Flexible ankle brace

An improved ankle brace may have two relatively rigid side supports, the outer edge portion of the lower area of the side supports, adjacent to the ankle being covered with a flexible or resilient material. The flexible resilient material may be permanently secured to the side supports by bonding, mechanical interlocking, or by any other suitable arrangements. Additional resilient flexible material may be placed on the interior surface of the side supports to improve the fit and comfort of the brace around the user's lower leg. The rigid side supports may be of an open type with the resilient flexible material extending across the side supports and beyond the edges thereof.

FIELD OF THE INVENTION 
The present invention relates to an improved orthopaedic device, and 
specifically to an ankle brace for stabilizing an ankle before or after 
injury. In particular, the ankle brace of the present invention stabilizes 
the ankle against inversion and eversion and anterior subluxation while 
allowing normal dorsiflexion and plantarflexion movement. 
BACKGROUND OF THE INVENTION 
After injury to an ankle, such as a fracture or severe ankle sprain, it is 
often necessary to completely immobilize the injured ankle through the use 
of a molded plaster or resin cast. Once the injury has been stabilized, 
however, recovery may be accelerated by removing the molded plaster or 
resin east and replacing it with a removable functional walking brace so 
that the ankle can be exercised while healing. 
Even if the injury is not severe enough to warrant complete immobilization 
of the ankle, it is still sometimes necessary to use a functional walking 
brace to stabilize the ankle against inversion (the foot rolling inward), 
eversion (the foot rolling outward) and/or subluxation (partial 
dislocation) while still allowing the normal dorsiflexion and 
plantarflexion movement of the ankle. 
A variety of ankle braces, walking casts and other orthopaedic ankle 
apparatuses have previously been proposed. For instance, in my prior U.S. 
Pat. No. 4,977,891, granted Dec. 18, 1990, and entitled "Variable Support 
Ankle Brace," an ankle brace comprising two relatively rigid side supports 
with inflatable bladders attached to them is described. Other ankle braces 
including air inflatable bladders are shown in Glenn W. Johnson, Jr.'s 
U.S. Pat. Nos. 4,280,489 and 4,628,945. These prior art devices proposed 
by Johnson are intended to be worn within a separate shoe and are also 
inflatable. 
Thermal treatment has been made available with the use of orthopaedic gel 
pads which tend to mold themselves to fit the area they are applied to, 
providing a level of comfort and padding as well as providing thermal 
treatment of the affected area. One such pad is shown in my U.S. Pat. No. 
5,027,801. 
Prior art walking braces have frequently employed rigid support shells 
which may engage and irritate, pinch and damage the skin within the shoe. 
A principal object of the present invention is to effectively avoid this 
problem. 
SUMMARY OF THE INVENTION 
In accordance with one broad aspect of this invention, the outer edge 
portions of at least the lower area of the side supports, adjacent to the 
ankle, are formed of a flexible material. 
In accordance with another broad aspect of this invention, each entire side 
support is bonded to or integrally associated with flexible material, 
slightly larger in size but similar in shape to the side support. Both of 
these side support designs improve the fit and the comfort of the brace 
around the user's lower leg. 
In accordance with yet another broad aspect of this invention, a more 
flexible material is formed around a more rigid material. In an 
alternative implementation, the more flexible material is formed with 
protrusions/tab and/or receptacles for protrusions/tabs formed in the more 
rigid material. This allows the more flexible material and more rigid 
material to be mated and interlocked to one another. 
In accordance with another broad aspect of this invention, the more rigid 
material is hollowed out in certain areas to form a frame. The frame is 
covered with the more flexible material and the resultant structure is 
employed as an ankle brace. 
Accordingly, it is a primary object of the present invention to prevent 
undesired inversion, eversion and anterior subluxation while allowing 
plantarflexion and dorsiflexion of the ankle, without irritating or 
pinching the skin. 
Another object of this invention is to provide a more comfortable ankle 
brace which will firmly support an injured lower leg. 
The foregoing and other features and advantages of the present invention as 
well as a more complete understanding thereof will be made apparent from a 
consideration of the following detailed description in connection with the 
accompanying drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
Initially, it is noted that the drawings in the present case relate to two 
inventions, with the present invention being described in detail in 
connection with FIGS. 7 and 9-18. FIGS. 1-8 are included for convenience 
as disclosing a complete ankle support assembly as shown in FIG. 7. The 
embodiments of FIGS. 9-18, illustrating the principles of this invention, 
may be used as side supports 18, 20 in the configuration of FIG. 7. 
With reference to FIGS. 6 and 7, an improved ankle brace 16 includes a pair 
of side support members 18 and 20 preferably made of vacuum molded 
plastic, for example, nylon or rigid polypropylene, having sufficient 
thickness and other properties so that they are relatively stiff or rigid; 
and they are shaped so as to fit about the lower leg and ankle and are 
approximately eight to ten inches long. Also included are two main 
inflatable bladders 22 and 24 and a pump 26 which are interconnected and 
formed with one welding process. The inflatable bladders 22 and 24 can be 
attached to the side supports 18 and 20 using a fastening fabric, such as 
the fabric sold under the tradename "VELCRO.RTM." double sided adhesive or 
any other suitable means. Additional inflatable bladders 30 and 32, as 
shown in FIGS. 1 and 2, can be placed distally upon the main inflatable 
bladders 22 and 24. 
Interconnecting the two side support members 18 and 20 is a bottom strap 
33. The bottom strap may include a surface 35 of VELCRO.RTM. material and 
with the bottom strap being adjustable through the use of double openings 
50 and 52 located near the bottom end of the side supports 18 and 20. The 
ends of the bottom strap 33 may be fixed in position with the use of 
additional VELCRO.RTM. material 54 and 56 located on the outside of the 
side support members 18 and 20. Specifically, the adjustment is 
accomplished by positioning the ends of the strap 33 to extend from the 
outside of each support member 18 and 20 through opening 50 or 52 and then 
through the other one of the openings 50 or 52 and then attached by the 
VELCRO.RTM. material 54. Thus, the proper distance may be easily adjusted 
between the side support members 18 and 20 at the lower most portion. 
The side supports 18 and 20 may be securely attached around the lower leg 
and ankle just below the calf area using two strap members 34 and 36. 
These strap members 34 and 36 also include VELCRO.RTM. portions 40 and 42 
on their outer surfaces, and with VELCRO.RTM. material 44 and 46 at the 
end portions of the straps 34 and 36. The VELCRO.RTM. 40 and 42 is 
attached to the side support 18 or. 20. As shown in FIG. 7, these straps 
34 and 36 may be tightly drawn around the lower leg using the VELCRO.RTM. 
material so that the ankle brace securely and firmly supports the ankle. 
The ankle brace includes, in addition to the strap arrangement set forth 
above, a counter strap 60 which is similar in construction to the bottom 
strap 33. Specifically, the counter strap 60 may include a cushioning pad 
61 and an inner surface covered with VELCRO.RTM. material 62 and with the 
strap 60 passing through double openings 64 in the side support 18 and 
double openings 66 in the other side support 20. An additional piece of 
VELCRO.RTM. material 67 is attached to side support member 18 and another 
piece of VELCRO.RTM. material 67 is attached to side support 20. By having 
this arrangement the counter strap 60 may be adjusted in a similar manner 
to the bottom strap 33 to prevent the back portion of the side support 
means 18 and 20 from twisting or flexing outward at the lower end of the 
ankle brace 16 to compress the distal 1/3 to 1/2 of the brace. 
The ankle brace may incorporate a lace fastening means similar to that set 
forth in detail in Grim, U.S. Pat. No. 4,844,094 to insure that the side 
supports 18 and 20 do not twist or flex outward and to more properly 
stabilize and compress the ankle against inversion, eversion and anterior 
subluxation. It is preferred, as shown in FIG. 7, that the lace fastening 
arrangement in the present invention comprises a hole or slot 70 and 72 
integrally molded at the bottom end of each side support member 18 and 20. 
It is to be appreciated, however, that other attachment means such as 
those set forth in the U.S. Pat. No. 4,844,094 may be used. 
FIGS. 1 and 2 illustrate an inflatable bladder and pump arrangement. The 
foot pump 26 is comprised of an open cell foam and or a flexible hollow or 
curved resilient material (for example, rubber, plastic, etc.) which when 
compressed offers an increased pressurization of the entrapped fluid 
within its support membranes 27. The foot pump 26 is characterized by a 
variety of strategically placed weld lines 80 which serve to create 
channels through which fluid transfer can take place between the pump 26 
and the inflatable bladders 22 and 24. Other welded "darts" 82 may also be 
used which will aid in reducing the thickness in certain areas of the pump 
26 to enhance comfort. The pump 26 may be constructed by welding in a foam 
of a thickness or space provided by the surrounding semi-enclosed pump 
material, preferably urethane or some other resilient material, whereby 
the foam is placed in a compressed state initially and when further 
compressed by the foot will be more resilient and recover quicker than if 
not compressed. 
The foot pump 26 is approximately three and one-half inches in length and 
three inches in width. 
In the ankle brace the two main inflatable bladders 22 and 24 are 
interconnected with the foot pump 26. In this case, the two bladders 22 
and 24 and the pump 26 are formed with one welding process and may be 
considered one member but is not so limited, and may include bladders 
which are connected to the pump by other fluid transfer means such as with 
tubes or valves. 
As shown in FIGS. 1, 2, 3 and 8, the main bladders 22 and 24 each have 
inlet valves 84 and 86 which could be flap-type valves. In such a valve, 
air drawn in (entering the bladders 22 and 24) forces the valve's sealing 
flaps, which are normally biased together, apart which allows the air to 
flow into the valve. Air forced in a direction opposite to the air drawn 
in (exiting the bladders 22 and 24) forces the flaps together and they 
create a substantially airtight seal. Other types of valve arrangements 
may be used such as an air pressure release and bleed valve or inlet 
valves. 
Thus, as shown in FIG. 4, the main bladders 22 and 24 become inflated when 
air is directed through their valves 84 and 86. The bladders 22 and 24 
expand a maximum width of approximately two and one-half inches. The 
preferred length of each main bladder 22 and 24 is approximately ten and 
one-half inches long and is approximately three and three-quarters inches 
wide. As also shown in FIG. 4, the walls 87 of bladder 22 and 24 are 
constructed of a non-porous resilient material such as LYCRA.RTM. fabric 
coated with or bonded to a thin layer of urethane. Each wall 87 is 
approximately 0.015 inch (15 mills) thick and is capable of stretching 
under force to allow the bladders a variety of widths to accommodate a 
wider foot base. Further, a fabric coating 88, for example, 
nylon-LYCRA.RTM., may be laminated to the plastic film that makes up the 
bladders 22 and 24 to allow the skin to breathe and to increase comfort to 
the user. This fabric coating 88 may be approximately 0.002 inch (2 mills) 
thick. 
FIG. 5 shows a portion of the bladder that includes additional foam padding 
89 which is located at the bottom half of each main bladder 22 and 24. 
This padding 89 is about five inches in length and provides further 
comfort to the region surrounding the ankle. 
As shown in FIGS. 1, 2 and 3 two more smaller inflatable bladders 30 and 32 
may be placed distally upon the main inflatable bladders 22 and 24 to 
provide cushioning and support as well as protect the injured limb from 
the rigid support shell should either main bladder 22 and 24 puncture. 
Alternatively, these additional bladders 30 and 32 may also be made to 
pulsate and the longer main bladders 22 and 24 may serve as non-pulsating 
protective membranes. The smaller bladders 30 and 32 may be comprised of 
the same material and consist of the same valve arrangement as the main 
bladders 22 and 24. 
The shorter additional bladders 30 and 32 extend from the bottom of the 
main bladders 22 and 24 to about halfway up towards the upper most portion 
of the main bladders 22 and 24. The outside surface of each bladder 22, 
30, 24 and 32 has a VELCRO.RTM. portion 90 attached to it in order to 
affix the support member 18 and 20 to the bladders. It should be further 
mentioned that all bladder arrangements 22, 30, 24 and 30, preferably, are 
to be distributed with a certain amount of preinflation. 
FIGS. 9 through 18 illustrate the principles of this invention and show 
alternate side support members 18 and 20, which may be used in the 
assembly of FIG. 7. 
FIGS. 9 and 10 show a support member 20 which is constructed of a rigid 
polypropylene in one embodiment. Support member 18 may be constructed in 
an identical manner to support member 20. The support member 20 is 
slightly curved (see FIG. 10) to better hug and support the ankle. One or 
more holes 19 for venting any heat that accumulates within the entire 
ankle brace 16 are also provided. Holes 19 may be used for positioning the 
part into a mold and also, in some cases, for mechanically securing the 
resilient material to the support member. The bottom perimeter of each 
support member 18 and 20 are covered with a flexible padded material 95, 
preferably vinyl, rubber, or synthetic rubber such as "SANTOPRENE.RTM." 
manufactured by Monsanto, "KRATON" manufactured by Shell, or "ALORYN" 
manufactured by DuPont, in order to prevent each support 18 and 20 from 
cutting into the user's lower leg or from puncturing the bladders 22, 23, 
24 and 25, and most importantly, to improve the fit of each side support 
18 and 20 around the user's lower leg. Support members 18 and 20 may be 
manufactured of a suitable rigid or semi-rigid material such as Nylon or 
Glass reinforced nylon by DuPont or High Density Polyethylene (HDPE) made 
by Dow Chemical Co. 
Flexible resilient or padding material. 95 may be bonded to support members 
18 and 20 by a permanent or semi-permanent adhesive. The flexible padded 
material 95 may also be formed in place around support members 18 and 20, 
or may be thermally bonded in place. The material 95 may, for example, be 
rubber or other similar material. 
Openings such as slots 51 and 65 may be included in support member 20 in 
order to allow straps to be passed through the side support 20. In 
addition, slots 101, 103, 105, 107, 109, and 111, or others, may be 
provided to allow mechanical interlocking of the resilient or padding 
material 95 to secure material 95 to side support 20. Slots 101, 103, 105, 
107, 109, and 111 may be replaced by suitable grooves, channels or other 
suitable interlocking arrangements which can be readily mated with the 
resilient material 95 which is positioned against side support 20. 
In this manner, the resilient material and the side support may be 
interlocked without requiting the use of additional mechanical fasteners 
such as straps, tape, cement or the like. However, cement or heat bonding 
is preferred to supplement the mechanical interlocking. 
Additionally, the inner surface of each side support 18 and 20 may include 
a strip or strips of VELCRO.RTM. material 91 to allow the side supports a 
means of attaching themselves to the VELCRO.RTM. portions 90 of each 
bladder or other padding. 
FIGS. 11 and 12 show the support member 20' similar to the support member 
shown in FIGS. 9 and 10 except that the support is secured on top of a 
flexible cushioning material 95 having a slightly larger area than the 
side support 20 but is substantially the same shape as the side support, 
more securing holes 19 are present, and the strap slots 51, 65, 101, 103, 
105, 107, 109, and 111 have been removed. 
Alternative embodiments shown in FIGS. 13-14 and 17-18 illustrate side 
supports 20" and 20'", respectively similar to the side supports shown in 
FIG. 9-12, except that the side support is reduced in mass by forming a 
structural frame instead of a solid surface. The structural support 
consists of peripheral members 116 (FIGS. 13, 14) and 116 (FIGS. 17 and 
18) which extend around the perimeter of the side support 20. Single 
support members 20" and 20'" are illustrated, however, the support members 
for the opposing side of the ankle are constructed in the same manner. In 
FIGS. 13 and 14 openings 110 and 112 are present in the upper and lower 
portions of the support member 20", and a lateral structural member 114 is 
located between openings 110 and 112 to told strength to the framework 
116. 
In FIGS. 17 and 18, structural members of the three transverse members 114' 
add strength to the perimeter frame 116 of the side support 20'". Thus, 
additional structural members can be employed to increase the structural 
strength and integrity of the side support 20'" without significantly 
increasing the weight of this support member. The configurations shown in 
FIGS. 13 and 17 have a weight which is reduced from the weight of side 
supports as shown in FIGS. 9-12, because of the material which is removed 
in forming openings 110, 112, 120, 122, 124, and 126. This configuration 
also allows the reduction in pressure in specific areas such as the 
malleoli or ankle bones, see area 112 in FIG. 13, and 122 in FIG. 17. 
As shown in FIGS. 13 and 17, the entire perimeter of support member 20 is 
covered with a flexible resilient or padded material 95 in order to 
prevent the support members 18 and 20 from cutting into the user's lower 
leg, or from puncturing the bladders 22, 23, 24, and 25, and to improve 
the fit of each side support 18 and 20 around the user's lower leg. 
It is recognized that the more rigid molded material as shown in FIGS. 9-14 
may be constructed using new plastic molding techniques to include a 
material which is more rigid towards the center, and is extremely flexible 
or pliable towards the edges. This material may readily replace the use of 
a two piece assembly shown in FIGS. 9-18. This technique would be 
especially useful when employed with the configuration shown in FIGS. 
9-12, wherein a more flexible, pliable layer of plastic may coat the 
inside surface of the side support 20 as shown in FIG. 12. This pliable 
material may replace the flexible material 95 in this configuration, 
forming a single, integral assembly which includes both a more rigid 
material such as a high strength reinforced plastic structural strength 
and a more flexible material for comfort. 
In the embodiment shown in FIGS. 15 and 16, side support 128 is formed to 
accommodate the "bulge" of the ankle of the wearer. Flexible or resilient 
material 132 is shaped or formed to complement the shape of side support 
128 and provide padding between the ankle of a wearer and side support 
128. The showing of FIG. 15 is a view of the outside 130 of the ankle 
brace of FIG. 16. Flexible material 132 may be formed integrally with side 
support 128, or may be integrally bonded thereto, as shown in FIG. 16. The 
material 132 may be a soft vinyl foam of the type sold under the tradname 
"SANTOPRENE.RTM.." 
In the embodiments shown in FIGS. 9 and 10, a single plastic body having a 
more rigid central portion and grading into a more flexible plastic around 
the outer edges of side support 20 may be employed. This combination may 
eliminate the need for separate padded or resilient material 95, thereby 
reducing the thickness of the edges of side support 20. This may result in 
a side support which has a uniform thickness and is more flexible towards 
the edges of the side support 20 and more rigid towards the center. It is 
recognized that this technique may be applied to all of the edges of side 
support 20 in the configurations of FIGS. 9-18. 
In another embodiment of the present invention, either side support 18 or 
20 may be applied to the ankle of the wearer by the use of one or more 
straps fastening a single side support to the leg of the user. This 
configuration can be successfully employed to treat less severe ankle 
injuries while reducing the weight and bulkiness of the brace which must 
be worn by the user. Preferably the side support is located on the side of 
the leg of the wearer to provide the greatest support to the ankle, and 
immobilize the ankle against particular undesired rotation based on the 
nature of the ankle injury. 
For many users, it is additionally desirable to place a padded material 
between the ankle and the straps that surround the lower leg, holding the 
side support 18 or 20 against the lower leg of the wearer. 
The operation of the ankle brace 16 in conjunction with air bladders would 
be as follows: the bladder and pump arrangement is to be attached to the 
inside of the side supports 18 and 20. If the brace 16 has been previously 
used, the bottom strap 33 and the counter strap 60 would already have been 
adjusted. If not, the wearer would position the side supports 18 and 20 to 
both sides of the ankle, and then after the side supports 18 and 20 are 
properly positioned, the ankle brace 16 would be held in place using the 
strap members 34 and 36. The bottom strap 33 would then be adjusted by 
peeling the VELCRO.RTM. material 35 back from the corresponding 
VELCRO.RTM. 54 and 56 and pulling up both sides of the strap 33 until the 
bottom of the side supports are firmly in position. The ends of the strap 
35 would then be firmly pressed down on the VELCRO.RTM. 54 and 56 to lock 
the strap in 33 in position. Similarly the counter strap 60 would be 
adjusted to pull the back lower end of the side supports 18 and 20 
together above the heel. 
The shoe would now be fitted over the entire ankle brace 16, as shown in 
FIG. 7, and the laces laced through the holes 70 or in other fastening 
means located at the lower end of the side supports 18 and 20. The laces 
would then be pulled tightly and tied, again as shown in FIG. 7, so that 
the ankle brace 16 is firmly in position. 
Subsequently the bladders 22, 30, 24 and 32 are inflated to their 
therapeutically desired pressure by using, for example, an attachable 
hand-held pump. 
Therefore, while in use, the fluid within the pressurized ankle support 
bladders 22, 30, 24 and 32 and the interconnected preinflated foot pump is 
displaced back and forth between either the main bladders 22 and 24 and/or 
the shorter bladders 30 and 32 thereby creating a pulsing action which 
lends to a massaging compression effect that helps reduce swelling and 
atrophying and increases venous and lymphatic return throughout the lower 
leg while effectively preventing inversion, eversion and anterior 
subluxation of the ankle. 
While FIGS. 1-8 relate to the combination using bladders, it is to be 
understood that the arrangements of FIGS. 9-18 may be employed using gel 
or foam rubber pads, for example, between the side members and the ankle, 
or in some cases with no additional padding. 
Although the invention has been described with reference to particular 
embodiments, it is to be appreciated that other adaptations and 
modifications may be used without departing from the spirit and scope of 
the present invention. For example, in FIG. 8 a heel cup 100 which may or 
may not be inflatable may be included to provide further support to the 
ankle region. Also, a possible extra bladder surrounding the ankle may be 
incorporated into the brace 16 to contain gel or water, with or without 
foam, for hot or cold therapy. 
Accordingly, the present invention is not limited to the constructions 
precisely as shown in the drawings or described in the detailed 
description.