Abstract:
A process of manufacturing a belt wherein a plurality of strips of a first material are sewn together to create an outer member having a desired length with a plurality of vertical seams. A layer of a second material is placed over the seams and sewn thereto create a plurality of vertical slots. After staves are inserted in the slots, a layer of a resilient material is placed over the second material and a layer of perforated material is placed over the resilient material. A strip of material is placed on the peripheral surface of the inner and outer members and sewn to define the belt. First and second fasteners on the first and second side sections joined together to apply a force through the staves to provide support for an underlying area of the torso of an individual to assist in attaining a desired posture.

Description:
This invention relates to a belt for providing support to the torso of an individual having staves located in a plurality of vertical pockets that define a ring for gently applying pressure on an area underlying the belt to assist in attaining a desired pain free posture. 
     BACKGROUND OF THE INVENTION 
     Back pain is a common problem experienced by many people. Most low back pain is a result of soft tissue injure such as disc herniation of spinal disc that does not require surgery but may require the use of anti-inflammatory drugs and medication therapy. During rehabilitation it may be necessary for a person to employ some type of bracing, such as disclosed in U.S. Pat. Nos. 5,267,947; 5,407,422; 5,569,171; 5,737,774; and 6,676,617, to support the effect area and perform normal daily activities. The brace functions to alert the person of posture, flexion and movements that may expand the injury or extend the healing time for the person. However, if a brace is too rigid or continually worn by a person, the time for recovery of an injury to the soft tissue may be extended, as the person may become too dependent on the brace. 
     SUMMARY OF THE INVENTION 
     This invention provides a belt that provides support for soft tissue of the spine of a person such that a substantially constant force may be applied to vertebrae while a reduced force is applied as a pressure ring to the tissue surrounding the vertebrae to assist in achieving a desired posture. 
     In more particular detail, the belt is defined by inner and outer members with intermediate layers of a material there between to define a semi-rigid structure having a shape in center section that approximates the thoracio-lumbar vertebrae and sacro-coccygael of an individual. The outer member is created by sewing a plurality of strips of a first material together to create a desired length for the belt. The individual strips have a desired length such that on sewing the strips together, a plurality of vertical seams are created along an entire length of the belt and a center section is created that transitions into first and second side sections. The length of the center section and first and second side sections are about equal in defining the length of the belt. A first layer of an intermediate second material is placed over the outer member and attached thereto by sewing first and second parallel seams adjacent the plurality of vertical seams in the outer layer to create a corresponding plurality of vertical slots in the center and side sections. A stave is inserted in each slot and an intermediate layer of a third material is placed over the intermediate layer of the second material. The third material is an open pore sponge that has a resiliency such that it may be compressed on the application of a force. An inner member defined by a fourth material that has perforations therein to allow the communication of air there through is placed over the intermediate layer of third material. A binding defined by a strip of a fifth material is placed around the peripheral surface of the first, second, third and fourth materials and sewn to define a unitary structure wherein the plurality of staves are located in a vertical position along substantially the entire length of the resulting belt. A first fastener is attached to the first side section of the outer member and a second fastener member is attached to the second side section of the outer member. On positioning the belt on a torso of the individual, the first fastener and second fastener are joined together with a force to exert a corresponding constant force on the thoracio-lumbar vertebrae and sacro-coccygael and a variable force through the plurality of staves on the underlying area of the torso covered by the inner member such that a desired pain free posture may be attained. 
     An advantage of the present invention is achieved through a belt whereby a direct force may be applied to a specific area of the torso and a variable force applied to the area surrounding the specific area that allows flexible movement while providing support to soft tissue of the muscles associated with the movement. 
     A further advantage of this invention resides in a belt that is semi-rigid to provide support for soft tissue while allowing flexible movement for an individual to perform daily activities. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an individual illustrating a posture associated with a protruding disc of the spine of such an individual; 
         FIG. 2  is a sectional view of the spinal disc of the circumscribed area  2  of  FIG. 1 ; 
         FIG. 3  is a perspective view of an individual having a belt, made according to the present invention, that is affixed to his lower torso to provide bracing and assist in achieving a desired posture; 
         FIG. 4  is a sectional view of the spine of the circumscribed area  4  of the individual of  FIG. 3 ; 
         FIGS. 5–18  illustrate a sequential process of manufacturing the belt illustrated in  FIG. 3  and in particular; 
         FIG. 5  is a view an outer member of the belt; 
         FIG. 6  is a sectional view taken along lines  6 — 6  of  FIG. 5 ; 
         FIG. 7  is a view of the outer member of  FIG. 5  wherein a first intermediate member sewn to the outer member of  FIG. 5  to define a plurality of vertical pockets; 
         FIG. 8  is a sectional view taken along lines  8 — 8  of  FIG. 7 ; 
         FIG. 9  is a view of the outer member and first intermediate member a portion of which is removed to show staves that are inserted in the vertical pockets; 
         FIG. 10  is a sectional view taken along lines  10 — 10  of  FIG. 9 ; 
         FIG. 11  is a view of a second intermediate member for the brace that is placed over the first intermediate member; 
         FIG. 12  is a view of an inner member for the brace that is placed over the second intermediate member; 
         FIG. 13  is a sectional view taken along lines  13 — 13  of  FIG. 12 ; 
         FIG. 14  is a sectional view taken along lines  14 — 14  of  FIG. 12 ; 
         FIG. 15  is a view of the assembly of  FIG. 12  with binding attached about the peripheral surface; 
         FIG. 16  is a sectional view taken along lines  16 — 16  of  FIG. 15 ; 
         FIG. 17  is a view of the belt with fasteners attached thereto; and 
         FIG. 18  is a view taken along lines  18 — 18  of  FIG. 17 . 
     
    
    
     DETAILED DESCRIPTION 
     In this application a same number may be used with respect to a different component if a same feature is present. 
     An individual suffering from a strain or back injury may assume a posture, as illustrated in  FIG. 1 , as a result of pain associated therewith. In such a situation, one or more disc  11 , 11 ′ . . .  11   n  that separate the vertebrae of the thoracio-lumbar spine  10 , 10 ′ . . .  10   n , may extrude inwardly and bulging outwardly such that the curvature of the thoracio-lumbar spine  10 , 10 ′ . . .  10   n  may be changed and as a result act on nerves, as schematically illustrated in  FIG. 2 . Depending on the pain experiences by the individual, treatment for such injury may include rest, surgery, or strengthening exercises. In any event, in order for an individual to perform normal activities it may be advisable and/or necessary to wear a belt  20  around the lower region of torso  18 , as illustrated in  FIG. 3 , to support the muscles and soft tissue in the area of the thoracio-lumbar vertebrae  10 , 10 ′ . . .  10   n . The belt  20  of the present invention is designed to provide a constant force or support for at least the second through the fourth lumbar vertebrae  10 , 10 ′ . . .  10   n , variable support up to the eighth/ninth thoracic vertebrae  10 , 10 ′ . . .  10   n  and cover the sacro-coccygael junction  12  to assist in achieving a desired posture that approximates a normal curvature of the spine as illustrated in FIG.  4 . When the belt  20  firmly surrounds the torso  18  of an individual, hip and leg movement is not restricted provided and the stomach muscles  22  are also supported in a manner such the flow of blood to the muscles and soft tissue is not restricted and as a result the time to heal the injured tissue may be reduced. The belt  20  provides a constant force to the center section of the belt and a variable force that is gentle to provides a massage effect to the soft tissue underlying the belt to ease any discomfort and pain the individual may experience. 
     In more particular detail, the belt  20  is defined by a plurality of layers of material that form a semi-rigid structure and may be manufactured through the following process. 
     A first plurality of strips  24 , 24 ′ . . .  24   n  of a first material are sewed together see  FIG. 5 , to create a first side section  26  for an outer member  100  having a first length  28  and a first width  30  to define a shape with a plurality of vertical seams  32 , 32 ′ . . .  32   n , as illustrated in  FIG. 6 . The preferred first material is leather having a thickness of about 3 ply. 
     First  34 , second  36  and third  38  pieces of a intermediate second material are layered over the first side section  26 , see  FIG. 7 , and sewed along the plurality of vertical seams  32 ,  32 ′ . . .  32   n  to create vertical seams  40  and  42  adjacent each vertical seam and thereby produce a plurality of vertical slots  44 ,  44 ′ . . .  44   n  in the first side section  26 , as illustrated in  FIG. 8 . The space between the edges of the first  34 , second  36  and third  38  pieces of the second material define linear hinges  46  and  48  such that the area covered by the upper first piece  34  and the area covered by the lower third piece  38  may independently flex with respect to the second piece  36 . The preferred second material is suede leather. 
     A second plurality of strips  24 , 24 ′ . . .  24   n  of the first material are sewn together to create a second side section  50  having a same first length  28 ′ and a same first width  30 ′ to define a shape for a second side section  50  with a plurality of vertical seams  32 , 32 ′ . . .  32   n , as the first side section  26  illustrated in  FIG. 5 . 
     As with the first side section  26 , first  34 , second  36  and third  38  pieces of the intermediate second material for the second side section  50  are layered over the second side section  50  and sewed along the plurality of vertical seams  32 ,  32 ′ . . .  32   n  to create first and second vertical seams  40  and  42  to produce a plurality of vertical slots  44 ,  44 ′ . . .  44   n  in the second side section  50 . The space between the edges of the first  34 , second  36  and third  38  pieces of the second material for the second side section  50  also define linear hinges  46  and  48  such that the area covered by the first piece  34  and the area covered by the third piece  38  may independently flex with respect to the second piece  36 . The first  26  and second  50  side sections are complementary and designed such that the length of a section may be changed by adding additional strips  24  of the first material at a transition point  29 ,  29 ′. 
     A third plurality of strips  24 , 24 ′ . . .  24   n  of a first material are sewn together to create a center section  52  having second length  54  and a second width  56  with a plurality of vertical seams  32 , 32 ′ . . .  32   n , to define a shape as illustrated in  FIG. 5 . 
     First  34 ′, second  36 ′ and third  38 ′ pieces of the intermediate second material are layered over the center side section  52  and sewed adjacent the plurality of vertical seams  32 , 32 ′ . . .  32   n  to create first and second vertical seams  41  and  43  and ultimately the plurality of vertical slots  44 , 44 ′ . . .  44   n  in the center section  52  that are parallel to the vertical slots in the first  26  and second  50  side sections. 
     A strip  24  of the first material for at least the center section  52  is defined by a desired length having a first end  23  and a second end  25  with a first width “W” at a mid-point “m” between the first end  23  and the second end  25  that expands to a second width “W+1” at a points  27 ,  27 ′ respectively located adjacent the first  23  and second  25  ends. When the plurality of strips  24  are sewed together to define a length  54  for the center section  52 , a desired vertical arc is created between the first end  23  and the second end  25  that is designed to approximate the shape of the thoracio-lumbar vertebrae  10 , 10 ′ . . .  10   n  of the spine of an individual as illustrated in  FIG. 4 . 
     The first side section  26  is sewn to the center section  52  at a transition point  29  and the second side section  50  is sewn to the center section  52  at a transition point  29 ′ to define a desired length for a resulting belt  20 , as shown in  FIG. 5 . With the first side section  26  and second side section  50  sewn to the center section  52  a central section having a uniform width defined by the second piece  36  of the second intermediate material substantially extends along the entire length of the belt  20 , while an upper section  62  has a first variable width that substantially extends along the entire length of the belt  20  and a lower section  64  has a second variable width that substantially extends along the entire length of the belt  20 . 
     The plurality of vertical slots  44 , 44 ′ . . .  44   n  substantially extend from the first end  19  to the second end  21  and each receive a corresponding stave  66  as illustrated in  FIGS. 9 and 10 . The staves on being inserted in the slots  44 ,  44 ′ . . .  44   n  are designed to extend to approximately the points  27 ,  27 ′ adjacent the first  23  and second  25  ends of the strips  24  of the first material. 
     Once a stave  66  is placed in each slot  44 , 44 ′ . . .  44   n , a single piece  68  of an intermediate third material that has a uniform thickness, see  FIG. 11 , is placed over the entire length and width of the outer member  100  with the layer of the first  34 ′, second  36 ′ and third  38 ′ pieces of the intermediate second material attached thereto. The intermediate third material is preferred to be a sponge material that has a resiliency that is compressible on the application of a force thereto. 
     Next, a layer  70  having a first member  72  and a second member  74  of a fourth material is placed over the layer of the single piece  68  of the third material to define an inner member  102  for the belt  20 , see  FIGS. 12 and 13 . The first member  72  and second member  74  are complimentary and have a seam  75  that is located at the mid-section of the center section  52  of the outer member  100 . The fourth material is preferred to be leather that has perforations  73 , 73 ′ . . .  73   n  therein, only a few of which are shown, allow the communication of air there through. 
     Thereafter, a centering tab  76  is placed located at the top of the seam  75 , see  FIG. 14  and a binding strip  90  of a fifth material placed to cover the peripheral surfaces of the first, second, third and fourth materials, see  FIGS. 15 , and  16 . The binding strip  90  is sewn to secure the inner member  102  to the outer member  100  such the stave  66  in the slots  44 , 44 ′ . . .  44   n  are retained in a vertical position with respect to the length of the belt  20 . 
     A first fastener arrangement  81  consisting of loop members  80   a , 80   b  and  80   c  are attached to the first side section  26  and a second fastener arrangement  83  consisting of straps  82   a ,  82   b  and  82   c  are attached to the second side section  50 , see  FIGS. 17 and 18 . Loop member  80   b  and strap  82   b  are aligned located along the center line of the length of the belt  20  while loop member  80   a  and strap  82   a  and loop member  80   c  and strap  82   c  are located in an alignment above the hinges  46  and  48 . 
     When the first  81  and second  83  fastener arrangements are attached to the first  26  and second  50  side sections, the manufacture of belt  20  is completed. 
     The plurality of strips  24 , 24 ′ . . .  24   n  that make up the outer member  100  may be sewn together and the first  34 , second  36  and third  38  pieces sequentially attached thereto to define the plurality of vertical slots  44 , 44 ′ . . .  44   n  when a quantity of belts have a same or fixed length rather that making the first  26  and second  50  side sections and then attaching them to the center section  52 . 
     Method of Use 
     Belt  20  is placed on the lower torso  18  of an individual and with the centering tab  76  located along the vertical axis of the spine such that the upper section  62  reaches to approximately the ninth thoracic vertebrae, the center section  52  covers the second through the fourth lumbar vertebrae and the lower section  64  covers sacro-coccygael  12 . With belt  20  firmly secured to the individual, a force applied through the center section  52  is constantly applied to the second through the fourth lumbar vertebrae while a variable force is applied to the soft tissue adjacent the center section  52  through the staves  66  act to assist in achieving a desired posture that approximates a normal curvature of the spine as illustrated in  FIG. 4 . The side sections  26  and  50  are designed to hold to intestines at the front of the waist of the individual upward toward the chest. Because of water retention by the intestines, the organs in the abdomen have a tendency to drop resulting in stretching of blood vessels associated with the organs and as a result the effectively efficiency of the organs may be reduced. By supporting the abdomen, the blood vessels return to a normal size and allow unrestricted circulation of blood through to organs and contribute to the return of normal functioning including the healing of injured tissue associated with the thoracio-lumbar vertebrae.