Patent Publication Number: US-2017354528-A1

Title: Moldable wrist brace

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Patent Application No. 62/349,182 filed Jun. 13, 2016, the disclosure of which is hereby incorporated herein in its entirety by reference. 
    
    
     BACKGROUND 
     A common practice for treatment of joints, bones, muscles, and the like includes immobilizing or supporting the area to be treated. A variety of devices are available for such treatments. The devices can be configured to completely immobilize the joint or to simply support the body part to relieve stresses thereon. 
     Removable devices for temporary or intermittent support are useful as treatment during activities that cause or exacerbate a particular ailment. The devices can be worn during the activity and then removed upon completion thereof. Such available devices can be problematic because they may not fit well, do not provide a sufficient support or compression, and are difficult to put on. Generally such devices are configured based on an average or common size and shape of the respective body part based on a large population of patients. The devices thus do not necessarily provide a perfect fit for all patients. And the devices often employ a variety of straps or ties that must be stretched and coupled to attach the device around the body part. The straps can be difficult to couple while also holding the device in position, especially when being applied to an arm or wrist and thus requiring the stretching and coupling to be completed one-handed while also holding the brace in the desired position. 
     SUMMARY 
     Exemplary embodiments are defined by the claims below, not this summary. A high-level overview of various aspects thereof is provided here to introduce a selection of concepts that are further described in the Detailed-Description section below. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. In brief, this disclosure describes, among other things, a wrist brace that includes a moldable insert and a plurality of fastening straps with locking tabs. 
     The wrist brace includes a body panel that is sized and shaped to wrap around the wrist of a user. The body panel includes a pocket in which a moldable insert is disposed. The insert is formed from a material that is substantially rigid or resilient at ambient temperatures, but, when heated, can be molded or shaped to a desired form, e.g. molded to the form of the user&#39;s wrist. After molding, the insert is installed into the pocket to provide the wrist brace with a custom-fit to the user. 
     The fastening straps are each comprised of mating sections of hook-and-loop fastener strips, i.e. a loop section and a hook section. One end of the loop section is coupled to the body panel and the opposite end is coupled to the hook section at a location spaced apart from but adjacent to a first end of the hook section. The first end of the hook section is thus a free end that overlies the loop section and forms locking tab. 
     In use the second end of the hook section is inserted through a buckle on the body panel. The strap is pulled through the buckle a sufficient distance to pull the locking tab through the buckle. The locking tab is deflected to lie on top of the loop section by the buckle to allow passage through the buckle. Once pulled through the buckle, the locking tab extends at least partially away from the loop section of the strap and the free end thereof is directed toward the buckle. When the strap is moved toward withdrawal from the buckle the locking tab engages and is deflected away from the loop section by the buckle and obstructs withdrawal of the strap through the buckle. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
       Illustrative embodiments are described in detail below with reference to the attached drawing figures, and wherein: 
         FIG. 1  is an exterior-side plan view of a moldable wrist brace depicted in accordance with an exemplary embodiment; 
         FIG. 2  is a plan view of a moldable insert configured for use in the moldable wrist brace of  FIG. 1  and depicted in accordance with an exemplary embodiment; 
         FIG. 3  is an interior-side plan view of the moldable wrist brace of  FIG. 1  with a moldable insert inserted therein in accordance with an exemplary embodiment; 
         FIG. 4  is a perspective view of the moldable wrist brace of  FIG. 1  applied to the wrist of a user in accordance with an exemplary embodiment; and 
         FIG. 5  is perspective view depicting the moldable wrist brace of  FIG. 1  applied to the wrist of a user with the straps in an uncoupled state and with the locking tabs engaging buckles to resist withdrawal of the straps from the buckles in accordance with an exemplary embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     The subject matter of select exemplary embodiments is described with specificity herein to meet statutory requirements. But the description itself is not intended to necessarily limit the scope of claims. Rather, the claimed subject matter might be embodied in other ways to include different components, steps, or combinations thereof similar to the ones described in this document, in conjunction with other present or future technologies. Terms should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly described. The terms “about” or “approximately” as used herein denote deviations from the exact value by +/−10%, preferably by +/−5% and/or deviations in the form of changes that are insignificant to the function. 
     With reference to  FIGS. 1-5 , a moldable wrist brace  10  is described in accordance with an exemplary embodiment. The brace  10  is described herein with respect to applications in which the brace  10  is configured for use on the wrist of a user for at least partially supporting the hand and/or wrist. However it is understood that the brace  10  may be configured for application to a variety of other body parts, such as the ankle, without departing from the scope of embodiments described herein. 
     The brace  10  includes a body panel  12  formed from a plurality of material swatches including an exterior body swatch  14  and an interior body swatch  16 . The exterior and interior body swatches  14 ,  16  have substantially the same overall outline or form, but for a flap  18  included on the interior body swatch, and are configured to wrap around the wrist of a user. Both the exterior body swatch  14  and the interior body swatch  16  form a thumbhole  19  extending therethrough. The thumbhole  19  is sized large enough to enable full dexterity of the user&#39;s thumb and to avoid application of pressure on the carpometacarpal joint of the user. 
     The exterior body swatch  14  is layered on the interior body swatch  16  and is coupled thereto, such as by sewing along three edges of the exterior body swatch  14 . One edge (the bottom edge as shown in  FIG. 1 ) of the exterior body swatch  14  is left uncoupled to the interior body swatch  16  to form an opening  20  into a pocket  22  formed between the swatches  14 ,  16 . One or more additional stitch lines  24  may be provided to further define the size and/or shape of the pocket  22 , further couple the swatches  14 ,  16 , and/or to act as additional stiffeners for the body panel  12 . 
     The exterior and interior body swatches  14 ,  16  are preferably comprised of materials such as a neoprene, a nylon, and/or a spandex material and may incorporate three-dimensional knitted fabrics. The materials preferably include antibacterial and or anti-odor properties and are hypoallergenic. The materials may be selected to enhance comfort, breathability, insulation, compression, durability, and recovery among other characteristics. 
     The flap  18  extends beyond a first side edge  25  of the exterior body swatch  14 . The flap  18  is sized to substantially span a gap between the opposing side edges of the exterior body swatch  14  when the brace  10  is wrapped around the wrist of a user. Although, the flap  18  is described herein as comprising a portion of the interior body swatch  16 , the flap  18  might alternatively be formed by the exterior body swatch  14 , both the exterior and interior body swatches  14 ,  16 , or a separate swatch coupled to the body panel  12 . 
     A plurality of straps  26  are coupled to the body panel  12  near a second side edge  27 , opposite the flap  18 . The straps  26  can be configured to employ an available coupling technique, including buckles, snaps, ties, or the like, but preferably comprise hook-and-loop fasteners. The straps  26  are also preferably formed from generally non-extensible materials, but are not necessarily so limited. As depicted in  FIGS. 1-5 , the straps  26  are each comprised of two sections, a loop section  28  and a hook section  30 , each formed with the respective component of a hook-and-loop fastener. The loop section  28  is coupled at a first end to the exterior body swatch  14  near the second side edge  27 . A second end of the loop section  28  is coupled to the hook section  30  at a location spaced apart from, but near a first end of the hook section  30 . The first end of the hook section  30  thus overlaps at least a portion of the loop section  28 . The first end is folded back onto itself to form a loop or locking tab  32  that overlies the loop section  28  of the strap  26 , as depicted in  FIG. 5 . In another embodiment, the first end is not folded back onto itself and the locking tab  32  is thus formed by the free first end of the hook section  30 . The locking tab  32  deflects at least partially away from the plane of the loop section  28 . 
     A coupling swatch  34  is applied over a portion of the exterior body swatch  14  and overlaps the first ends of the straps  26 . The coupling swatch  34  may be configured for engagement by the hook section  30  of the straps  26 . 
     A plurality of buckles  36  are coupled along and/or adjacent the first edge  25  of the exterior body swatch  14  adjacent the flap  18 . The buckles  36  are positioned for engagement by respective ones of the straps  26  when the brace  10  is wrapped around the wrist of the user. The buckles  36  comprise loops or rings, such as plastic or metal generally rectangular rings, coupled to the body panel  12  by a securement  38  comprising a short section of non-extensible material that is folded onto itself to pass through the buckle  36 ; ends of the securement  38  are attached to the exterior body swatch  14 . It is understood that the buckles  36  may take a variety of forms depending on the form of the straps  26  and the coupling mechanism provided thereby. All such forms are within the scope of exemplary embodiments described herein. 
     A reinforcing swatch  40  is disposed on the exterior body swatch  14  near the attachment of the securement  38  to the exterior body swatch  14 . The reinforcing swatch  40  reinforces the exterior body swatch  14  against forces applied thereto by the buckles  36  and securements  38  when tension is placed thereon. A stay  42  is also installed between the reinforcing swatch  40  and the exterior body swatch  14  to further reinforce the body  10 . 
     A moldable insert  44  is removably installed in the pocket  22 . The insert  44  is comprised of a material, such as a polyvinyl chloride (PVC) material or similar plastic, composite or other material, that is substantially resilient and/or rigid at ambient or room temperatures. However, when heated, the material can be formed into a desired shape and then cooled to regain the original resilience or rigidity. The insert  44  is shaped to generally follow the perimeter of the pocket  22  so as to be insertable therein. The insert  44  and the pocket  22  are configured to extend substantially the full length of the brace  10  (extending generally parallel to and along the first and second edges  25 ,  27 ) to maximize the length along the wrist of the user that is supported thereby. The insert  44  and pocket  22  are also configured to wrap around about two-thirds of the circumference of the wrist of the user, however the insert  44  and pocket  22  may extend a further or lesser extent around the wrist. A fastener  46 , such as a hook-and-loop faster may be provided along the opening  20  of the pocket  22  to retain the insert within the pocket  22 , as depicted in  FIGS. 1 and 3 . 
     With continued reference to  FIGS. 1-5 , use of the moldable wrist brace  10  is described in accordance with an exemplary embodiment. The brace  10  may be provide in a variety of sizes to accommodate users of all sizes and/or body parts of all sizes. An appropriately sized brace  10  is selected for the user. If installed in the pocket  22 , the insert  44  is removed from the pocket  22  and heated using, for example, an oven, a heat tray, a heat gun, or hot water to a temperature at which the insert material becomes at least partially pliable. For example, if the insert  44  is comprised of a PVC material, the material may become pliable at temperatures above about 71° C. Once the insert  44  has been sufficiently heated it is removed from the heat source and may be allowed to cool for a short time period, e.g. about 15 seconds. 
     The user&#39;s wrist or other body part on which the brace  10  is to be worn may be covered with a stockinette or other thin, cloth-like material to provide at least a partial barrier against the heat of the insert  44 . The material should not be overly thick so as to avoid interfering with molding of the insert  44  to the form of the user&#39;s wrist. The heated insert  44  is placed on the user&#39;s wrist and gently molded by hand to follow the form of the wrist. The insert  44  is maintained on the wrist until it is no longer substantially pliable. The insert  44  can then be removed and allowed to cool. If desired the insert  44  can be reheated and remolded to the user&#39;s wrist. In another embodiment, the material comprising the insert  44  may not be remoldable. 
     The molded insert  44  is installed into the pocket  22  and the fastener  46  fastened to retain the insert  44  therein. The brace  10  is applied to the user&#39;s wrist by inserting the thumb of the user through the thumbhole in the body panel  12 . The body  10  is wrapped around the user&#39;s wrist with the flap  18  positioned against the wrist and overlapped by the second edge  27  of the body panel  12 . In one embodiment, the heated insert  44  is installed in the pocket  22  and the body  10  is applied to the user&#39;s wrist to mold the insert  44  to the user&#39;s wrist. 
     The distal ends of the straps  26  are inserted through the buckles  36  a distance sufficient to draw the locking tabs  32  thereon through the buckles  36 . As the locking tab  32  moves through the buckle  36  the locking tab  32  is pressed toward the loop section  28  of the strap  26  and lies generally parallel to the loop section  28 . Upon passing through the buckle  36  the locking tab  32  deflects at least partially away from the loop section  28  with the end thereof (e.g. the loop formed by the first end of the hooked section  30 ) being directed toward the buckle  36 . 
     When the strap  26  is moved to withdraw from the buckle  36  the locking tab  32  contacts and is deflected away from the loop section  28  by the buckle  36 . Interaction between the locking tab  32  and the buckle  36  thus resists withdrawal of the strap  26  from the buckle  36 . As such, a user is aided in donning the brace  10 , especially when doing so one-handed, because the straps  26  are retained in engagement with the buckles  36 . The user can thus slide on the brace  10  by inserting the hand into the pre-wrapped brace  10  rather than being required to wrap the brace  10  around the wrist. 
     To remove the straps  26  from the buckles  36 , the locking tab  32  can be held against the loop section  28  and inserted through the buckle  36 . Or additional withdrawal force may be applied to the strap  26  to cause the locking tab  32  to be folded onto the hook section  30  and forced through the buckle  36 . This method may require additional force because four layers of the strap  26  (e.g. three layers of the hook section  30  and one layer of the loop section  28 ) must be forced through the opening in the buckle  36 . 
     As depicted in  FIG. 4 , after passing through the buckles  36 , the straps  26  are folded back onto themselves to engage the hook section  30  with the loop section  28  and complete securement of the brace  10  on the wrist. The straps  26  may be pulled as tightly as desired by the user to provide the desired level of compression and support to the wrist. The distal end of one or more of the straps  26  may extend beyond the first end of the respective loop section  28 ; the additional length of the hook section  30  may engage the coupling swatch  34  and couple thereto. Such may avoid the distal ends of the straps  26  from extending away from the exterior of the brace  10  and being bothersome by catching on clothing or other items. 
     Many different arrangements of the various components depicted, as well as components not shown, are possible without departing from the scope of the claims below. Embodiments of the technology have been described with the intent to be illustrative rather than restrictive. Alternative embodiments will become apparent to readers of this disclosure after and because of reading it. Alternative means of implementing the aforementioned can be completed without departing from the scope of the claims below. Identification of structures as being configured to perform a particular function in this disclosure and in the claims below is intended to be inclusive of structures and arrangements or designs thereof that are within the scope of this disclosure and readily identifiable by one of skill in the art and that can perform the particular function in a similar way. Certain features and sub-combinations are of utility and may be employed without reference to other features and sub-combinations and are contemplated within the scope of the claims.