Support brace
Support braces and methods of manufacturing the same are disclosed. A support brace includes a flexible fabric substrate and an elastomeric member disposed on the surface of the flexible fabric substrate. The elastomeric member is disposed so as to apply pressure non-uniformly about a limb or joint of the wearer, in a pattern selected to divert pain and/or reduce loads on the joint. The flexible fabric substrate can include regions having different levels of elasticity, to provide different levels of compression to different parts of the joint or limb in addition to the compression provided by the elastomeric member. The elastomeric member can be deposited, screen printed, injection molded, or otherwise applied to the fabric substrate, optionally without adhesive.
1. A knee brace comprising:
a flexible fabric substrate configured to encircle the knee of a wearer and to extend above and below the wearer's knee;
a first elastomeric member secured to an outward-facing surface of the flexible fabric substrate, the first elastomeric member extending through an arc of between 180 and 320 degrees about the wearer's patella and being configured to reduce loads on the knee joint;
a second elastomeric member spaced apart from the first elastomeric member and secured to the outward-facing surface of the flexible fabric substrate, the second elastomeric member being disposed medially of the wearer's patella; and
a third elastomeric member disposed entirely to one of a lateral or medial side of the wearer's patella and secured to an inward-facing surface of the flexible fabric substrate that is configured to face the knee of the wearer in an opposite direction from the outward-facing surface, the third elastomeric member comprising:
a first portion configured to extend substantially longitudinally along the lateral or medial side of the wearer's patella;
a plurality of bars, each extending from a different respective position on the first portion that is proximal of the wearer's patella and each configured to extend laterally away from the wearer's patella, and
an additional bar extending substantially diagonally and laterally away from the wearer's patella from a position on the first portion that is distal of the plurality of bars.
2. The knee brace of claim 1 , wherein the first elastomeric member is configured to apply pressure non-uniformly about the wearer's patella.
3. The knee brace of claim 1 , wherein the first elastomeric member is configured to apply a frontal plane force so as to decrease pressure in at least one of the medial and lateral knee compartments.
4. The knee brace of claim 1 , wherein at least a portion of the first elastomeric member extends laterally of the wearer's patella.
5. The knee brace of claim 1 , wherein the third elastomeric member has a dimpled surface.
6. The knee brace of claim 1 , wherein the first elastomeric member comprises silicone.
7. The knee brace of claim 1 , wherein the first elastomeric member has a thickness of between about 0.3 mm and about 5 mm.
8. The knee brace of claim 1 , wherein the flexible fabric substrate comprises a generally tubular sleeve.
9. The knee brace of claim 1 , wherein the flexible fabric substrate comprises a wrap-around.
10. The knee brace of claim 1 , wherein the flexible fabric substrate comprises at least a first region and a second region, the second region having a higher modulus of elasticity than the first region.
11. The knee brace of claim 1 , wherein the first elastomeric member is joined to the flexible fabric substrate without adhesive.
12. A method of manufacturing a knee brace, the method comprising:
providing a flexible fabric substrate configured to encircle the knee of a wearer and to extend above and below the wearer's knee;
securing a first elastomeric member to an outward-facing surface of the flexible fabric substrate in a pattern selected to reduce loads on the knee joint, the first elastomeric member extending through an arc of between 180 and 320 degrees about the wearer's patella;
securing a second elastomeric member to the outward-facing surface of the flexible fabric substrate such that the second elastomeric member is spaced apart from the first elastomeric member and disposed medially of the wearer's patella; and
securing a third elastomeric member to an inward-facing surface of the flexible fabric substrate that is entirely to one of a lateral or medial side of the wearer's patella and configured to face the knee of the wearer in an opposite direction from the outward-facing surface, the third elastomeric member comprising:
a first portion configured to extend substantially longitudinally along the lateral or medial side of the wearer's patella;
a plurality of bars, each extending from a different respective position on the first portion that is proximal of the wearer's patella and each configured to extend laterally away from the wearer's patella; and
an additional bar extending substantially diagonally and laterally away from the wearer's patella from a position on the first portion that is distal of the plurality of bars.
13. The method of claim 12 , wherein the first elastomeric member is applied by an injection molding process.
14. The method of claim 12 , wherein the first elastomeric member is applied to a thickness of between about 0.3 mm and about 5 mm.