[0001] The invention relates to body braces and other orthotic devices used in the treatment of spinal disorders and/or used subsequent to surgery where flexing of the torso is to be minimized. More particularly, the invention relates to back brace apparatus and orthotic devices for partial or substantial immobilization of portions of the torso, the devices having multiple modes of adjustment facilitating both rapid donning and doffing and individualized adjustment to fit the user of the device.
[0002] A common method of alleviating pain in people suffering from back injuries and promoting healing in post-operative back surgery patients is to stabilize the spine by means of an orthosis, such as a brace. Such braces include a multitude of materials and designs which can be snugly fitted around the patient's trunk. The back portion of such orthosis may also be provided with pockets into which are inserted lordotic pads for treating spinal lordosis.
[0003] Such braces are effective in achieving spinal stability if worn properly and consistently; however, most patients have difficulty in manually adjusting the brace to fit tightly enough to provide adequate support. This is especially true in the case of post-operative patients who are generally in pain and frequently lack sufficient strength to make the necessary adjustments. This is also true when the devices cover a large portion of the torso or when materials used in the construction of the orthoses are rigid. For many patients suffering spinal ailments, these braces are also difficult to don, appropriately position and fasten and subsequently remove. This is also particularly true when the devices are large or cumbersome or when they are constructed from rigid materials. In addition, because of the structures of many of these devices and/or the choice of materials used in their construction, the orthoses are quite uncomfortable, in many instances inducing extensive perspiring and/or chafing. Without being consistently worn and properly adjusted, such patient non-compliance obviously reduces the effectiveness of the brace.
[0004] Another frequently encountered problem with these types of braces is their inability to conform to the torso as the patient moves from a standing to a sitting position or vice versa. Thus, although such a device may have been properly adjusted initially, the patient is required to make any necessary adjustments manually to vary the tension, depending on whether the patient is standing or sitting. Similar situations and corresponding adjustments may be required as, or shortly after, a meal is consumed or digested. In addition, it is often difficult to adjust the brace to have exactly the same amount of tension that a patient previously found acceptable or even to set a particular tension for a particular patient.
[0005] Advances have been made in recent years to provide orthotic devices which can be more easily adjusted to the individual patient and readjusted when their physical position changes. Thus, in U.S. Pat. No. Re 35,940 an electromechanical back brace apparatus is described which is provided with an electromechanical mechanism for tightening the brace around the trunk of the patient to a desired tension. A cable and pulley arrangement is tightened by a small motor to provide the desired tension in the brace. A microprocessor is also provided to control the motor to obtain desired repeatable tension settings. While such a device facilitates rapid and repeatable adjustment of such a brace, the inclusion of an electromechanical mechanism and a microprocessor increases the cost of such a device to a patient or to their medical insurance program. In addition, there is the need to periodically replace batteries to power the electrically operated components.
[0006] In some situations larger orthotic devices are necessary either because the portion of the torso being supported constitutes a large volume or because the user of the device is large. In such situations, a single means for tensioning the device over a large area proves somewhat ineffective since the dimensions of the portion of the torso being supported or in which there is contact with the device vary significantly. That is, a single means of adjustment may not provide the necessary conformity to the physical profile of the patient or may provide too little tension or support to achieve the orthotic objectives with respect to a specific portion of the torso while imparting excessive tension or pressure to other parts of the torso.
[0007] Accordingly, it is an object of the present invention to provide orthotic devices which result in greater patient compliance since the key to successful orthotic treatment is patient compliance. The attributes of an effective orthotic device which induces patient compliance includes ease of donning an doffing the device, ease of adjusting the device, comfort to the wearer of the device, and effective heat dissipation. More specifically, it is a primary object of this invention to provide orthoses which may be tightened around the torso of a patient to provide the necessary support with the minimal physical effort required on the part of the patient.
[0008] It is another object of the invention to provide orthoses which are easily donned and doffed. It is a further object of the present invention to include individual controls for adjustment and custom fitting of different parts of the orthotic device. It is an additional object to provide substantially the same pressure to all portions of the torso supported by the orthosis.
[0009] It is another object of the present invention to provide multiple modes of adjustment to achieve individualized adjustment of various portions of orthosis. It is still another object of the present invention to provide multiple and independent means of adjustment of various portions of an orthotic device. It is yet another object of the present invention to provide a rigid back brace apparatus having a significant mechanical advantage that may be individually adjusted to a desired tension and conformity to an individual patient's dimensions.
[0010] It is yet another object of the present invention to provide a thoracic lumbar sacral orthosis (TLSO) which is provided with multiple means of adjustment for individually fitting to a patient.
[0011] It is another object of the invention to provide an orthotic device which is capable of being rapidly adjusted and, where appropriate, readjusted to an appropriate tension. It is another object of the present invention to provide an orthotic device to be easily disassembled to clean component parts of the device. It is also an object of the invention to provide orthoses which are comfortable and which readily dissipate body heat.
[0012] The present invention is directed to braces and orthotic devices which result in significantly increased patient compliance. This is attributable to orthoses that are both easily donned and doffed as well as being easily and rapidly adjustable to accommodate changes in the position of a wearer of the device. The orthotic devices of the invention include multiple modes of adjustment which are independently adjustable to accommodate and conform to varying physical profiles of a user of the device as well as to accommodate a change in the position of the torso about which the devices are secured. The devices of the invention provide greater patient comfort and adjustability and result, therefore, in greater patient compliance. Preferably, component parts of the devices may be easily dissembled and assembled for cleaning.
[0013] The orthotic devices of the present invention, include an orthosis or brace body adapted to be wrapped around the torso or trunk of a user, the brace body including at least two segments. Fasteners are provided at the distal or outer ends of the segments of the brace body to detachably secure the ends around a user's torso. At least two cables are operatively connected to the at least two segments. The orthotic devices include at least two independent sets of pulleys, each set mounted on adjacent sides of opposing segments with each cable running through a pulley on each adjacent segment in series and in alteration, shortening of each cable pulling the adjacent segments together and tightening the brace apparatus with the aid of mechanical advantage dependent upon the number of pulleys mounted in each set of pulleys on each brace segment.
[0014] In one embodiment of the invention, the brace body includes at least two segments and employs at least two independent sets of pulleys arranged vertically with one set disposed above the other(s). In another embodiment of the invention, at least two sets of pulleys are arranged horizontally with one set disposed in opposition to the other(s). In each of these embodiments, several separate and independent means of adjustment are provided, preferably including separate adjusters for each pulley set.
[0015] In the latter embodiment of the invention, the brace body includes at least three brace body segments and at least two independent pulley sets with at least one set of pulleys securing a centrally disposed brace body segment to a first lateral segment at one side of the central brace segment and at least one other set of pulleys joining the centrally disposed brace segment to a second lateral brace segment disposed at an opposing side of the central brace segment.
[0016] To facilitate disassembly and cleaning of the devices of the invention, many of the component parts are preferably constructed to be easily detached and separated from other component parts. This includes each pulley set and its connecting cable. Thus, in a preferred embodiment, each set of pulleys comprises two modular banks of pulleys which are detachably secured to adjacent brace segments. A cable is provided to connect pulleys in the opposing banks of pulleys in a set in series and in alteration. The ends of each cable preferably may be joined to form an endless cable or are attached to a handle which also achieves the effect of an endless cable. Preferably, the handle may be removed from the body of the device when the modular banks of a pulley set are removed.
[0017] Although useful for custom fitting the orthotic device to the physical profile of an individual wearing the device, in most situations, the individualized control of adjustment and fitting of orthotic devices according to the invention is also quite effective when the device is intended to cover a large portion of the torso of the wearer or the wearer is tall. Thus, it has been found that attempting to provide both the necessary support with the appropriate tension as well as providing sufficient comfort to the wearer of a brace or other orthotic device frequently falls short when a single means of control is provided to adjust the tension of the device to suitably support and comfortably fit the affected portion of the torso, particularly when the extent of support extends over a large region of the torso in the longitudinal direction of the body of the user wearing the device or when the orthosis is constructed of rigid materials. Providing a plurality of separate adjustment devices, as in the invention, preferably at least two separate means of adjustment, allows for individualized fitting for appropriate support and comfort over the surface area covered by the device.
[0018] To improve appropriate support when used as a back brace, such as in a body jacket, an embodiment of the present invention includes a modular lordotic pad system. The system includes one or more flexible and compressible pads having a size and contour appropriate to the dimensions of the wearer of the device, preferably located in the portion of the brace corresponding to the lumbar region of the back.
[0019] Other objects, features and advantages will become evident in light of the following detailed description, considered in conjunction with the referenced drawings of preferred embodiments according to the present invention. It should be understood that these drawings are exemplary only and should not be construed as limiting the invention in any way.
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[0034] It may be noted that the term “rigid”, as used herein to describe materials from which the orthoses of the invention are constructed, does not mean totally inflexible or unyielding, since many of materials employed can be bent when a sufficient force is applied to a surface of the material. These materials typically resume their original configurations when the deforming force is removed, however. As used in describing the materials from which the invention is constructed, rigidity refers to a resistance to deformation exhibited when in use, orthoses constructed of such materials are not bent or deformed when someone wearing the device bends in a fore or aft direction or in a lateral direction using a force to move in such direction which is considered not to be excessive for that person.
[0035] In a preferred embodiment of the brace body
[0036] The preferred tension adjusters used to custom fit the orthotic devices of the present invention to the profile of the individual wearer of these orthotic devices are shown in preferred embodiments illustrated in
[0037] The number of pulleys provided in each bank of pulleys is determined by such factors as the amount of space provided for pulleys within each bank and the mechanical advantage being sought. The size of the particular bank of pulleys is determined in part by the size of the orthotic device and manufacturing considerations. Larger devices allow for concomitantly larger pulley sets and their respective banks of pulleys. The appropriate mechanical advantage is determined with a consideration of the strength of the user or the type of ailment necessitating the use of the orthotic device, the rigidity of the orthosis being adjusted, the volume of the torso covered by the device, portion thereof being adjusted. Generally, each pulley system used in the orthoses of the invention is constructed with an appropriate number of pulleys to provide a minimum of effort to achieve abdominal compression but not high enough to cause injury by over-tensioning the orthosis. Typically, this equates to a mechanical advantage for each pulley system in the range of about 4:1 to about 30:1. For those devices which require less effort to tighten, such as smaller orthoses and those formed from compliant materials such as those used only to treat the lumbar region of a patient, a mechanical advantage of about 4:1 to about 8:1 is preferred. For orthoses which are larger or are constructed at least in part from rigid material, such as body jackets, a mechanical advantage of about 6:1 to about 18:1 is preferred. In orthotic devices which are very large or are substantially rigid because of the rigid nature of the materials from which they are constructed or the number of rigid component parts, such as thoracic lumbar sacral orthoses, a mechanical advantage of about 12:1 to about 30:1 is preferred.
[0038] As illustrated in
[0039] Each bank of pulleys
[0040] Although the individual pulleys may be secured directly to the material from which the brace body
[0041] Although each of the pulleys in a bank may be of the same size and spaced from the next adjacent pulley, a greater force is achieved. Accordingly, in situations where the nature of the anatomy varies in the area over which the pulley set extends, an embodiment such as that illustrated in
[0042] By forming the pulley sets
[0043] Each pulley bank
[0044] To apply appropriate support and pressure to portions of the spine, as required by the patient's condition, a preferred embodiment of the invention includes appropriately configured lordotic pads
[0045] Although in many applications it may be unnecessary to provide a lining on the interior surface of the brace body
[0046] In using this embodiment of the invention, the wearer merely places the device
[0047] Although the orthotic devices of the present invention permit custom fitting and adjusting over a wide range of dimensional variables, it is preferred to provide the present invention in a range of sizes to permit an orthotist to tailor individualized fitting of the devices to a wide range of individuals within different size and profile ranges. In a preferred embodiment of the invention, an edge or bias binding
[0048] Another embodiment of the invention is shown in
[0049] The pulley sets
[0050] Orthotic device
[0051] As indicated above, depending upon the particular ailment or medical condition of the patient, the orthoses of the present invention my be formed from either flexible materials or rigid materials. In both of the previously discussed embodiments of the invention, when a rigid body jacket is desirable, either portions of, or the entire device, may be formed of a rigid plastic material, in which the rigidity of the plastic is selected based upon the amount of patient body flexure which can be tolerated for the ailment or prescribed treatment procedure of the user of the device. In many instances, all or a portion of the orthosis, particularly the rear portion of the device, is formed from a rigid plastic material. This is true for rigid body jackets. In many instances, as a result of surgery, forward flexure of the patient is to be minimized or substantially eliminated. In such instances, a physician may prescribe a thoracic lumbar sacral orthosis (TLSO), which is intended to prevent forward flexure of the upper portion of the torso. The body braces of the present invention may be used with additional component parts to form TLSOs which are both easily donned and doffed and include multiple means of adjustment which allow the devices to be individually and separately adjusted to provide extensive posterior and anterior adjustment options, as well as assuring that certain portions of the body brace conform to the profile and body dimensions of the wearer. Although the preferred TLSO orthosis of the invention is discussed herein in terms of a combination with the body brace device
[0052] The three component parts used in addition to and in conjunction with the previously described body brace type of orthotic devices of the invention to form the TLSO devices of the invention include the component parts illustrated in FIGS.
[0053] A substantially rigid breast plate or front piece
[0054] At the lateral upper portions of the body contacting piece
[0055] The back piece
[0056] As illustrated in
[0057] The inner surface of the back piece (as shown in
[0058] When preferred embodiments of the invention are employed, the adjustment piece
[0059] In using the TLSO devices of the present invention, the TLSO component parts e.g., the front piece