Granted Patent B2

US 12,672,974 · App. 18/958,346 · Granted Jul 7, 2026

Inventors: Henry Hsu (Foothill Ranch, CA); Tim McMorrow (Foothill Ranch, CA)

Assignee: OSSUR ICELAND EHF

A61F5/0102A61F5/0123A61F2005/0139

Abstract

Claims (24)

1 . A knee brace having a longitudinal, central vertical axis, comprising:

a first frame component adapted to secure to a user's upper leg and correspond to a femur;

a second frame component adapted to secure about a user's lower leg and correspond to a tibia;

a hinge assembly connecting the first frame component to the second frame component;

wherein the hinge assembly is integrally formed from first and second end portions of the first and second frame components, respectively;

wherein the first frame component defines first and second struts, and a first mast, the first mast being rigid and depending centrally from a first central segment extending between the first and second struts;

wherein the second frame component defines third and fourth struts, and a second mast, the second mast being rigid and depending centrally from a second central segment extending between the third and fourth struts;

wherein the first and second frame components are configured to laterally sway from the vertical central axis, the first and second masts are angled relative to the vertical central axis;

wherein the first and second masts are arranged at first and second angles, respectively, at 3°±1.0° from the vertical central axis.

2 . The knee brace of claim 1 , wherein the first frame component and the second frame are constructed from a long fiber-reinforced thermoplastic material.

3 . The knee brace of claim 2 , wherein long fibers in the fiber-reinforced thermoplastic material are carbon and form 40% of the long fiber-reinforced thermoplastic material.

4 . The knee brace of claim 1 , wherein the first frame component defines first and second struts, the hinge assembly includes first and second hinge arms that are continuously formed without interruption from a same material with the first and second struts, respectively, with the material blending across the first and second struts to the first and second hinge arms, respectively.

5 . The knee brace of claim 4 , wherein the second frame component defines third and fourth struts, the hinge assembly includes third and fourth hinge arms that are continuously formed without interruption with the third and fourth struts, wherein the first and third hinge arms, and the second and fourth hinge arms, are oriented at 15° to 25° relative to a vertical plane.

6 . The knee brace of claim 1 , wherein the first frame component defines first and second arms extending generally horizontally from the first mast a distance from the first central segment and relative to the vertical central axis.

7 . The knee brace of claim 6 , wherein the first mast leans into the first and second arms by transitioning from greater rigidity at the first mast to reduced rigidity at the first and second arms.

8 . The knee brace of claim 7 , wherein the first and second arms are adapted to extend or rotate less than a quarter of a circumference of a user's leg, less than 60° from the vertical central axis.

9 . The knee brace of claim 6 , wherein the first mast tapers in thickness in a horizontal direction toward a peripheral edge.

10 . The knee brace of claim 6 , wherein a thickness of the first and second arms varies from distal to proximal directions relative to the vertical central axis.

11 . The knee brace of claim 6 , wherein a thickness of the first and second arms tapers away from the first mast, as the first and second arms are thinner as they extend from the first mast thereby being more flexible than the first mast.

12 . The knee brace of claim 6 , wherein the first arm has thickened a first edge portion and a second edge portion with a center portion between the first and second edge portions thinner than the first and second edge portions.

13 . The knee brace of claim 12 , wherein the center portion is recessed relative to the first and second edge portions.

14 . The knee brace of claim 1 , wherein the first mast is rigid and has a tapered thickness greater at a distal end whereas the greater thickness blends into the first central segment compared to a proximal end of the first mast.

15 . The knee brace of claim 1 , wherein the first mast defines a crescent-shaped relief edge at a proximal end whereat a thickness of the first mast at the proximal end is substantially less than a thickness of the first mast at a distal end.

16 . The knee brace of claim 1 , further comprising at least one D-ring connected to at least one of the first and second frame components, wherein at least one of the first and second frame components defines a contoured recess configured to limit an extent by which the D-ring rotates such that the D-ring is supported by and exerts forces against a surface of the at least one of the first and second frame components.

Assignments (1)

Continuity (3)

References Cited (284)