Patent Publication Number: US-2016242947-A1

Title: Split footplate, ankle braces and bracing systems including the same and associated methods

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     A claim for priority to the Feb. 20, 2015, filing date of U.S. Provisional Patent Application 62/119,098, titled SPLIT FOOTPLATE, ANKLE BRACES AND BRACING SYSTEMS INCLUDING THE SAME AND ASSOCIATED METHODS (“the &#39;098 Provisional Application”), is hereby made pursuant to 35 U.S.C. §119(e). The entire disclosure of the &#39;098 Provisional Application is hereby incorporated herein. 
    
    
     TECHNICAL FIELD 
     This disclosure relates generally to footplates for ankle braces and, more specifically, to footplates that are configured to be mass produced while providing for a custom fit. Even more specifically, this disclosure relates to footplates with separate lateral and medial elements and an expandable element between the lateral and medial elements. In addition, this disclosure relates to ankle braces and other types of bracing systems that include such a footplate, as well as to methods in which the disclosed footplate is used. 
     SUMMARY 
     An ankle brace according to this disclosure includes a footplate with a lateral element, a medial element and an expandable element. The lateral element and the medial element of the footplate are separate and are spaced apart from one another. Accordingly, the footplate may be referred to as a “split footplate.” The expandable element is located between the lateral element and the medial element. It secures the lateral element and the medial element of the split footplate to one another. 
     As its name implies, the expandable element is configured to expand. It is also configured to resiliently contract. Accordingly, the expandable element may impart the split footplate with a variety of different widths, which may enable a split footplate to accommodate feet of a plurality of different widths. Thus, a few sizes of split footplates (e.g., small, medium, large, extra large, etc.) according to this disclosure may provide a relatively custom fit for a much wider variety of foot shapes and sizes. 
     The lateral element and the medial element of the split footplate may comprise a somewhat rigid material. The use of a rigid material may enable one or both of the lateral element and the medial element to support a corresponding portion of the foot; i.e., a portion of the foot under which that element is configured to be positioned. In some embodiments, one or both of the lateral element and the medial element of a split footplate according to this disclosure may be configured to conform to a shape of a portion of the foot against which, or beneath which, that element is to be positioned. The degree to which an element of a split footplate conforms to a corresponding portion of a foot may vary. For example, an element of a split footplate may conform partially to the contour of the foot. Alternatively, an element of a split footplate may conform substantially to the contour of the corresponding portion of the foot; e.g., to a majority of the corresponding portion of the foot; to the general contour of the corresponding portion of the foot while standing still; to a “normal” or desired contour of the corresponding portion of the foot; etc. As another alternative, an element of a split footplate may conform completely to a contour of the foot while the foot is in a particular position and/or orientation. 
     The lateral element of the split footplate may be configured to prevent supination of an individual&#39;s foot and/or lateral rolling of the individual&#39;s ankle. In a specific embodiment, the lateral element of the split footplate may include a heel plate and a lateral stabilizer. The heel plate may be configured to extend from a lateral side of the foot medially to a location that will enable it to be positioned beneath (and, optionally, medially beyond) a calcaneus of the foot. The lateral stabilizer may extend upwardly from a lateral edge of the heel plate. The lateral stabilizer may be configured to extend toward or even adjacent to a lateral side of the individual&#39;s ankle. 
     The medial element of the split footplate may be configured to unload a medial column of the individual&#39;s foot. In this regard, the medial element may include a base that is configured to be positioned beneath the medial column. The medial element may also include an upright portion that extends upwardly from a rear portion of a medial edge of the base in manner that enables the base to be pulled upwardly. 
     A split footplate according to this disclosure may comprise part of a brace for supporting a foot and/or an ankle. In addition to the split footplate, such a brace may include a securing element. 
     In a specific embodiment, the securing element of such a brace may comprise a collar. The collar may be secured to the split footplate and is configured to hold the split footplate in place beneath an individual&#39;s foot. More specifically, the collar may be configured to be secured in place around a portion of the leg above the ankle. In addition to the split footplate and collar, a brace may include a lateral hinge and a medial hinge that secure the collar to the lateral element of the split footplate and the medial element of the split footplate, respectively. In some embodiments, one or both of the lateral hinge and the medial hinge may comprise a pivot point and a convexly oriented arcuate slot that is configured to be positioned below the malleolus of an individual&#39;s ankle. 
     When such an embodiment of brace is properly placed on an individual&#39;s foot and ankle, relative configurations of the collar, the lateral hinge and the lateral element of the split footplate may provide a lateral block that prevents supination of the individual&#39;s foot and/or lateral rolling of the individual&#39;s ankle. Relative configurations of the collar, the medial hinge and the medial element of the split footplate may enable the medial element of the split footplate to lift and provide support for the medial arch of the individual&#39;s foot. 
     In another specific embodiment, the securing element of a brace that includes a split footplate according to this disclosure may comprise a stabilizer that comprises one or more stabilizing straps, such as the stabilizers disclosed by U.S. Pat. No. 7,115,105 to Cropper (“the &#39;105 Patent”). The stabilizer may include a foot-securing portion that is configured to be secured to the split footplate, and to secure the split footplate to an individual&#39;s foot. In addition, in embodiments where the stabilizer is configured to support or brace the individual&#39;s ankle, it may include an ankle-spanning portion that extends from the foot-securing portion to a leg-securing portion, which is configured to be secured to the individual&#39;s leg at a location above his or her ankle. 
     Of course, a wide variety of other embodiments of securing elements may be used with a split footplate according to this disclosure to secure it to an individual&#39;s foot and, along with the split footplate, to provide support to the individual&#39;s foot and/or ankle. 
     In some embodiments, a split footplate according to this disclosure and/or a brace that includes such a split footplate may be configured to be worn by an individual as he or she wears a standard shoe or other footwear. Thus, systems for supporting a foot and/or an ankle of an individual may include a split footplate according to this disclosure, an optional securing element and standard footwear. 
     A method for supporting a foot and/or an ankle may include selecting a split footplate having a size that generally corresponds to a shape and/or size of an individual&#39;s foot. An expandable element of a split footplate may be expanded (e.g., stretched, etc.) to increase a distance between a lateral element of the split footplate and a medial element of the split footplate, thus placing the split footplate in an open orientation. While the split footplate is in the open orientation, an individual&#39;s foot may be positioned over or on the lateral element and the medial element of the split footplate, and the expandable element may be allowed to contract, pulling the lateral element and the medial element toward one another. With the split footplate in place beneath the individual&#39;s foot, the lateral element and the medial element may be adjusted to ensure that they are properly and comfortably positioned. 
     With the split footplate in place relative to the individual&#39;s foot, it may be secured in place. In a specific embodiment, the split footplate may be secured in place by securing a collar to the individual&#39;s leg at a location above his or her ankle. As the collar is secured to the individual&#39;s leg, it may urge one or both of the lateral element and the medial element of the split footplate toward the other. 
     Other aspects, as well as features and advantages of various aspects, of the disclosed subject matter will become apparent to those of ordinary skill in the art through consideration of the ensuing description, the accompanying drawings and the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the drawings: 
         FIG. 1  is a front isometric view of an embodiment of an ankle brace with a split footplate, showing the ankle brace in place on a skeletal foot, ankle and lower leg; 
         FIG. 2  is a front view of the embodiment of ankle brace shown in  FIG. 1 ; 
         FIG. 3  is a rear view of the embodiment of ankle brace shown in  FIG. 1 ; 
         FIG. 4  is a top view of the embodiment of ankle brace shown in  FIG. 1 ; 
         FIG. 5  is a bottom view of the embodiment of ankle brace shown in  FIG. 1 ; 
         FIG. 6  is a lateral side view of the embodiment of ankle brace shown in 
         FIG. 1 ; 
         FIG. 7  is a medial side view of the embodiment of ankle brace shown in  FIG. 1 ; and 
         FIG. 8  is a rear isometric view of the embodiment of ankle brace shown in 
         FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
       FIGS. 1 through 8  provide various views of an embodiment of a brace, which is depicted as being an ankle brace  10 , that is configured to be worn on an individual&#39;s ankle A, as well as on parts of the individual&#39;s foot F and lower leg L that are adjacent to the ankle A. All references in this disclosure to positioning and orientation of an ankle brace  10  (or any other embodiment of brace including a split footplate  20  according to this disclosure) and its component parts correspond to the positions and orientations when the ankle brace  10  is worn on an individual&#39;s foot F, with the sole of the foot F oriented on a horizontal surface. 
     Generally, the ankle brace  10  comprises a split footplate  20  with a lateral element  30  and a medial element  50 , as well as an expandable element  80 . The lateral element  30  is configured to be positioned on a lateral (out) side of an individual&#39;s foot F. The medial element  50  is configured to be positioned on a medial (in) side of the individual&#39;s foot F. The expandable element  80  holds the lateral element  30  and the medial element  50  of the split footplate  20  in place relative to one another, and may be configured to secure the split footplate  20  in place on the individual&#39;s foot F. The lateral element  30  and the medial element  50  of the split footplate  20  may be relatively rigid, while the expandable element  80  may comprise a material that is pliable and elastic. In embodiments where the split footplate  20  comprises part of an ankle brace  10 , the ankle brace  10  may also include a securing element  70 . 
     In the illustrated embodiment of split footplate  20 , and as can best be seen from the views provided by  FIGS. 3, 5 and 6 , the lateral element  30  of the split footplate  20  includes a heel plate  34  and a lateral stabilizer  36 . The heel plate  34  includes a lateral edge  32  that is configured to be aligned with and positioned beneath a lateral edge of the individual&#39;s foot F. A remainder of the heel plate  34  is configured and oriented to extend medially to a location beneath a calcaneus of the foot F. As shown in  FIG. 5 , the anterior extent of the heel plate  34  may be limited in such a way that the heel plate  34  may be configured not to extend beneath the transverse arch of the individual&#39;s foot F. 
     The lateral stabilizer  36  of the lateral element  30  of the split footplate  20  extends upwardly from the lateral edge  32  of the heel plate  34  of the lateral element  30 . As depicted by  FIGS. 3 and 6 , the lateral element  30  may be substantially vertical oriented, and it may be configured to reside adjacent to a lateral side of the individual&#39;s ankle A. 
     In embodiments where the split footplate  20  is part of a hinged ankle brace  10 , such as that depicted by  FIGS. 1 through 8 , a top portion of the lateral stabilizer  36  of the lateral element  30  may comprise a lateral hinge element  38 , as illustrated by  FIG. 6 . The lateral hinge element  38  may define at least part of a simple pivot point or axis, or it may be part of a more complex hinge, such as the arcuate motion hinge disclosed by U.S. Patent Application Publication No. 2013/0281898 A1 of Cropper, et al., titled “FOOT AND ANKLE ORTHOSES THAT ENABLE NATURAL MOVEMENT OF THE FOOT” (“the &#39;898 Publication”), the entire disclosure of which is hereby incorporated herein, which hinge may be configured to align with or to be substantially aligned with the tibialtalor junction, or talocrural joint, of the individuals&#39; ankle A when the ankle brace  10  is properly positioned. 
     Optionally, as shown in  FIG. 3 , as well as by  FIGS. 5 and 6 , the lateral stabilizer  36  may include a posterior extension  35 , which may be substantially vertically oriented, and extend posteriorly and then medially to a location around and partially behind a lateral side of the individual&#39;s heel. A posterior extension  35  with such a configuration may facilitate proper longitudinal, or anterior-posterior, positioning of the lateral element  30 , and of the split footplate  20 , along the length of the individual&#39;s foot F. 
     Referring now to  FIGS. 3, 5 and 7 , the medial element  50  of the split footplate  20  includes a base  54  and an upright portion  56 . As illustrated by  FIG. 5 , the base  54  may include an anteriorly extending portion that is configured to reside beneath and to provide support to the medial column of the individual&#39;s foot F (e.g., as an upward force, etc.). The locations of the foot F beneath which the base  54  is configured to reside may differ from the locations beneath the individual&#39;s foot F beneath which the heel plate  34  of the lateral element  30  of the split footplate  20  is configured to be positioned. Thus, the base  54  and the heel plate  34  may lack any overlapping, or superimposed, regions. The base  54  and the heel plate  34  may even be laterally spaced apart from one another. In the illustrated embodiment, at posterior location, the base  54  of the medial element  50  accommodates the heel plate  34  of the lateral element  30  of the split footplate  20 ; thus, the posterior portion of the base  54  resides primarily beneath a medial edge of the sole of the individual&#39;s foot F. 
     The upright portion  56  of the medial element  50  of the split footplate  20  extends upwardly from a medial edge  52  of the base  54  of the medial element  50 . More specifically, the upright portion  56  extends upwardly from a portion of the medial edge  52  that is configured to be positioned below a medial side of the ankle A. Thus, the upright portion  56 , which may be oriented substantially vertically, may be configured to extend over the medial side of the ankle A. 
     In embodiments where the split footplate  20  is part of a hinged ankle brace  10 , such as that depicted by  FIGS. 1 through 8 , a top portion of the upright portion  56  of the medial element  50  may comprise a medial hinge element  58 , as illustrated by  FIG. 7 . The medial hinge element  58  may be configured to at least partially define a simple pivot point or axis, or it may be part of a more complex hinge, such as the arcuate motion hinge disclosed by the &#39;898 Publication. 
     The upright portion  56  of the medial element  50  may optionally include a posterior extension  55 , as depicted by  FIG. 3 , and by  FIGS. 5 and 7 . The posterior extension  55  of the upright portion  56  may be substantially vertically oriented, and may extend posteriorly and then laterally to a location around and partially behind a medial side of the individual&#39;s heel. A posterior extension  55  with such a configuration may facilitate proper longitudinal, or anterior-posterior, positioning of the medial element  50 , and of the split footplate  20 , along the length of the individual&#39;s foot F. 
     The lateral element  30  and the medial element  50  of the split footplate  20  may comprise a somewhat rigid material or combination of materials. It addition, each of the lateral element  30  and the medial element  50  may be formed from a material that provides a desired degree of one or more other characteristics, such as flexibility, strength, durability and/or fracture mechanics. Examples of suitable materials include, but are not limited to, thermoplastic materials (e.g., polypropylene, polyethylene, etc.), thermoplastic composite materials (e.g., carbon fiber-reinforced thermoplastic materials, etc.) and resins (e.g., a polypropylene-like material, such as the DurusWhite™ material available from Objet Geometries, Ltd., of Rehovot, Israel, etc.). In some embodiments, features that are formed from a relatively hard material may be coated with a softer, more compliant material (e.g., natural rubber, silicone, a compliant thermoplastic material (or oil-extended thermoplastic material), a cushioning material (e.g., ethylene-vinyl acetate (EVA) foam, or foam rubber; etc.), etc.). 
     The expandable element  80  of the split footplate  20  may hold the lateral element  30  and the medial element  50  in place relative to one another. In some embodiments, the expandable element  80  may be located laterally between adjacent sections of the split footplate  20  (e.g., the lateral element  30 , the medial element  50 , etc.). In other embodiments, the expandable element  80  may be configured as a sock or a stocking on which or in which other elements of the split footplate  20  reside. 
     In addition, the expandable element  80  is configured to impart the split footplate  20  with a variety of different widths (e.g., distances between the lateral element  30  and the medial element  50 , etc.), which may enable a split footplate  20  to accommodate feet of a plurality of different widths. In some embodiments, the expandable element  80  may comprise a fabric or another material that can expand and resiliently contract. Breathability may also be a desirable characteristic of the expandable element  80 . A variety of materials may be used to form the expandable element  80 , including, without limitation, stretchable, elastic materials, such as the laminate material available from Cropper Medical, Inc., of Ashland, Oreg., under the BIOSKIN® trademark, which material includes a polyurethane membrane sandwiched between two layers of a four-way stretchable fabric, such as spandex, or elastane, or a stretchable, elastic nylon. 
     As shown in  FIG. 5 , a base section  82  of the expandable element  80  is configured to be positioned beneath the individual&#39;s foot F. At least part of the base section  82  is located between opposed, or facing, edges of the heel plate  34  of the lateral element  30  and the base  54  of the medial element  50  of the split footplate  20 . 
       FIGS. 4 and 6  illustrate an upper section  84  of the expandable element  80 , which may extend between an upper anterior edge of the lateral stabilizer  36  of the lateral element  30  of the split footplate  20  and an upper anterior edge of the upright portion  56  of the medial element  50  of the split footplate  20 . As shown, the upper section  84  of the expandable element  80  may be configured to reside atop the individual&#39;s foot F. 
     In addition, the expandable element  80  may include a posterior portion  86 , as depicted by  FIGS. 3, 6, 7 and 8 . The posterior portion  86  may extend between upper and posterior edges of the lateral stabilizer  36  of the lateral element  30  and of the upright portion  56  of the medial element  50 . Thus, the posterior portion  86  of the expandable element  80  may be configured to be positioned around the back of an individual&#39;s heel and/or ankle A. 
     In addition to the split footplate  20 , an ankle brace  10  or other embodiments of brace that includes a split footplate  20  may also include a securing element  70 , which may secure the brace in place relative to a particular portion of an individual&#39;s anatomy (e.g., his or her ankle, etc.). The embodiment of ankle brace  10  shown in  FIGS. 1 through 8  includes a specific, but non-limiting, example of a securing element  70  (see  FIGS. 1-4, 7 and 8 ) that may be configured for use with a split footplate  20  according to this disclosure. 
     The securing element  70  is configured to be secured around an individual&#39;s lower leg L. The securing element  70  may include a collar  72  that is configured to extend around the posterior side, or back, of an individual&#39;s lower leg L (e.g., his or her calf, etc.). Sides of the collar  72  may extend anteriorly and, thus, be configured to be positioned over sides of the lower leg L. At its anterior edges, or front edges, the collar  72  may include strap engagement elements  74  ( FIGS. 6 ) and  76  ( FIG. 7 ). The strap engagement elements  74  and  76  may be configured to receive or otherwise engage portions of an elongated element, such as a strap  78  (e.g., a strap with a touch fastener, etc.), which may be configured to pull the collar  72  tightly against the back and sides of the lower leg L and, thus, to fasten the securing element  70  in place around the lower leg L. 
     As best seen in  FIGS. 3, 6 and 7 , the depicted embodiment of securing element  70  includes a lateral hinge element  42  ( FIGS. 3 and 6 ) and a medial hinge element  62  ( FIGS. 3 and 7 ) that extend downwardly from respective lateral and medial sides of the collar  72 . In some embodiments, such as the illustrated embodiment, the lateral hinge element  42  and the medial hinge element  62  may be located at the bottom ends of a lateral support member  44  and a medial support member  64  of the collar, which respectively extend downwardly from lateral and medial sides of the collar  72 . 
     Each of the lateral hinge element  42  and the medial hinge element  62  may be configured to cooperate with its corresponding lateral hinge element  38  or medial hinge element  58  of the split footplate  20 . Together (i.e., when assembled), the lateral hinge elements  38  and  42  may define a lateral hinge  40  ( FIGS. 3 and 6 ), while the medial hinge elements  58  and  62  may define a medial hinge  60  ( FIGS. 3 and 7 ). Thus, the lateral hinge  40  and the medial hinge  60  couple the securing element  70  to the split footplate  20 . 
     The collar  72 , the lateral support member  44  and the medial support member  64  of the securing element  70  may be substantially rigid, and may be constructed from any suitable material, such as a thermoplastic material, a thermoplastic composite material, a resin or any other suitable material. In addition, surfaces of one or more of these features that are configured to be positioned against part of an individual&#39;s lower leg L may be lined with a material that provides cushioning, a conformal fit or any other desired function. 
     An embodiment of ankle brace such as that depicted by  FIGS. 1 through 8  may be configured to support the individual&#39;s ankle A. More specifically, when the split footplate  20  is worn on the individual&#39;s foot F and the securing element  70  is secured to the individual&#39;s lower leg L, the components and the materials from which they are made may provide a combination of a customized fit (even though the ankle brace  10  may not be custom-made), support, freedom of motion and comfort. Without limitation, the rigid material and configurations of the lateral element  30  and the medial element  50  may support the foot F, while conforming to the shapes of the portions of the foot F against which, or beneath which, the lateral element  30  and the medial element  50  are positioned. Even more specifically, when the heel plate  34  is forced against an individual&#39;s heel, the heel plate  34  and the lateral stabilizer  36  of the lateral element  30  may, alone or in combination with the lateral support member  44  of the securing element  70 , be configured to prevent supination of the individual&#39;s foot F and/or lateral rolling of the individual&#39;s ankle A. 
     In addition, when the ankle brace  10  is positioned on an individuals&#39; foot F, over his or her ankle A and around his or her lower leg L, the heel plate  34  of the lateral element  30  provides an anchor that defines a position along the lower leg L. When the securing element  70  is snugly and properly fastened to the lower leg L, it pulls the medial element  50  of the split footplate  20  upward, generating a tension in the base  54  of the medial element  50 . That tension causes the base  54  to pull the medial column of the foot F upward, or unloads the medial column. 
     Another specific embodiment of a brace according to this disclosure may include a split footplate, such as the embodiment of split footplate  20  depicted by  FIGS. 1 through 8 , as well as a stabilizer with one or more stabilizing straps, such as those disclosed by the &#39;105 Patent. The stabilizer may include a foot-securing portion that is configured to be secured to the split footplate, and to secure the split footplate to an individual&#39;s foot. In addition, in embodiments where the stabilizer is configured to support or brace the individual&#39;s ankle, it may include an ankle-spanning portion that extends from the foot-securing portion to a leg-securing portion, which is configured to be secured to the individual&#39;s leg at a location above his or her ankle. Such a stabilizer, when used in combination with a split footplate  20 , may enable independent unloading of the medial and lateral columns of the foot F, as well as controlled unloading of each of the medial column and the lateral column. 
     Although the preceding disclosure provides many specifics, these should not be construed as limiting the scope of any of the ensuing claims. Other embodiments may be devised which do not depart from the scopes of the claims. Features from different embodiments may be employed in combination. The scope of each claim is, therefore, indicated and limited only by its plain language and the full scope of available legal equivalents to its elements.