includes a sacral window, and even more preferably includes a malleable frame about the window. A series of pressure spreading tabs can be advantageously disposed along the top and bottom of the body of the brace.

The cord can be threaded back and forth any reasonable number of times, including twice for a mechanical advantage of six, and three times for a mechanical advantage of six. The transition elements comprise an eyelet, spindle, pulley or any other suitable unit. The drawing regions to which the transition elements are attached can be affixed directly or indirectly to the body of the brace. In an especially preferred embodiment one of the drawing regions is affixed to a belt, which is then affixed to the body of the brace.

Although the brace can be fully tightened using the single cord, it is contemplated that one or more retaining straps can be used to stabilize the upper and lower portions of the brace.

Various objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components.

Brief Description of the Drawing Figure 1 is a right front view of a back brace according to the inventive subject matter, in the process of being tightened.

Figure 2 is a left front view of the back brace of Figure 1 in a fully tightened configuration. Figure 3 is a rear view of an alternative back brace of Figure 1, showing separate side panels and a back panel with a sacral window.

Detailed Description In Figure 1 a brace 10 is worn by a wearer / user 20. The brace 10 generally comprises a one-piece, wrap-around body 12. Two drawing regions 20A, 20B are attached to side panel 10A and a draw belt 30, respectively, and each include a plurality of transition elements 22 among which is distributed a web 40 of cord 42. A pull member 44 is being drawn in the direction of arrow 46 to tighten the brace 10.

As used herein, the term "back brace" is used in a medical sense to mean a therapeutic or prophylactic orthotic device. Such devices will generally be issued by health care professionals, but may also be purchased and worn in a workplace or other environment to prevent injury. There are distinctions between commercial products for these different markets, including differences in distribution, price, design, instructions, and so forth.

Brace 10 can comprise any suitable material or materials. Presently preferred materials include a synthetic polymer fabric such as polyethylene, that bends readily but is not especially stretchy. Since back braces are often worn for weeks at a time, the material should be durable, and resistant to water damage. Braces can be short or tall as appropriate to the patient or other wearer, and can accommodate a greater or smaller girth. It is contemplated that a hospital or other distributor of braces would have multiple sizes. Since the particular brace in Figure 1 is a single one-piece, wrap-around piece of material, the back, sides and front portions are essentially contiguous with one another. Using this nomenclature, one skilled in the art will appreciate that the existence of back, sides and front portions does not require there to be back, side and front pieces.

The drawing regions 20 A, 20B are preferably constructed of hard plastic. That provides the strength to handle the stresses placed upon the various transition elements 22. Those skilled in the art will appreciate that the transition elements 22 are shown in dotted lines, and with little detail to signify that they are most likely not visible to the casual observer, and are emblematic of all the various different types of elements, including eyelets, spindles and pulleys. Of course, a single brace would likely have all the same type of transition elements, but may alternatively include some combination of same. Eyelets tend to be the least preferred because they create the greatest friction. Pulleys (wheels) work well, but are expensive. Spindles are currently the most preferred. There can be any suitable number of transition elements, depending on the mechanical advantage desired, 2x, 4x, 6x, 8x, etc. In Figure 1 the sole web 42 is positioned off to one side. Those of ordinary skill in the art will indeed wonder how one can achieve balanced (i.e. symmetric) tightening of the brace 10 when the web is off to one side. In most instances, that would result in asymmetric tightening of the brace 10. But in this case attachment of drawing region 20B to the draw belt 30 allows tightening to be symmetric about the brace 10 even though the web is positioned on only one side of the brace 10. In effect, the draw belt 30 decouples placement of the web from localization of the tightening.

Draw belt 30 and cord 42 are also preferably made from a polymeric material that is strong, substantially non-elastic, and is resistant to water damage. Figure 1 also shows stabilizing straps 50A, 50B, which can be made from the same or similar material. Stabilizing straps 50A, 50B compensate in part for the absence of separate upper and lower tightening webs, which were considered to be of such great import in the Heinz patent '968 and the reissue, RE35940. Here, although they can theoretically be used to induce some marginal tightening, they are not needed to fully tighten the brace 10.

Pull member 44 is preferably attachable to both sides of the brace 10 using a hook and loop type connection system. Thus, landing areas 32, 34 (see Fig 2) on belt 30 can removably attach pull member 44. Stabilizing straps 50A, 50B can also preferably attach to their target areas in a similar manner.

Foam 60 cushions the body of the wearer 20 against the hard plastic of the main body. Tabs 70 disposed along the upper and lower edges of the main body also improve comfort by providing additional flexibility and "give" of the main body against the tissues. Holes 72 provide a convenient stopping point for cutting the body to effectively increase the length of the tabs 70. Those skilled in the art will appreciate that different numbers and/or distributions of tabs 70 and holes 72 could be employed.

Figure 2 shows a left front view in which the pull member 44 has been pulled away from the web 40, and has been removably attached to the top of belt 30, which itself is removably attached to common landing area 80 on the left portion of the brace 10. The stabilizing straps 50A, 50B are also attached to common landing area 80.

Figure 3 shows an alternative design in which a brace 110 has a three-panel body, comprising two side panels 110A, HOB and a back panel 1 IOC. The side panels 110A, HOB connect to back panel 110C in a rigid manner using spaced rivets, screws, or other couplings 114.

Window 120 is formed along the center line, and is positioned to overly the sacrum of the wearer. Frame 124 defines the perimeter of the window 120, and preferably comprises a malleable metal bar. The malleability is such that the frame can be bent up to five or ten degrees (or more in some instances) using a significant amount of force, but force that can be generated by an attending medical person. If the frame is too malleable, it will not satisfactorily hold its shape during use.

Protector 126 is disposed around the malleable bar 124 to protect the bar and to attach it to the back panel 14. The protector has overlapping edges outside of the malleable bar, which are attached to the back panel 110C by sewing, rivets, adhesive, or other suitable means. The malleable bar 124 and its attachment 126 are arranged so that they lie around the edge of the window 120. This structure is positioned so that the medical provider can bend the bar 124 to shape the back panel of the back brace 110 to the sacrum and spinal curvature of the patient. The window 120 also gives additional freedom to the back panel 110C so that the panel can be bent into compound curves near the window 120. A typical window will measure between about 5 - 7 cm by about 10 - 13 cm. The web is disposed on one of the side panels 110A, 110B, and cannot be seen in this view. The window 120 is sufficiently large so that the orthopedist can insert his fingers into the window and run them up and down along the sides of the window to tactilely determine the fit of the back panel against the back of a patient. The window 120 also permits viewing of the manner of engagement of the back panel against the patient to insure that the proper contact is provided.

The window 120 is sufficiently tall along the length of the spine so that at least three vertebrae are exposed for visual and tactile observation of the fit of the back panel 110C at that critical area of the back. The proper curvature and distribution of pressure of the back panel against the patient is important to both the comfort of the back brace 110 and to provide of the proper orthopedic support to achieve the orthopedic goal. The orthopedist can visually and tactilely observe the engagement at the sacrum and against the lower back to derive optimum results.

Use of the Device Use of the back braces contemplated herein is extremely straightforward. The wearer places the brace 10 or 110 about his/her waist as one would an ordinary belt. Assuming that the brace is the right size, the wearer can then pull the belt 30 over to common landing area 60, and pull member 44 to a sufficient tightness, and then finally couple member 44 to the top of belt 30. If needed, the brace 10 or 110 is then removed so that the window bar 124 can be adjusted to comport with the shape the sacral region of the wearer.

Thus, various embodiments of a lumbar back brace with mechanically advantaged draw mechanism have been shown and described. In particular, embodiments have been shown and described in which a single side web is used to tighten the brace, which then provides for a lumbar window. It should be apparent, however, to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. Moreover, in interpreting the disclosure, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms "comprises" and "comprising" should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps could be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced.

Claims

CLAIMSWhat is claimed is:

1. A back brace comprising a cord system in which a cord is threaded back and forth between multiple transition elements at relatively rearward and relatively forward drawing regions, such that pulling on the cord is effective to tension and pull together the entire drawing regions in a mechanical advantaged manner that thereby fully tighten the brace about a wearer.

2. The brace of claim 1 having a main body that is a single wrap-around piece of material.

3. The brace of claim 1 wherein the front portion comprises overlapping ends of the brace.

4. The brace of claim 1 wherein the cord comprises a polymeric material.

5. The brace of claim 1 wherein the cord is threaded back and forth at least twice for a mechanical advantage of at least 4.

6. The brace of claim 1 wherein the cord is threaded back and forth at least three times for a mechanical advantage of at least 6.

7. The brace of claim 1 wherein at least one of the transition elements comprises an eyelet.

8. The brace of claim 1 wherein at least one of the transition elements comprises a spindle.

9. The brace of claim 1 wherein at least one of the transition elements comprises a pulley.

10. The brace of claim 1 wherein at least one of the drawing regions is coupled to a belt that translates with respect to at least one of a back, a side and a front portion of the brace during tightening of the brace.

11. The brace of claim 1 wherein at least one of the drawing regions is coupled to a belt that extends from a side of the brace and across a front of the brace.

12. The brace of claim 1 further comprising a pull member that releasably attaches to at both sides of the brace.

13. The brace of claim 12 wherein the pull member releasably attaches to at least one of the side portions using a hook and loop fastener mechanism.

14. The brace of claim 1 further comprising a non-mechanically advantaged retaining strap.

15. The brace of claim 1 having no second mechanically advantaged pull cord.

16. The brace of claim 1 further comprising a plurality of pressure spreading tabs along an edge of the brace.

17. The brace of claim 1 wherein the back portion includes a sacral window having an adjustable frame.

18. A back brace having a single, side mounted web that can be fully tightened in a mechanically advantaged manner by drawing on a single cord.