Bi-directional dampening and assisting unit

Abstract

A dynamic platform with extending struts has fastened thereto a bi-directional torsional power unit to selectively deliver force opposing either extension or flexion, and to provide assistance in a respective opposite direction. The power unit is threadably mounted on a hinge pin (spline) centrally located on the platform, and is latched to a catch assembly radially located thereto, the hinge pin of the platform communicating with one end of a torsion spring of the power unit and the catch assembly communicating with another end of the torsion spring, to selectively deliver the extension/flexion force. The power unit can be detached, with simple manual operation of the catch assembly, without tools, flipped over and reattached to the same platform attachment points to switch (reverse) extension torque to flexion torque and vice versa.

Claims

1. A hinge assembly for an orthotic, prosthetic or rehabilitative device, comprising: a first strut and a second strut pivotally attached to one another at a pivot point; a spline extending in a first direction perpendicularly from the first strut and the second strut and serving as the pivot point for the first strut and the second strut, the spline being rotatably fixed relative to a one of the first strut and the second strut; and a torsion spring having a first end and a second end; an other one of the first strut and the second strut having a catch extending in the first direction, located radially of the pivot point; wherein: in a first configuration, the first end of the torsion spring is removably attached to the spline and the second end of the torsion spring is removably attached to the catch, the torsion spring being configured to apply a biased force opposing a relative pivotal movement between the first strut and the second strut in a first of two opposite rotational directions, and to aid the relative pivotal movement in a second of the two opposite rotational directions; and in a second configuration, the first end of the torsion spring is removably attached to the spline and the second end of the torsion spring is removably attached to the catch, wherein in the second configuration the torsion spring lies in a turned over orientation relative to the first configuration such that the torsion spring is configured to apply a biased force opposing the relative pivotal movement between the first strut and the second strut in the second of the two opposite rotational directions, and to aid the relative pivotal movement in the first of the two opposite rotational directions.

2. The assembly of claim 1, further comprising: a toothed tension wheel mounted about the pivot point and rotatably fixed relative to the spline; and an axially rotatable preload worm gear located about a perimeter of the tension wheel, the preload worm gear threadably communicating with the tension wheel to preload the torsion spring.

3. The assembly of claim 1, further comprising: a linearly translatable toothed disk that toothedly engages a gear centered about the pivot point to arrest the relative pivotal movement between the first strut and the second strut.

4. The assembly of claim 1, further comprising: at least one end range tapped hole within, and rotatably fixed relative to, the one of the first strut and the second strut; and at least one end range screw inserted into and extending from the at least one end range tapped hole; wherein the at least one end range screw abuts the other one of the first strut and the second strut to limit pivotal range of motion between the first strut and the second strut.

5. The assembly of claim 4, where a position of the at least one end range tapped hole, with the at least one end range screw inserted therein, is configured to allow motion of the assembly from 135 of flexion to 15 of hyperextension, thereby providing correct anatomical range of motion for a knee.

6. The assembly of claim 4, further comprising a second end range tapped hole, each end range tapped hole having a position, where, with end range screws inserted therein, is configured to allow motion of the assembly between 75 of plantar flexion to 75 of dorsiflexion, thereby providing correct anatomical range of motion for a wrist or ankle.

7. The assembly of claim 1, further comprising: a platform, where the first strut and the second strut form at least a portion thereof; the platform further including: a joint assembly including the pivot point and the spline, where the spline is threaded and is workably fixed to the one of the first strut and the second strut, the other one of the first strut and the second strut having the catch located thereon; and a power unit including: the torsion spring; and a housing around the torsion spring, the housing having an internally threaded reception slot centrally located on each of opposing housing sides of the power unit, the reception slot workably attached to the first end of the torsion spring, removably communicating the first end of the torsion spring to the spline, the housing further having a catch receiver located on each of opposing housing sides of the power unit, the catch receiver workably attached to the second end of the torsion spring, removably communicating the second end of the torsion spring to the catch; wherein, in the first configuration, with a first housing side exposed away from the platform, the power unit is configured to attach to the platform to apply a biased force opposing the relative pivotal movement between the first strut and the second strut in the first of the two opposite rotational directions, and to aid the pivotal movement in the second of the two opposite rotational directions; and wherein, in the second configuration, with a second housing side exposed away from the platform, the power unit is configured to attach to the platform to apply a biased force opposing the relative pivotal movement between the first strut and the second strut in the second of the two opposite rotational directions, and to aid the pivotal movement in the first of the two opposite rotational directions.

8. The assembly of claim 7, wherein the power unit is configured to be detached, turned over and reattached to the platform, without the use of tools, from the first housing side being exposed away from the platform to the second housing side being exposed away from the platform.

9. The assembly of claim 7, wherein points of attachment between the power unit and the platform consist only of the reception slot, centrally located, the spline, the catch receiver, and the catch.

10. The assembly of claim 7, wherein the platform further comprises an axially translatable handle that toothedly engages a gear centered about the pivot point to arrest the relative pivotal movement between the first strut and the second strut.

11. The assembly of claim 7, wherein the power unit further comprises: an externally threaded spring band located about a perimeter of the torsion spring, centered about the pivot point, and workably attached to the second end of the torsion spring; and an axially rotatable preload worm gear located about a perimeter of the spring band, the preload worm gear threadably communicating with the spring band to preload the torsion spring.

12. The assembly of claim 11, wherein the torsion spring, the spring band and the preload worm gear, are positioned in a same plane, the same plane being perpendicular to a longitudinal axis of the spline and the reception slot.

13. The assembly of claim 7, wherein the catch extends perpendicularly from a respective strut, and includes at a distal end thereof a lip extending perpendicularly toward the pivot point, the catch being spring biased toward the pivot point and linearly translatable along a longitudinal axis of the respective strut, wherein the catch receiver is an aperture opposingly located on each housing side of the power unit, and wherein the catch causes a snap connection of the lip to the aperture when the power unit is attached to the platform.

14. The assembly of claim 13, wherein the platform further comprises an axially translatable handle that toothedly engages a gear centered about the pivot point to arrest the relative pivotal movement between the first strut and the second strut, and wherein the catch extends perpendicularly from the respective strut from within, and is surrounded by, the axially translatable handle.

15. The assembly of claim 7, wherein the platform further comprises: a toothed range of motion ROM wheel mounted about the pivot point and rotatable relative to the first strut and the second strut; and an axially rotatable ROM worm gear located about a perimeter of the ROM wheel, the ROM worm gear threadably communicating with the ROM wheel to adjust a range of motion of the first strut relative to the second strut.

16. The assembly of claim 7, wherein the joint assembly further comprises: at least one end range tapped hole rotatably fixed relative to the one of the first strut and the second strut; at least one end range screw inserted into and extending from the at least one end range tapped hole; and an arcuate slot rotatably fixed relative to the other one of first strut and the second strut, the at least one end range screw extending into the arcuate slot to limit a range of motion of the first strut relative to the second strut; wherein the platform is configured to provide up to a 150 range of motion of the first strut relative to the second strut.

17. The assembly of claim 16, where the joint assembly further comprises: a toothed range of motion ROM wheel mounted about the pivot point and rotatable relative to one of the first strut and the second strut; and an axially rotatable ROM worm gear located about a perimeter of the ROM wheel, the ROM worm gear threadably communicating with the ROM wheel to adjust the range of motion of the first strut relative to the second strut within fixed limits established by the at least one end range tapped hole, the at least one end range screw, and the arcuate slot.

18. The assembly of claim 1, wherein the torsion spring is a circular leaf spring.

19. A method of reversing an angular direction of force applied by the assembly of claim 7, the method comprising the steps of: linearly translating the catch along a longitudinal axis of the other one of the first strut and the second strut, away from the pivot point and against the catch; pulling the power unit in a direction perpendicular to the first strut and the second strut, lifting the power unit off of the spline, thereby detaching the power unit from the platform; turning the power unit over; threadably engaging the reception slot of the housing with the spline while aligning the catch receiver of the housing with the catch, without the use of tools, and without requiring use of any other point of attachment on or between either the platform or the power unit; and pressing the power unit against the platform until the catch causes a snap connection of the catch to the catch receiver, thereby attaching the power unit to the platform to apply a biased force opposing the relative pivotal movement between the first strut and the second strut in a direction opposite that of a force applied prior to turning the power unit over, and to aid the pivotal movement in a direction opposite that provided prior to turning the power unit over.

20. A method of reversing an angular direction of force applied by the assembly of claim 1, the method comprising the steps of: moving the catch relative to the other one of the first strut and the second strut, and relative to the pivot point; removing the torsion spring from the first strut and the second strut, lifting the torsion spring from the spline; turning the torsion spring over; and engaging the torsion spring with the spline while aligning and attaching the second end of the torsion spring with the catch, without the use of tools, and without requiring use of any other point of attachment on the first strut or the second strut, thereby engaging the torsion spring with the spline, and with the first strut and the second strut, to apply a biased force opposing the relative pivotal movement between the first strut and the second strut in a direction opposite that of a force applied prior to turning the torsion spring over, and to aid the pivotal movement in a direction opposite that provided prior to turning the torsion spring over.

Description

BRIEF DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

(1) The present invention will be better understood with reference to the following description taken in combination with the drawings. For the purpose of illustration, there are shown in the drawings certain embodiments of the present invention. In the drawings, like numerals indicate like elements throughout. It should be understood, however, that the invention is not limited to the precise arrangements, dimensions, and instruments shown:

(2) FIG. 1 illustrates a bi-directional dampening/assisting unit according to one embodiment of the present invention, including power unit attached to a platform, where the power unit provides extension or flexion torque upon respective angular movement of struts extending from the platform, and where the power unit can be flipped over to switch from extension torque to flexion torque, or vice versa, in the respective angular direction;

(3) FIG. 2a illustrates a platform according to an embodiment of the present invention that includes two struts interconnected at a pivot point, with threaded spline extending therefrom, where the struts are located in one working position; FIG. 2b illustrates the platform of FIG. 2a, where the struts are located in another working position;

(4) FIG. 3 illustrates the platform of FIGS. 2a and 2b in exploded view;

(5) FIG. 4 illustrates a bi-directional dampening/assisting unit according to another embodiment of the present invention, again including power unit attached to a platform of the present invention, where the power unit provides extension or flexion torque upon respective angular movement of struts extending from the platform, and where the power unit can be flipped over to switch from extension torque to flexion torque, or vice versa, in the respective angular direction;

(6) FIG. 5 illustrates a side view of the bi-directional dampening/assisting unit of FIG. 4, with power unit attached to the platform; and

(7) FIG. 6 illustrates the power unit of FIGS. 4 and 5 in exploded view;

(8) FIGS. 7a, 7b and 7c illustrate a front, side and exploded view, respectively, of another embodiment of the platform 10 of the present invention (i.e., the platform 10 shown in FIG. 1);

(9) FIGS. 8a, 8b, 8c, 8d and 8e illustrate perspective, top side, edge, opposite side and exploded views, respectively, of another embodiment of the power unit 100 of the present invention (i.e., the power unit 100 shown in FIG. 1);

(10) FIGS. 9a, 9a and 9b illustrate a front profile, a side profile and a reverse profile of the platform 10 embodiment of FIGS. 1, 7a, 7b, and 7c;

(11) FIGS. 10a and 10b illustrate a front profile and a reverse profile of the power unit 100 embodiment of FIGS. 1, 8a, 8b, 8c, 8d and 8e;

(12) FIGS. 11a, 11b and 11c illustrate fine tuning of the platform 10 embodiment of FIGS. 1, 7a, 7b, 7c, 9a, 9a and 9b, to block excessive or unwanted flexion or extension range of motion; and

(13) FIGS. 12a, 12b, 12c, 12d and 12e illustrate how to use the bi-directional dampening/assisting unit of FIG. 1; more specifically, how to set up the platform 10 and attach the power unit 100 thereto for certain flexion/extension assist.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

(14) The present invention provides a dynamic platform, having struts extending therefrom, and having fastened thereto a bi-directional torsional power unit, between first and second struts. The torsional power unit selectively delivers force opposing either extension or flexion, while providing assistance in a respective opposite direction. The torsional power unit is mounted on a hinge pin (spline) extending from a pivot point of the platform, where the power unit can be flipped over to switch (reverse) the force opposing extension or flexion to the respective other thereof.

(15) FIG. 1 illustrates a bi-directional dampening/assisting unit 5 according to one embodiment of the present invention, including power unit 100 and platform 10. FIGS. 2-3 illustrate a platform 10 of the present invention including a first and a second strut 12, 14 interconnected at a pivot point 16, with threaded spline 18 extending therefrom, FIG. 3 illustrating an exploded view. The threaded spline 18 is rotationally fixed in relation to the second strut 14. The pivot point and components of the platform other than the struts 12, 14 form a joint assembly.

(16) FIG. 2a illustrates the platform 10 in one working position, aligned for use (range of motion (ROM) appropriate for) a knee or elbow joint. Alignment of the platform 10 is shown by graduated markings 20 posted on a side of the platform 10. Alignment of the platform is performed by manual operation of a toothed disk 22, associated and aligned with the first strut 12, to linearly translate the toothed disk 22 in relation to the first strut 12 to engage a stationary and toothed alignment wheel 24. FIG. 2b illustrates the platform in another working position, aligned for use (range of motion appropriate for) an ankle or wrist. In one embodiment, each graduated marking represents 15 degrees, which is equal to the degree range associated with each thread of the spline 18.

(17) Alignment is shown by a tab or pin 26. The tab 26 is fixed in relation to, and extends at a relative distal end location of, the first strut 12. Accordingly, the first strut 12 and the second strut 14 communicate with the joint assembly, providing that the first strut 12 can pivotally move relative to the second strut 14 about the pivot point 16.

(18) Referring now to FIG. 3, the platform 10 further includes a stationary and toothed range of motion (ROM) wheel 28. Two worm gears 30, 32, each communicating with, and movable in relation to, a perimeter of the ROM wheel 28, provide range of motion stops (or limiters) for the platform 10. Accordingly, the pivotal range of motion of one strut (e.g., the first strut 12) relative to the other strut (e.g., the second strut 14) is limited by a relative position of each worm gear 30, 32, acting as a strut stop, about the perimeter of the ROM wheel 28. Axial rotation of each worm gear 30, 32, respectively indexes (translates) the respective worm gear about the perimeter of the stationary ROM wheel 28.

(19) FIGS. 4-6 illustrate a power unit 100 of the present invention attached to a platform 10 of the present invention, whereby the power unit 100 provides extension or flexion torque upon respective angular movement of the struts 12, 14. FIG. 6 illustrates an exploded view. The power unit 100 can be flipped over on the platform 10 to switch from extension torque to flexion torque, or vice versa, in a respective direction.

(20) The power unit 100 includes a torsion spring 102 (e.g., a circular leaf spring) and a internally threaded reception slot 104 open to, and centrally located on, each of opposing sides of the power unit 100 (i.e., open to, and centrally located within, each of opposing housing side plates 106, 108). The respective reception slot 104 communicates with a first end 110 of the torsion spring 102.

(21) The power unit 100 threadably attaches to the platform 10 via the spline 18 and the reception slot 104 open on a first side housing plate 108 of the power unit 100 (as shown in FIGS. 4 and 5) to apply a bias force opposing relative pivotal movement between the first and the second struts 12, 14 in a first of two opposite directions and aiding such pivotal movement in a second of the opposite directions. Facilitating the bias force is a second attachment of the power unit 100 to the platform 10, occurring between tab 26 and tab reception aperture 112. A tab reception aperture 112 is also located on each of opposing sides of the power unit 100 (i.e., on each housing side plate 106, 108).

(22) In one embodiment, the tab 26 includes a shelf, or 90 degree lip (as best shown in FIG. 2b), creating a latch mechanism. The tab reception aperture 112 includes, at an outer edge (near to the top) thereof, a movable (slidable) door 111 adapted to slide over the tab reception aperture 112 and catch (latch) to the lip or shelf of the tab 26. The slidable door 111 is operable from, and communicates with, a spring biased, slidably translatable sliding bar 113, which extends from a center area of the power unit 100. Translating the sliding bar 113 away from the center of the power unit 100 fully opens the tab reception aperture 112 to receive the 90 degree angled tab 26. Releasing the sliding bar, via spring bias closing, returns the slidable door towards the center of the power unit 100 to catch the shelf portion of the tab 26.

(23) Thereafter, the power unit 100 can be detached from the platform 10, via sliding bar 113, flipped over and reattached to the platform 10, again via the spline 18 and the reception slot 104 open on a second housing side plate 106 of the power unit 100, and via the tab 26, tab reception aperture 112 and sliding bar 113. The power unit 100 will then apply a bias force opposing relative pivotal movement between the first and the second struts 12, 14 in a second of two opposite directions and will aid such pivotal movement in a first of the opposite directions.

(24) Referring now to FIG. 6, the power unit 100 further includes an externally threaded spring band 114 located about a perimeter of the torsion spring 102. The spring band 114 is fixedly attached (e.g. by pin and socket connector 116) to a second end 118 of the torsion spring 102. Further, a stationary, but axially rotatable, worm gear 120 is located about a perimeter of the spring band 114. The worm gear 120 threadably communicates with the spring band 114 to preload the torsion spring 102. In one embodiment, the torsion spring 102, the spring band 114 and the worm gear 120 are positioned in the same plane (e.g., positioned in a similar plane, perpendicular to a longitudinal axis of the reception slot 104 (and thereby the spline 18, when the assembly is in operation).

(25) In one embodiment of the invention, the platform 10 and torsion spring 102 provide a 150 degree range of motion of the struts 12, 14. The torsion spring 102 operates over 402 degrees. The externally threaded spring band 114 includes threads over a portion of the external perimeter. Through operation of the worm gear 120, the spring band 114 provides torsion spring preload over seven (7) settings at 36 degree increments, for a total of 252 degrees. This 252 degree preload capability, plus the 150 degree operable range of motion, cover the 402 degree range of the torsion spring 102 for this certain embodiment. Multiple variations and permutations are possible.

(26) FIGS. 7a, 7b and 7c illustrate a front, a side and an exploded view, respectively, of another embodiment of the platform of the present invention (i.e., the platform 10 shown in FIG. 1). Much of the detailed description of the component parts and functionality of the FIG. 7 platform embodiment is similar to the platform embodiment of FIGS. 2a, 2b and 3. Note that the proximal and distal struts are shown in cropped format (actual length can vary due to patient need). Table 1 provides a convenient list/explanation of component parts of the FIGS. 7a, 7b and 7c embodiment of the platform 10 of the present invention.

(27) TABLE-US-00001 TABLE 1 An Embodiment of Platform 10 of the Present Invention (see FIGS. 7a, 7b, 7c) Component No. Component Description 12 Proximal Strut-Platform 14 Distal Strut-Platform 18 Spline Driver Shaft-Platform 22 Don/Doff Lock Slide-Platform 26 Power Unit Catch-Platform 28 Range of Motion (ROM) Wheel, or ROM Gear-Platform 30 ROM Worm Gear-Platform 34 ROM Worm Gear Housing, or ROM Worm Housing-Platform 35 Platform Retainer-Platform 37 Catch Housing-Platform 38 Don/Doff Handle, or Lock Out Handle-Platform 42 Washer 42A Washer 43 Compression Spring 44 Compression Spring 45 Dowel Pin 46 Screw-e.g., Flat Head Phillips 47 Screw-e.g., Flat Head Phillips 48 Ball Bearing 49 Grooved Pin 50 Bushing-Platform 52 Stop Angle Mark(s) (SAM) 53 Power Unit Release Button 54 End Range Tapped Holes 55 End Range Screw(s) 56 Arcuate Slot (retaining therein end range screws 55 inserted into end range tapped holes 54)

(28) FIGS. 8a, 8b, 8c, 8d and 8e illustrate a perspective, a top side, an edge, an opposite side, and an exploded view, respectively, of another embodiment of the power unit 100 of the present invention (i.e., the power unit 100 shown in FIG. 1). Table 2 provides a convenient list/explanation of component parts of the FIGS. 8a, 8b, 8c, 8d and 8e embodiment of the power unit 100 of the present invention. In Table 2, and in FIGS. 8a, 8b, 8c, 8d and 8e, CW stands for clockwise and CCW for counter-clockwise.

(29) TABLE-US-00002 TABLE 2 An Embodiment of Power Unit 100 of the Present Invention (see FIGS. 8a, 8b, 8c, 8d, 8e) Component No. Component Description 101 Washer-Spring Componentry 102 Torsion Spring-Power Unit 103 Indicator Plate-CW Power Unit 104 Spline Pivot Shaft-Power Unit 106 Housing Side Plate, CCW-Power Unit 107 Indicator Plate, CCW Power Unit 108 Housing Opposite Side Plate, CW, Power Unit 112 Catch Receiver (through aperture with wall thickness) 114 Ring Gear, or Spring Band-Power Unit 116 Screw (e.g., Flat Head Socket) 120 Worm, or Worm Gear-Power Unit 121 Retaining Ring 122 Flat Washer 123 Grooved Pin 124 Tension Level Indicator 126 Assist Direction Indicator 128 Tension Adjustor Location (using Worm Gear)

Using Embodiments of the Present Invention

(30) Orthotic devices/braces that incorporate embodiments of the present invention are intended for therapeutic use to manage loss of motion associated with various neurological and orthopedic indications for both adults and pediatrics. Neurological indications include cerebral palsy, cerebral vascular accident, spina bifida, traumatic brain injury, brachial plexus injury, spinal cord injury, multiple sclerosis, and reflex sympathetic dystrophy. Orthopedic indications include ligament tears, tendon rupture/repair, toe walking, burns, limb loss, rheumatoid arthritis, severe fractures/trauma, arthrogryposis, muscular dystrophy, and total knee arthoplasty. Contraindications include fixed deformities.

(31) Two primary components of the present invention are the orthotic joint (platform) and the adjustable assist unit (power unit). When incorporated into an orthosis, the platform serves as an orthotic hinge or joint with features to statically control motion. The power unit mounts to the platform and provides continuous tension to a limb to restore range of motion to the affected joint.

(32) FIGS. 9a, 9a and 9b illustrate a front profile, a side profile and a reverse profile of the platform 10 embodiment of FIGS. 7a, 7b, and 7c. FIGS. 10a and 10b illustrate a front profile and a reverse profile of the power unit 100 embodiment of FIGS. 8a, 8b, 8c, 8d and 8e. During use of embodiments of the present invention, FIGS. 9a, 9a, 9b, 10a and 10b show that the following components of the platform and of the power unit can at least be, and/or variously can at least provide: Proximal Strut 12: aluminum upright bar contoured and fastened to an orthotic shell proximal to the anatomical joint; Lock Out Handle 38: blue-colored handle used to lock the platform 10; Power Unit Catch 26: spring loaded latch that inserts into a catch receiver 112 of the power unit 100, serving to maintain engagement between the platform 10 and the power unit 100; Spline 18: centrally located grooved shaft that mates with the spline receiver (reception slot) 104 of the power unit 100; Range of Motion (ROM) Wheel or Gear 28: circular ridged gear whose position can be adjusted to change extension or flexion range of motion limits; Stop Angle Mark 52: one of two red colored reference marks located on the ROM wheel, used to gauge the angle to which the ROM wheel 28 stops at a particular range of motion of the platform 10; Worm 30: a gear which, when turned, will change the position of the ROM wheel 28 and stop angle mark(s) 52 to set a range of motion stop for the platform 10; Distal Strut 14: aluminum upright bar contoured and fastened to an orthotic shell distal to the anatomical joint; Power Unit Release Button 53: allows for the power unit 100 to be detached from the platform 10 when pressed (linearly translated) in a upward direction; Platform Retainer 35: pivot point 16 and central fastener for the platform 10; is also used with tool (jig), engaged thereon, to facilitate proper alignment of orthotic joints to one another; End Range Tapped Holes 54: four tapped end range holes 54 (A, B, C, D) are provided (as shown in FIG. 9b) on a reverse profile of the platform 10. Each end range tapped hole 54A, 54B, 54C, 54D, is designed to receive an end range screw 55 to set up the platform 10 with a normal anatomical range of the respective jointintended to treat and to ensure proper functioning of the power unit 100. The end range screw(s) 55 extend from respective end range tapped hole(s) 54 into an arcuate slot 56 in a member becoming the distal strut 14. One or two end range screw(s) 55 are usually used (e.g. in holes A and B; in hole C only; in hole D only). Referring to FIG. 9b, two end range screws 55 (one in each of holes A and B) are shipped pre-installed from factory. End range screws 55 in only holes A and B are recommended for ankle or wrist applications. An end range screw 55 in hole C is recommended for right knee or left elbow applications. An end range screw 55 in hole D (see FIG. 12e) is recommended for left knee or right elbow applications; Catch Receiver 112: a through feature (aperture with wall thickness) located on a proximal aspect of the power unit 100designed to interface with the power unit catch 26; Tension Level Indicator 124: indicates through housing window a current tension setting of the power unit 100. Tension settings can range from a minimum of 0 to a maximum of 7, in increments of 0.5. An initial factory setting can be 1. Spline Receiver (Reception Slot) 104: grooved (internally threaded) feature that engages the spline 18 of the platform 10; Assist Direction Indicator 126: markings on housing of power unit (clockwise or counterclockwise) indicating a direction of the assistance generated by the power unit 100; and Tension Adjustor 128: mechanism used to increase/decrease tension generated by the power unit 100.

(33) Locking and unlocking the platform 10 (see FIGS. 9a and 9a). The lock out handle 38 is used to immobilize or lock-out the platform 10, primarily for donning and doffing the orthosis with the power unit 100 attached and tensioned. In FIGS. 9a and 9a, the platform 10 is shown without the power unit 100 to better illustrate the mechanics of the locking mechanism. To use the lock out handle 38, follow these steps: to lock, press the lock out handle 38 downward, linearly translating the lock out handle 38 along a longitudinal axis of the proximal strut 12, until a toothed lock slide 22 (connected at a distal end of the lock out handle 38) is fully engaged with the toothed perimeter edge of the ROM wheel 28 (as shown in FIGS. 9a and 9a); and to unlock, pull the lock out handle upward (proximally), linearly translating the lock out handle 38 along the longitudinal axis of the proximal strut 12 away from the ROM wheel 28, until the toothed lock slide 22 is fully disengaged from the toothed perimeter of the ROM wheel 28 (as shown in FIG. 11a).
An audible snap will be heard when the lock out handle 38 is successfully locked or unlocked.

(34) In certain embodiments of the present invention, the platform 10 can provide up to a 150 range of motion of the proximal and the distal struts 12, 14. As detailed above, and referring to FIG. 9b, initial setup for a left knee or right elbow can allow motion from 135 of flexion to 15 of hyperextension with an end range screw 55 inserted into end range tapped hole 54D (see also FIG. 12e). Initial setup for a right knee or left elbow can allow motion from 135 of flexion to 15 of hyperextension with an end range screw 55 inserted into end range tapped hole 54C. For wrist or ankle applications, initial setup having end range screws 55 inserted in each of end range tapped holes 54A and 54B allows motion from 75 of plantar (palmar) flexion to 75 of dorsiflexion. The end range screws 55 provide correct anatomical range for the joint to be treated.

(35) FIGS. 11a, 11b and 11c illustrate how the platform 10 may be further fine-tuned to block excessive or unwanted flexion or extension, allowing for infinite positioning options between the fixed limits established by the end of range screw(s) 55 inserted into the end range tapped hole(s) 54 (A, B, C, D) and engaging the arcuate slot 56. The ROM wheel 28 includes two red colored stop angle marks (SAMs) 52 within the teeth of the ROM wheel 28. The stop angle marks 52 are most clearly visible from a side view of the platform (see FIGS. 9a and 9a). One SAM 52 corresponds to extension range limitation and the other SAM 52 to flexion range limitation. The key to success with fine tuning the platform's range of motion lies in understanding the relationship between the SAMs 52 and the proximal strut 12. Specifically, the platform's motion will stop at an angle where a SAM 52 intersects the midline of the proximal strut 12.

(36) Note that platform 10 fine-tuning is provided to limit range of motion in either a flexion or extension directionone cannot limit both directions simultaneously. Therefore, only one SAM 52 has significance to platform range of motion. The illustrations of FIGS. 11a, 11b and 11c show fine-tuning with the power unit 100 detached from the platform 10 (just to better illustrate the mechanics involved). However, the platform's range of motion may be fine-tuned with or without the power unit 100 attached.

(37) To adjust the range of motion: unlock the platform 10 (as detailed above); the initial factory position of the platform 10 is shown in FIG. 11a. Note the position of the proximal and distal struts 12, 14 at a 180 relationship, and of the red stop angle marks (SAMs) 52 at the 5 and 7 o'clock positions. In the initial factory position (at 5 and 7 o'clock; as shown in FIG. 11a), the ROM wheel 28 does not influence the range of motion of the platform 10; the ROM wheel 28 position is adjusted by turning the worm 30 with a ball driver 200 (see FIGS. 11b and 11c). The worm 30 may be turned in either direction; and starting at the initial factory position, depending on the direction the worm 30 is turned, one of the SAMs 52 will move into closer proximity to the proximal strut 12 compared to the other SAM 52. The closer SAM 52 represents the stop point. The platform 10 will not be moveable (rotatable) past the region where the SAM 52 intersects the midline of the proximal strut 12free range of motion will be available in the other direction. FIGS. 11b and 11c illustrate two possible settings of the ROM wheel 28. In FIG. 11b, range of motion of the proximal strut 12 relative to the distal strut 14 is limited to approximately 35 in the direction (arrow) indicated. In FIG. 11c, range of motion of the proximal strut 12 relative to the distal strut 14 is limited to approximately 90 in the direction (arrow) indicated.

(38) FIGS. 12a, 12b, 12c, 12d and 12e illustrate how to set up the platform 10 and attach the power unit 100 to the platform 10 for certain flexion/extension assist: set the ROM wheel 28 to its initial factory position (as detailed above); move the distal strut 14 of the platform 14 to the maximum end range of the direction to be assisted;
For example, to assist ankle dorsiflexion move the distal strut 14 to its maximally dorsiflexed position (+75 dorsiflexion). If the platform 10 is not moved to the maximum end range of the direction to be assisted, internal stops of the power unit 100 will limit the range of motion of the platform 10thereby diminishing assistance output of the power unit 100. lock the platform 10 in the position of maximum end range of the direction to be assisted. FIG. 12a shows the platform 10 oriented for right elbow extension assist (and/or left knee extension assist). As shown in FIG. 12a, maximum extension end range for an elbow setup is 15 of hyperextension; orient the power unit 100 so the assist direction indicator 126 (on the side up, away from the platform upon attachment) shows the direction (clockwise or counterclockwise) of the motion you wish to assist. FIG. 12b shows the power unit 100 oriented to assist right elbow extension (and/or left knee extension); line up the spline 18 and the power unit catch 26 of the platform 10 with the spline receiver (reception slot) 104 and the catch receiver 112 of the power unit as shown in FIG. 12c. Press the power unit 100 onto the platform 10. You should hear the power unit 100 catch click into place upon successful latching of the power unit 100; FIG. 12d shows a successfully attached power unit 100 to platform 10 from a top profile view; FIG. 12e shows the same, attached power unit 100 to platform 10 from a rear side profile view (also showing one end range screw 55 inserted in an end tapped hole 54 (specifically, end tapped hole 54Dsee also FIG. 9b) and extending into the arcuate slot 56); and unlock the platform 10 and test the assembly, ensuring correct range of motiont. For an elbow or knee assembly (as detailed above), the platform 10 should have range of motion from 135 of flexion to 15 of hyperextensionensure that resistance is felt in correct direction

(39) To remove the power unit 100 from the platform 10: move the lock out handle 38 of the platform 10 to the unlocked position (as detailed above); for removal of the power unit 100 from the platform 10, the platform 10 must again be at the end range of the assisted direction. Using the lock out handle 38, lock the platform 10 in this position; and push the power unit release button 53 upward (proximally, linearly away from the pivot pointsee FIG. 9b). While holding the power unit release button 53 upward (against spring bias), lift the power unit 100 off the platform 10.

(40) The assist direction of the power unit 100 can be reversed to assist in the opposite direction. For example, a power unit 100 oriented on a platform 10 for knee extension assist could be reversed for knee flexion assist; a power unit 100 oriented on a platform 10 for wrist extension assist could be reversed for wrist palmar flexion assist, etc. To reverse the assist direction of the power unit 100 on the platform 10 (for example, here, setting the power unit 100 for flexion assist of the right elbow: remove the power unit 100 and set the ROM wheel 28 to its initial factory position (as detailed above); move the distal strut 14 into maximum flexion range (for a right elbow or left knee135); lock the platform 10 in this position (using lock out handle 38); orient the power unit 100 so that the assist direction indicator 126 on the side facing up (i.e., away from the platform 10 upon attachment) shows (points in) the direction (clockwise or counterclockwise) you wish to assist (here, counterclockwise for right elbow or left knee flexion force); and attach the power unit 100 to the platform 10.

(41) To adjust the tension of the power unit 100: the power unit 100 can be adjusted for tension between a minimum level of 0 and a maximum level of 7. In its initial factory setting, the power unit 100 has tension set at level 1 (see FIGS. 10a and 10b for tension adjuster location 138operation of worm 120); the power unit 100 may be adjusted for tension on or off the platform 10. Use the included Ball Driver 200 to turn the worm 120 (tension adjustor location 138) to increase/decrease the tension of the power unit 100 (torsion spring 102). The tension adjustor 138 can be approached (with the ball driver 200) from either side of the worm 120. Depending on the side of the power unit 100 (specifically, the worm 120) chosen to make the adjustment, as well as the direction of the assist selected, the tension adjustor 138 (worm 120) may require turning either toward you or away from you (clockwise or counterclockwise) to increase (decrease) the tensionwatch tension level indicator 124. to decrease the tension, simply turn the tension adjustor 138 (worm 120) in the opposite direction.

(42) These and other advantages of the present invention will be apparent to those skilled in the art from the foregoing specification. Accordingly, it will be recognized by those skilled in the art that changes or modifications may be made to the above-described embodiments without departing from the broad inventive concepts of the invention. For example, features detailed as included in certain specific embodiments above are recognized as interchangeable and possibly included in other detailed embodiments. Specific dimensions of any particular embodiment are described for illustration purposes only. It should therefore be understood that this invention is not limited to the particular embodiments described herein, but is intended to include all changes and modifications that are within the scope and spirit of the invention.