IP Library Granted Patent US 12697240
Granted Patent B2
US 12697240 · App. 18/106,364 · Granted Aug 4, 2026

Modular support system

Inventors: Bryan Shepherd (Selbyville, DE); Eugene Welch (Ellicott City, MD); Morris Brian Polsky (Reisterstown, MD); Edward Spirko (Millsboro, DE)
Assignee: Ortho Innovations, LLC
A61F5/0106A47C20/021A61F2005/0167A61F5/0585
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Quick Facts
Patent No.
US 12697240
App. No.
18/106,364
Granted
Aug 4, 2026
Kind
B2
Abstract

A modular knee brace assembly includes a brace and a wedge. The brace comprises a sleeve portion comprising a first opening at a first end of the sleeve portion and a second opening at a second end of the sleeve portion, the first opening and the second opening adapted to enable a first portion of a user's body to pass through the sleeve portion and a second portion of the user's body to remain within the sleeve portion and a first mating unit comprising a plurality of discrete attachment points coupled to an outer surface of the sleeve portion. The wedge comprises a second mating unit, wherein the second mating unit is adapted to couple with a set of the plurality of discrete attachment points to support one or more portions of the user's body.

Claims (42)

1 . A modular support system, comprising:

a brace comprising:

a sleeve portion extending in a length direction between a first opening at a first end of the sleeve portion and a second opening at a second end of the sleeve portion, the first opening and the second opening adapted to enable a first portion of a user's body to pass through the sleeve portion and a second portion of the user's body to remain within the sleeve portion, the sleeve portion extending about the first and second openings in a circumferential direction; and

a first mating unit comprising a plurality of discrete attachment points coupled to an outer surface of the sleeve portion, the discrete attachment points including a first set of the discrete attachment points and a second set of the discrete attachment points being spaced from one another in the length direction, wherein each of the first and second sets of the discrete attachment points are arranged as an array with a plurality of the discrete attachment points in a plurality of rows in the length direction, and a plurality of the discrete attachment points in the circumferential direction about the sleeve portion, and wherein the first and second sets of the discrete attachment points span around an entire circumference of the sleeve portion; and

a wedge comprising:

a second mating unit, wherein the second mating unit is adapted to couple with a set of the plurality of discrete attachment points to support one or more portions of the user's body.

2 . The modular support system of claim 1 , wherein the wedge further comprises an inner support comprising:

a first lateral surface that is concavely arcuate configured to conform to a curvature of a portion of the user's body adjacent a joint; and

a third mating unit coupled to the first lateral surface, wherein the third mating unit is removably coupled to the sleeve portion such that the inner support is positioned on the portion of the user's body at a medial side of the joint.

3 . The modular support system of claim 2 , wherein the wedge further comprises an outer support comprising:

a second lateral surface that is concavely arcuate configured to conform to the curvature of the portion of the user's body adjacent the joint; and

a fourth mating unit coupled to the second lateral surface, wherein the fourth mating unit is removably coupled to the sleeve portion such that the outer support is positioned on the portion of the user's body at a lateral side of the joint.

4 . The modular support system of claim 3 , wherein the fourth mating unit is adapted to couple with another set of the plurality of discrete attachment points to support the one or more portions of the user's body.

5 . The modular support system of claim 2 , wherein the third mating unit is adapted to couple with another set of the plurality of discrete attachment points to support the one or more portions of the user's body.

6 . The modular support system of claim 2 , wherein the inner support further comprises:

a second lateral surface that is concavely arcuate configured to conform to the curvature of the portion of the user's body adjacent another joint; and

a fourth mating unit coupled to the second lateral surface, wherein the fourth mating unit is removably coupled to a sleeve portion of a second brace such that the inner support is positioned on the portion of the user's body at a medial side of the other joint.

7 . The modular support system of claim 1 , wherein the sleeve portion further defines an opening for at least a portion of a joint.

8 . The modular support system of claim 7 , wherein the first set of the plurality of discrete attachment points are coupled to the outer surface of the sleeve portion in a section of the sleeve portion adjacent a first side of the opening and the second set of the plurality of discrete attachment points are coupled to the outer surface of the sleeve portion in a section of the sleeve portion adjacent a second side of the opening, wherein the first side is opposite the second side.

9 . The modular support system of claim 1 , wherein the plurality of discrete attachment points of each of the first and second sets are substantially evenly spaced from one another in the circumferential direction.

10 . The modular support system of claim 1 , wherein each discrete attachment point in a first row of the plurality of rows of each of the first and second sets of discrete attachment points is substantially aligned with a corresponding discrete attachment point in a second row of the plurality of rows of each of the first and second sets of discrete attachment points.

11 . The modular support system of claim 1 , wherein each discrete attachment point in a first row of the plurality of rows of each of the first and second sets of discrete attachment points is substantially staggered from one or more discrete attachment points in a second row of the plurality of rows of each of the first and second sets of discrete attachment points.

12 . The modular support system of claim 1 , wherein the plurality of discrete attachment points are substantially shaped as: a circle, an oval, a triangle, a square, a rectangle, a hexagon, an octagon, a decagon, a semi-hexagon, a semi-octagon, a semi-decagon, or any combination thereof.

13 . The modular support system of claim 1 , wherein the wedge further comprises a first top surface, a second top surface, and a peak, the first top surface adjoining the second top surface to form the peak, and wherein the second mating unit is coupled to the first top surface and the second top surface and is adapted to couple with the set of the plurality of discrete attachment points such that the peak aligns with a back portion of a joint of the user's body.

14 . The modular support system of claim 1 , wherein the first and second sets of attachment points are spaced from one another by a joint region of the sleeve configured to overlie a joint of the user during use.

15 . The modular support system of claim 1 , wherein the first and second sets of the discrete attachment points include two rows of the attachment points.

16 . A modular support system, comprising:

a brace comprising:

a sleeve portion extending in a length direction between a first opening at a first end of the sleeve portion and a second opening at a second end of the sleeve portion, the first opening and the second opening adapted to enable a first portion of a user's body to pass through the sleeve portion and a second portion of the user's body to remain within the sleeve portion;

a first mating unit comprising a plurality of discrete attachment points coupled to an outer surface of the sleeve portion, the discrete attachment points including a first set of the discrete attachment points, a second set of the discrete attachment points and a third set of discrete attachment points being spaced from one another in the length direction, wherein each of the first, second and third sets of the discrete attachment points are arranged as an array with a plurality of the discrete attachment points arranged in a plurality of rows in the length direction and a plurality of the discrete attachment points dispersed in a circumferential direction about the sleeve portion; and

a wedge comprising:

a second mating unit, wherein the second mating unit is adapted to couple with a set of the plurality of discrete attachment points to support one or more portions of the user's body.

17 . The modular support system of claim 16 , wherein the first set of the plurality of discrete attachment points are coupled to the outer surface of the sleeve portion in a section of the sleeve portion adjacent a first side of the opening and the second set of the plurality of discrete attachment points are coupled to the outer surface of the sleeve portion in a section of the sleeve portion adjacent a second side of the opening, wherein the first side is opposite the second side.

18 . The modular support system of claim 17 , wherein the first and second sets of the discrete attachment points span around an entire circumference of the sleeve portion.

19 . The modular support system of claim 16 , wherein the first and second sets of the discrete attachment points span around an entire circumference of the sleeve portion.

20 . A modular support system, comprising:

a brace comprising:

a sleeve portion extending in a length direction between a first opening at a first end of the sleeve portion and a second opening at a second end of the sleeve portion, the first opening and the second opening adapted to enable a first portion of a user's body to pass through the sleeve portion and a second portion of the user's body to remain within the sleeve portion, the sleeve portion extending about the first and second openings in a circumferential direction;

a first mating unit comprising a plurality of discrete attachment points coupled to an outer surface of the sleeve portion, the plurality of discrete attachment points includes a first set of the discrete attachment points and a second set of the discrete attachment points separated from one another in the length direction, wherein the discrete attachment points of each of the first and second sets are arranged in a plurality of rows and are substantially evenly spaced from each other in the circumferential direction;

wherein the sleeve portion defines a joint opening between the first and second sets of discrete attachment points for receiving a user's joint;

a wedge comprising:

a second mating unit, wherein the second mating unit is adapted to couple with a set of the plurality of discrete attachment points to support one or more portions of the user's body.