Abstract:
An orthopaedic brace includes a strut length adjustment assembly to change the operable length of the strut for sizing the brace on a patient without the need for special tools or cutting of the strut. The adjustment assembly includes a biased adjustment mechanism that coacts with a plurality of notches in the strut to variably set/position the strut relative to the adjustment assembly to set the struts length. Each upper and lower strut preferably includes a strut length adjustment assembly to independently set the length of each strut. The strut length adjustment assembly retains a strut and includes a strap retention mechanism that is configured to releasably engage the strap.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. application Ser. No. 11/510,408, filed on Aug. 25, 2006, which is a continuation of U.S. application Ser. No. 10/141,494, filed on May 7, 2002, now U.S. Pat. No. 7,097,627, which is a continuation of U.S. application Ser. No. 09/608,940, filed on Jun. 30, 2000, now U.S. Pat. No. 6,383,156, which claims the benefit of U.S. provisional application Ser. No. 60/156,342, filed on Sep. 27, 1999. Each of the priority applications is hereby incorporated by reference herein. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present application relates to orthopaedic braces adapted with an adjustable-length strut for use in stabilizing a joint after invasive surgery. 
         [0004]    2. Description of the Related Art 
         [0005]    In order to ensure the proper healing of a human joint after an injury or invasive surgery, it is often desirable to limit the pivotal motion of the human joint to a predetermined angular range between full extension and full flexion. The pivotal motion may be limited by a range of motion hinge disposed between an upper strut and a lower strut. In order for the orthopaedic brace to function properly, the struts must be adaptable to the body proportions of the patient. 
         [0006]    The following U.S. patents, which describe orthopaedic braces of this general type, are herein incorporated by reference to establish the nature of such range of motion braces, and how and why such equipment is used. U.S. Pat. No. 552,143 issued on Dec. 31, 1895; U.S. Pat. No. 649,237 issued on May 8, 1900; U.S. Pat. No. 4,776,326 issued to Young et al., on Oct. 11, 1988 entitled “Modular Lower Limb Bracing System”; U.S. Pat. No. 4,817,588 issued to Bledsoe on Apr. 4, 1989 entitled “Motion Restraining Knee Brace”; U.S. Pat. No. 4,982,732 issued to Morris on Jan. 8, 1991 entitled “Orthopedic Rehabilitation Knee Brace”; U.S. Pat. No. 5,052,379 issued to Airy et al., on Oct. 1, 1991 entitled “Combination Brace and Wearable Exercise Apparatus for Body Joints”; and U.S. Pat. No. 5,018,514 issued to Grood et al., on May 28, 1991 entitled “Knee Brace”. 
         [0007]    It is well known that the orthopaedic braces described in the aforementioned incorporated patents suffer various problems, shortcomings and disadvantages. In some cases such braces cannot be adjusted to fit the patient, rather, the braces come in various fixed sizes. Alternatively, the braces are not easily adjustable, requiring, for example, tools to change the size of the struts. Some braces require actual cutting or breaking off pieces of the struts to permanently change the length of the struts. Others rely upon friction, as from a tightening screw, to less than positively lock the strut at the desire length. 
         [0008]    It is thus an object of the present invention to provide an orthopaedic brace that is easy to adjust. 
         [0009]    It is thus another object of the present invention to provide an orthopaedic brace that is adjustable without a need for tools. 
         [0010]    It is thus further an object of the present invention to provide an orthopaedic brace that is adjustable without cutting or breaking a strut. 
       SUMMARY OF THE INVENTION 
       [0011]    The present invention is an orthopaedic brace that has adjustable length struts. 
         [0012]    In one form, the present invention is an orthopaedic brace including a first strut, a second strut, a hinge disposed between the first and second struts, and an adjustment assembly disposed on one of the first and second struts. The hinge is configured to allow movement of one of the first and second struts about an axis defined by the hinge. The adjustment assembly is configured to cooperate with the one of the first and second struts to adjustably set an operative length of the one of the first and second struts. 
         [0013]    In another form, the present invention is an orthopaedic brace including an upper strut, a lower strut, a hinge disposed between the upper strut and the lower strut, and an adjustment assembly disposed on one of the first and second struts. The hinge is configured to allow movement of one of the upper and lower struts about an axis defined by the hinge. One of the upper and lower struts has a plurality of notches defining a plurality of strut length settings. The adjustment assembly is configured to cooperate with any one of the plurality of notches of the one of the first and second struts to selectively set a length of the one of the first and second struts. 
         [0014]    In yet another form, the present invention is an orthopaedic brace including an upper strut, a lower strut, a hinge disposed between the upper strut and the lower strut, an upper adjustment assembly disposed on the upper strut, and a lower adjustment assembly disposed on the lower strut. The hinge is configured to allow movement of one of the upper and lower struts about an axis defined by the hinge. The upper adjustment assembly is configured to cooperate with the upper strut to adjustably set a length of the upper strut. The lower adjustment assembly is configured to cooperate with the lower strut to adjustably set a length of the lower strut. 
         [0015]    Accordingly, the present invention improves upon the prior art by providing an orthopaedic brace strut that may be changed in length without the use of tools and with the ability to return to the original length, or some other length as desired. 
         [0016]    The present invention also provides for a single-action positive lock for a strut length adjustment assembly rather than relying on friction. The ability to size and resize the struts provides a cost-effective and comfortable means to apply an orthopaedic brace to virtually any joint on the human body and eliminates the need to carry large inventories of braces that cannot be sized. By providing a positive lock, the improved brace also better protects the patient and speeds recovery. 
         [0017]    The present invention also allows contoured wings, with cushioning material and/or non-slip material attached, to be used to limit movement of the brace after it has been attached and to provide increased comfort to the patient. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0018]    The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein: 
           [0019]      FIG. 1  is a side perspective view of an adjustable orthopaedic brace assembly having adjustable-length strut assemblies that embodies principles of the present invention showing the brace operatively connected to a human leg; 
           [0020]      FIGS. 2A and 2B  are, respectively, top and underside perspective views of an adjustable-length strut assembly for the orthopaedic brace of  FIG. 1 ; 
           [0021]      FIG. 3  is an exploded, perspective view of the adjustable-length strut assembly of  FIGS. 2A and 2B ; 
           [0022]      FIGS. 4A and 4B  are cross-sectional views through the adjustable-length strut assembly taken along line  4 - 4  of  FIG. 3 ; 
           [0023]      FIG. 5  is a perspective view of a second embodiment of an adjustable-length strut assembly; 
           [0024]      FIG. 6  is a cross-sectional view through the second embodiment of the adjustable-length strut assembly taken along line  6 - 6  of  FIG. 5 ; 
           [0025]      FIG. 7  is a cross-sectional view through the second embodiment of the adjustable-length strut assembly taken along line  7 - 7  of  FIG. 6 ; and 
           [0026]      FIG. 8  is a perspective view of a third embodiment of an adjustable-length strut assembly. 
       
    
    
       [0027]    Corresponding reference characters indicate corresponding parts throughout the several views. 
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0028]    An orthopaedic brace  10  is shown in  FIG. 1  operatively attached to a leg  64  using a plurality of straps  54  mounted on an upper strut  12  and a lower strut  14  with a hinge assembly  16  disposed between the upper strut  12  and the lower strut  14 . While only one side of the orthopaedic brace  10  is shown (i.e. the hinge assembly  16 , the upper strut  12 , and the lower strut  14  or “assembly”) it should be understood that an identical, but mirror image, assembly is provided on the opposite side of the leg  64 . 
         [0029]    Each strut  12  and  14  is provided with a preferably identically configured wing assembly  18  although variations in either are contemplated, which is slidably mounted for adjustable movement on the elongated struts  12  and  14 . Stated in another manner, each strut  12  and  14  is adjustable in length relative to the length of the strut between the hinge  16  and the straps  54  through adjustable strut assemblies  18 . Such will be considered hereafter as the length adjustment of a strut. It should be appreciated that such assemblies  18  may be provided on both struts  12  and  14 , or only on one of the two struts  12  and  14 . As well, it should also be appreciated that adjustability of the length of a strut may be considered as either or both the adjustment of the assembly  18  relative to a strut ( 12  and/or  14 ), or as the adjustment of a strut ( 12  and/or  14 ) relative to the assembly  18 . 
         [0030]    The adjustable mounting of the wing assembly  18  on elongated struts  12  and  14  allows the struts to telescope or move in and out, one in opposition to the other, of the respective wing assembly  18 , as will be described subsequently, to accommodate long or short legs, as one example, or long or short arms, as another example. Because the structure and function of the wing assembly is similar regardless of whether mounted to the upper strut  12  or the lower strut  14 , reference will be made to only the upper strut  12  in the following description and its wing assembly  18 . As well, because the structure and function of the struts  12  and  14  are identical (assuming each strut terminates in a wing assembly  18 ), reference to strut  12  in the following description will be construed to pertain to strut  14 . 
         [0031]    Referring to  FIG. 2A , the wing assembly  18  has a wing body  20 , which is preferably formed of a relatively rigid material, as for example plastic. The wing body  20  has an arcuate profile and is provided with one or more strap-retaining loops  22  for receiving the one or more adjustable straps  54  that are threaded through the loops  22  to encircle both the wing assembly  18  and a human limb, such as the leg  64  (as depicted in  FIG. 1 ), thereby immovably securing the brace  10  to the leg  64 , for example.  FIG. 2B  shows that the underside of the arcuate-shaped wing body  20  is provided with a generous layer of non-slip cushioning  50 , both to pad the wearer&#39;s limb and to assure that the brace  10  remains in place. 
         [0032]      FIGS. 2B ,  3 ,  4 A and  4 B reveal that the underside of the wing body  20  defines a unitary channel  46  that runs longitudinally down the entire length the wing body  20 . While the channel  46  is generally open, splitting the cushioning  50  into two halves, a lip  48  portion of the wing body  20  overhangs the channel  46  at each of the side edges of the channel  46  down the entire longitudinal length of each side of the channel  46 . The channel  46  with opposing lips  48  receives the elongated strut  12  and retains and guides the strut  12  as it telescopes in and out of the channel  46 . The open nature of the channel  46  also helps to reduce the overall weight of the orthopaedic brace  10 . 
         [0033]    Referring to  FIGS. 2B and 3 , the strut  12  has formed through its body a longitudinal slot  60 . The length of the slot  60  may be varied depending upon the desired maximum and minimum lengths of the orthopaedic brace  10 . Longitudinally spaced down each side of the slot  60  are a plurality of arcuate-shaped, stop notches generally designated  62 . The notches  62  are equally divided into a plurality of notches  62   a  that are mirror images of, and directly across the slot  60  from, a plurality of opposing notches  62   b , such that the opposing, arcuate-shaped pairs of notches  62   a  and  62   b  would define a circle if their ends were connected by an arc of constant radius equal to the distance from the center of the slot  60  to the center of the opposing notches. One end of the slot  60  contains an arcuate-shaped notch  62   c  and the other end of the slot  60  contains a mirror image arcuate-shaped notch  62   d . Notches  62   c  and  62   d  are connected on each end to the outer ends of notches  62   a  and  62   b . It should be appreciated that the notches may be shaped other than that shown. 
         [0034]    Referring to  FIG. 3 , it can be seen that the wing body  20  also defines a depression or chamber  28  on the top of the body  20  which is shown as circular but can be any shape. The wing body  20  also defines an aperture  26  of smaller diameter than the chamber  28  that extends through the center of the chamber  28  all the way to the slot  60  on the underside of the wing body  20 . The chamber  28  and aperture  26  are adapted to house a positive-lock, adjustment or button assembly  30 . 
         [0035]    The adjustment assembly  30  ( FIG. 3 ) has a generally flat pushbutton top  32  that has a cylindrical extension  34  extending downward away from and perpendicular to the top. The cylindrical extension  34  has a radius that allows it to freely travel through the aperture  26  and the slot  60  without engaging any of the notches  62   a  and  62   b . With additional reference to  FIGS. 4A and 4B , a threaded aperture  36  extends down through the center of the top  32  and the extension  34  and is adapted to receive a screw  42  from the underside of wing body  20 . Fitting over the extension  34  is a biasing spring  38  of smaller diameter than the chamber  26 . A retaining bushing  40 , with a radius approximating that of the notches  62   a ,  62   b ,  62   c  and  62   d , is secured to the adjustment assembly  30  (extension  34 ) from the underside of the wing body  20  by the screw  42 , which runs through the aperture  28  into the threaded aperture  36  in the extension  34  and thus the button  32 . The spring  38  is thereby secured and sandwiched between the underside  33  of the top of the button  32  and a bottom  27  of the chamber  28 . 
         [0036]      FIGS. 2B and 4A  show the positively locked position of the adjustment assembly  30 . The spring  38  normally urges (biases) the push-button top  32  up and away from the bottom of the chamber  27  and thereby captively urges the attached bushing  40  up into the selected pair of opposing notches  62   a  and  62   b  to retain the strut  12 . The bushing  40  prevents the strut  12  from longitudinally moving relative to the wing assembly  18  while the bushing  40  is within a notch. 
         [0037]    When a finger  66  applies downward pressure on the push-button top  32 , the spring  38  is compressed and pushes the connected bushing  40  down out of the opposing notches  62   a  and  62   b . With pressure still applied, the entire wing assembly  18  can be translated up or down the slot  46  (or vice-versa) until the pressure on the button  32  is removed and the bushing (stop member)  40  re-engages one of the pair of opposing notches  62   a  and  62   b.    
         [0038]      FIGS. 5 ,  6  and  7  depict a second embodiment of a wing assembly, generally designated  118  that telescopes in the exact manner just described with respect to the wing assembly  18 . The second embodiment functions the same as the wing assembly  18  with respect to the adjustment of the length of the strut  12 . The wing assembly  18  is provided with at least one strap-retaining channel  72  that runs transversely across the wing member  20 . A strap-retaining loop  74  extends longitudinally outward from an adjustment assembly housing  131  that retains the adjustment assembly  30  across the entire width of the channel  72  and is flush with the top of the adjustment housing  131 . The loops  74  may be formed of plastic, metal, or other suitable material that is resilient enough to be repeatedly bent and still spring downward to retain the strap  54 . The adjustment assembly  30  is structured and functions in like manner to the adjustment assembly  30 . Features and/or functions not discussed below with respect to the wing assembly  118  should be considered to be the same as those features and/or functions with respect to the wing assembly  18  unless noted to the contrary. 
         [0039]    This configuration gives the wing assembly  118  a lower and sleeker profile that is less likely to get caught on obstructions during use. In addition, one end  78  of the retaining loop  74  is not connected to the wing body  20 . The end  78  has a nub  80  to keep the strap  54  in place ( FIGS. 6 and 7 ). The end  78  may also have a snap or other positive locking mechanism that is releasably engageable with the wing assembly  118 . Referring to  FIG. 6 , the retaining loop  74  can be pivoted or bent up at the unconnected end  78  in order easily to slip in the strap  54 . When the end  78  is released, the nub  80  ensures that the strap  54  will not slip out of the retaining channel  72 . The arrow in  FIG. 5  depicts where and how another strap may be placed. 
         [0040]      FIG. 8  depicts a third embodiment of a wing assembly, generally designated  218 . This third embodiment telescopes in the exact manner described with respect to the wing assemblies  18  and  118 . Other features and/or functions not discussed below with respect to the wing assembly  218  should be considered to be the same as those features and/or functions with respect to the wing assemblies  18  and  118 . 
         [0041]    The wing assembly  218  is similar in design/appearance to the wing assembly  118 . The wing assembly  218  includes a body or housing  20  having a unitary retaining loop  74  that defines two channels  72  for receipt of straps ( 54 ). The adjustment assembly  230  is oval rather than round to provide easier manipulation, and is situated at an end of the body  20 , proximate the strut  12 . The adjustment assembly  230  is surrounded by an adjustment housing  231 . 
         [0042]    Although the invention has been described in detail with reference to a preferred embodiment and an alternative embodiment, variations and modifications exist within the scope and spirit of the invention. Additional features of the invention will become apparent to those skilled in the art upon consideration of the detailed description of preferred embodiments exemplifying the best mode of carrying out the invention as presently perceived.