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 disposed on a first surface of the flexible fabric substrate, the elastomeric member being configured to reduce loads on the knee joint; and
a second elastomeric member disposed entirely to one of a lateral or medial side of a patella of the wearer's knee and secured to a second surface of the flexible fabric substrate that is configured to face the wearer's knee in an opposite direction from the first surface, the second elastomeric member comprising:
a first portion configured to extend substantially longitudinally along the lateral or medial side of the patella;
a plurality of bars, each extending from a different respective position on the first portion that is proximal of the patella and each configured to extend laterally away from the patella, and
an additional bar extending substantially diagonally and laterally away from the 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 the first elastomeric member is disposed on the first surface of the flexible fabric substrate so as to extend through an arc of between 180 and 320 degrees about the wearer's patella.
5. The knee brace of claim 1 , wherein at least a portion of the first elastomeric member extends laterally of the wearer's patella.
6. The knee brace of claim 1 , further comprising a third elastomeric member disposed on the first surface of the flexible fabric substrate, the third elastomeric member being spaced apart from the first elastomeric member, the third elastomeric member being disposed medially of the wearer's patella.
7. The knee brace of claim 6 , wherein the third elastomeric member has a dimpled surface.
8. The knee brace of claim 1 , wherein the first elastomeric member comprises silicone.
9. The knee brace of claim 1 , wherein the first elastomeric member has a thickness of between 0.3 mm and about 5 mm.
10. The knee brace of claim 1 , wherein the flexible fabric substrate comprises a generally tubular sleeve.
11. The knee brace of claim 1 , wherein the flexible fabric substrate comprises a wrap-around.
12. 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.
13. The knee brace of claim 1 , wherein the first elastomeric member is joined to the flexible fabric substrate without adhesive.
14. 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 a first surface of the flexible fabric substrate in a pattern selected to reduce loads on the knee joint; and
securing a second elastomeric member to a second surface of the flexible fabric substrate that is configured to face the wearer's knee in an opposite direction from the first surface entirely to one of a lateral or medial side of a patella of the wearer's knee, the second elastomeric member comprising:
a first portion configured to extend substantially longitudinally along the lateral or medial side of the patella,
a plurality of bars, each extending from a different respective position on the first portion that is proximal of the patella and each configured to extend laterally away from the patella, and
an additional bar extending substantially diagonally and laterally away from the patella from a position on the first portion that is distal of the plurality of bars.
15. The method of claim 14 , wherein the first elastomeric member is applied by an injection molding process.
16. The method of claim 14 , wherein the first elastomeric member is applied to a thickness of between 0.3 mm and 5 mm.
17. The method of claim 14 , wherein the first elastomeric member is applied to the first surface of the flexible fabric substrate so as to extend through an arc of between 180 and 320 degrees about the wearer's patella.
18. The method of claim 14 , further comprising applying a third elastomeric member to the first surface of the flexible fabric substrate, the third elastomeric member being spaced apart from the first elastomeric member such that the third elastomeric member is disposed medially of the wearer's patella.
19. The method of claim 14 , wherein the first elastomeric member is secured to the flexible fabric substrate without adhesive.
20. The method of claim 14 , wherein at least a portion of the first elastomeric member extends laterally of the wearer's patella.