Adjustable hinge for orthopedic brace

1. A medical device comprising:

an adjustable hinge for an orthopedic brace, the adjustable hinge including:

a housing;

a first member rotatably supported by the housing, the first member having a first gear portion pivotable about a first axis, the first gear portion having a first plurality of teeth and first and second cam surfaces;

a second member rotatably supported by the housing, the second member having a second gear portion pivotable about a second axis, the second axis parallel and spaced apart from the first axis, the second gear portion having a second plurality of teeth engageable with the first plurality of teeth;

a first control device rotatably supported on the housing, the first control device having a third cam surface, the third cam surface selectively rotatable in and out of engagement with the first cam surface and controlling a range of motion of the first and second gear portions in a first rotational direction; and

a second control device rotatably supported on the housing, the second control device having a fourth cam surface, the fourth cam surface selectively rotatable in and out of engagement with the second cam surface and controlling a range of motion of the first and second gear portions in a second rotational direction opposite to the first rotational direction.

2. The medical device of claim 1 , wherein the first and second members include corresponding first and second recesses receiving first and second brace arms couplable with the orthopedic brace, the first and second brace arms respectively pivotable about the first and second axes.

3. The medical device of claim 1 , wherein the third and fourth cam surfaces are formed on corresponding first and second cam extensions of the first and second control devices.

4. The medical device of claim 3 , wherein rotational positions of the first and second cam extensions determine a range of motion of the first and second gear portions respectively in flexion and extension/overextension.

5. The medical device of claim 3 , wherein first and second control devices include first and second driver engagement formations for rotating the first and second cam extensions.

6. The medical device of claim 1 , further comprising first and second spring washers surrounding the corresponding first and second control devices and biasing the first and second control devices axially against the housing.

7. A medical device comprising:

an orthopedic brace for an anatomic joint;

an adjustable hinge coupled to the brace and controlling a range of motion of the anatomic joint, the adjustable hinge including:

first and second gear portions rotatable about first and second axes, the first and second axes parallel to and spaced apart from one another, the first and second axes perpendicular to the first and second gear portions, the first gear portion including a first cam surface; and

a flexion control device having a flexion cam surface, the flexion control device selectively rotatable about a third axis parallel to the first and second axes, the flexion cam surface engaging the first cam surface of the first gear portion at a selected angle of flexion of the anatomic joint and preventing further flexion; and

first and second brace arms connected to the orthopedic brace at opposite sides to the anatomic joint, the first and second brace arms coupled to and rotatable with the first and second gear portions.

8. The medical device of claim 7 , further comprising an extension control device having an extension cam surface, the extension control device rotatable about a fourth axis parallel to the first and second axes, the extension cam surface engaging a second cam surface of the first gear portion at a selected angle of extension/overextension and preventing further extension.

9. The medical device of claim 8 , further comprising a housing rotatably supporting the first and second gear portions, the flexion control device and the extension control device.

10. The medical device of claim 8 , wherein each of the flexion control device and the extension control device includes a driver engagement formation extending through an outer surface of the housing.

11. The medical device of claim 7 , wherein a portion of the first brace arm is received in a conforming recess of the first gear portion and is rotatable about the first axis, and wherein a portion of the second brace arm is received in a conforming recess of the second gear portion and is rotatable about the second axis.

12. The medical device of claim 7 , further including a spring washer coupled to the flexion control device and biasing the flexion control device along the third axis.

13. The medical device of claim 12 , further comprising a friction washer coupled to the flexion control device opposite the spring washer.

14. The medical device of claim 7 , wherein the first gear portion includes a first plurality of teeth meshingly engaged with a second plurality of teeth of the second gear portion.

15. A method of controlling a range of motion of an anatomic joint, the method comprising:

attaching a first brace portion to a first anatomic member of an anatomic joint;

attaching a second brace portion to a second anatomic member of the anatomic joint;

connecting the first brace portion to a first brace arm;

connecting the second brace portion to a second brace arm;

coupling the first brace arm to an adjustable hinge for rotation about a first pivot axis of the adjustable hinge;

coupling the second brace arm to the adjustable hinge for rotation about a second pivot axis of the adjustable hinge, the second pivot axis parallel to the first pivot axis; and

rotating a flexion control device of the adjustable hinge about a third pivot axis parallel to the first and second pivot axes by a first selected degree of rotation; and

limiting a range of flexion between the first and second brace arms based on the selected degree of rotation.

16. The method of claim 15 , further comprising:

rotating an extension control device of the adjustable hinge about a fourth pivot axis parallel to the first and second pivot axes by a second selected degree of rotation; and

limiting a range of extension between the first and second brace arms based on the second selected degree of rotation.

17. The method of claim 15 , wherein limiting a range of flexion between the first and second brace arms based on the first selected degree of rotation includes engaging a first cam surface of the first gear portion with a cam surface of the flexion control device.

18. The method of claim 16 , wherein limiting a range of extension between the first and second brace arms based on the second selected degree of rotation includes engaging a second cam surface of the first gear portion with a cam surface of the extension control device.

19. The method of claim 15 , wherein rotating a flexion control device includes engaging a driver engagement formation of the flexion control device with a driver tool through an outer surface of a housing of the adjustable hinge.

20. The method of claim 16 , wherein rotating an extension control device includes engaging a driver engagement formation of the extension control device with a driver tool through an outer surface of a housing of the adjustable hinge.