Smart brace and hinge assemblies for same

1. A smart brace comprising:

a flexible compressive garment configured to be worn on a limb over a joint, the flexible compressive garment consisting of:

a sleeve consisting of a single continuous loop of material,

a rigid molded upper receptacle fixedly attached to an upper portion of the sleeve, and

a rigid molded lower receptacle fixedly attached to a lower portion of the sleeve; and

a smart hinge removably coupled to the flexible compressive garment, the smart hinge comprising:

a first bar at least partially received within the rigid molded upper receptacle of the flexible compressive garment above the joint, the first bar having a thickness less than about 0.5 mm and a width greater than or equal to about 5.0 mm, and wherein the first bar is configured to rotate about a first axis with flexion or extension of the joint,

wherein the rigid molded upper receptacle comprises an upper slot that removably receives a second end of the first bar to couple the first bar to the upper portion, and

wherein the first bar comprises a first insert overmolded on the first bar between a first end and the second end, the first insert configured to engage with the upper slot, thereby providing a tight fit between the first bar and the upper slot and distributing contact forces between the first bar and the upper slot over a larger surface area to prevent wear therebetween;

a second bar at least partially received within the rigid molded lower receptacle of the flexible compressive garment below the joint, the second bar having a thickness less than about 0.5 mm and a width greater than or equal to about 5.0 mm, and wherein the second bar is configured to rotate about a second axis with flexion or extension of the joint,

wherein the rigid molded lower receptacle comprises a lower slot that removably receives a second end of the second bar to couple the second bar to the lower portion, and

wherein the second bar comprises a second insert overmolded on the second bar between a first end and the second end, the second insert configured to engage with the lower slot, thereby providing a tight fit between the second bar and the lower slot and distributing contact forces between the second bar and the lower slot over a larger surface area to prevent wear therebetween; and

at least one potentiometer comprising a rotatable component that is rotationally coupled to the first bar or the second bar by way of a drive key;

wherein the first bar and the second bar are flexible in a frontal plane such that the first bar and the second bar are configured to be body conforming and low profile and rigid in a sagittal plane such that the first bar and the second bar are configured to accurately gather data related to motion of the joint.

2. The smart brace of claim 1 , wherein the smart hinge is coupled to the flexible compressive garment on a lateral side, and the smart brace further comprises a dummy hinge assembly coupled to the flexible compressive garment on a medial side.

3. The smart brace of claim 2 , wherein the dummy hinge assembly comprises:

a first bar coupled to an upper portion of the flexible compressive garment above the joint, the first bar configured to rotate about a first axis with flexion or extension of the joint; and

a second bar coupled to a lower portion of the flexible compressive garment below the joint, the second bar configured to rotate about a second axis with flexion or extension of the joint;

wherein the first bar and the second bar are flexible in a frontal plane and rigid in a sagittal plane.

4. The smart brace of claim 1 , wherein each of the first bar and the second bar comprise spring steel.

5. The smart brace of claim 1 , wherein:

the first end of the first bar is countersunk within a first gear; and

the first end of the second bar is countersunk within a second gear, the second gear meshingly engaged with the first gear such that rotation of the first bar about the first axis causes a corresponding rotation of the second bar about the second axis.

6. The smart brace of claim 1 , wherein the joint comprises a knee.

7. A low-profile hinge assembly for a smart brace, the hinge assembly comprising:

a first geared arm assembly comprising a first gear and a first bar, a first end of the first bar received flush within a recess of the first gear, wherein the recess of the first gear is identical in size and shape as the first end of the first bar;

a second geared arm assembly comprising a second gear and a second bar, a first end of the second bar received flush within a recess of the second gear, wherein the recess of the second gear is identical in size and shape as the first end of the second bar; and

a hinge plate, the first geared arm assembly connected to the hinge plate for rotation about a first axis and the second geared arm assembly connected to the hinge plate for rotation about a second axis, and the first gear meshingly engaged with the second gear such that rotation of the first geared arm assembly causes a corresponding rotation of the second geared arm assembly;

wherein the hinge plate is coupled with at least one potentiometer comprising a rotatable component that is rotationally coupled to the first bar or the second bar by way of a drive key, the at least one potentiometer configured to gather data related to motion of a joint, and

wherein the end of one of the first bar or the second bar comprises a keyed opening, the drive key engaged with the keyed opening to couple the potentiometer to the end of the one of the first bar or the second bar such that rotation of the one of the first bar or the second bar about the corresponding first or second axis adjusts an output of the potentiometer;

wherein the first bar and the second bar each have a thickness less than about 0.5 mm and a width greater than or equal to about 5.0 mm, and wherein the first bar and the second bar are flexible in a frontal plane such that the first bar and the second bar are configured to be body conforming and low profile and rigid in a sagittal plane such that the first bar and the second bar are configured to accurately gather data related to motion of the joint; and

wherein the low-profile hinge assembly is configured to be removably coupled to a flexible compressive garment, the flexible compressive garment consisting of:

a sleeve consisting of a single continuous loop of material,

a rigid molded upper receptacle fixedly attached to an upper portion of the sleeve, and

a rigid molded lower receptacle fixedly attached to a lower portion of the sleeve,

wherein the first bar comprises an insert overmolded on the first bar between the first end and a second end of the first bar, the insert configured to engage with an upper slot that removably receives the second end of the first bar to couple the first bar to the upper portion of the sleeve, thereby providing a tight fit between the first bar and the upper slot and distributing contact forces between the first bar and the upper slot over a larger surface area to prevent wear therebetween, and

wherein the second bar comprises an insert overmolded on the second bar between the first end and a second end of the second bar, the insert configured to engage with a lower slot that removably receives the second end of the second bar to couple the second bar to the lower portion of the sleeve, thereby providing a tight fit between the second bar and the lower slot and distributing contact forces between the second bar and the lower slot over a larger surface area to prevent wear therebetween.

8. The hinge assembly of claim 7 , further comprising:

at least one sensor configured to gather data related to motion of at least one of the first and second geared arm assemblies; and a power source electrically coupled to the at least one sensor.

9. The hinge assembly of claim 8 , wherein the at least one sensor and the power source are positioned on a printed circuit board, and the hinge assembly further comprises:

a gasket that at least partially receives the printed circuit board; and

a cover that covers the gasket and the printed circuit board, wherein the gasket and cover define a water resistant recess in which the printed circuit board is positioned.

10. The hinge assembly of claim 9 , wherein:

the hinge plate, the gasket, the printed circuit board, and the cover are positioned on a first side of the first and second geared arms;

a condyle is positioned on a second side of the first and second geared arms; and during use of a smart brace including the hinge assembly, the first side is positioned away from a wearer and the second side is positioned toward the wearer.

11. The hinge assembly of claim 7 , wherein the recess of each of the first and second gears comprises a shape that corresponds to a shape of the end of the corresponding first and second bars, such that the end of each of the first and second bars is closely received within the corresponding recess of the first and second gears.

12. The hinge assembly of claim 11 , wherein the recess of each of the first and second gears is configured such that the corresponding first and second bars is countersunk within the corresponding recess of the first and second gears.

13. The hinge assembly of claim 7 , wherein each of the first bar and the second bar comprise:

a width greater than or equal to about 7.5 mm providing rigidity in the sagittal plane.

14. The hinge assembly of claim 7 , wherein each of the first bar and the second bar comprise spring steel.