Polymeric polycentric hinge

Patent metadata

Field	Value
Publication number	US-9668903-B2
Application number	US-201514945701-A
Country	US
Kind code	B2
Filing date	Nov 19, 2015
Priority date	Nov 20, 2014
Publication date	Jun 6, 2017
Grant date	Jun 6, 2017

Abstract

A polycentric hinge for an orthopedic device includes first and second hinge arms, and two cover plates, rather than numerous individual parts and fasteners. The first and second cover plates define a plurality of bearings and a plurality of recesses for receiving the bearings, whereby the hinge arms are mounted about the bearings and are pivotable relative to one another while encased by the first and second cover plates.

First claim

The invention claimed is:

1. A hinge for an orthopedic device, comprising:
a first hinge arm defining a hole at a gear end thereof;
a second hinge arm defining a hole at a gear end thereof;
first and second cover plates for hingedly joining the first and second hinge arms;
wherein the first cover plate defines first and second bearings extending from a first surface thereof and the second cover plate defines first and second recesses extending into the second cover plate from a first surface of the second cover plate for receiving a first portion of the first and second bearings, a second portion of the first and second bearings extending between the first surface of the first cover plate and the first surface of the second cover plate to maintain a predetermined distance therebetween, the first and second bearings passing through the holes of the first and second hinge arms, respectively, to enable rotation of the second hinge arm within the predetermined distance and about the second bearing relative to the first hinge arm.

2. The hinge of claim 1 , wherein the first and second cover plates encase the gear ends of the first and second hinge arms to maintain the hinge arms in an orientation in which the gear teeth at mesh together, and hingedly connect the first and second hinge arms, the first and second hinge arms are mounted and rotatable about the first and second bearings defined by at least one of the first and second cover plates.

3. The hinge of claim 1 , wherein the first and second cover plates are ultrasonically welded together.

4. The hinge of claim 1 wherein the first and second cover plates are solely formed from a polymeric material.

5. The hinge of claim 4 , wherein the polymeric material from which the first and second cover plates are formed comprises nylon.

6. The hinge of claim 5 , wherein the nylon has a maximum moisture content of 0.18% by weight.

7. The hinge of claim 5 , wherein the nylon has a maximum moisture content of 0.15% by weight.

8. The hinge of claim 1 , wherein the bearings are defined solely by one of the first and second cover plates and the recesses are defined solely by another one of the cover plates.

9. The hinge of claim 1 , wherein the first cover plate defines a flexion/extension stop retention feature arranged for receiving a stop.

10. The hinge of claim 9 , wherein the flexion/extension stop feature includes first and second slots extending from a periphery of the first cover plate, and an aperture defined between the first and second slots, the flexion/extension stop having first and second extensions for sliding into the first and second slots, and a hole for receiving a fastener and engaging the first cover plate.

11. The hinge of claim 1 , wherein the bearings are solely confined between the first and second cover plates.

12. The hinge of claim 1 , wherein the first and second bearings each defines a bearing surface adjacent the first surface of the first cover plate and has a diameter greater than a diameter of the second portion extending from the first surface of the first cover plate, the bearing surface and the second portion being substantially concentric with one another.

13. The hinge of claim 12 , wherein the first portion has a diameter smaller than the second portion, the at least one recess having a diameter substantially the same as the second portion, the first and second portions being substantially concentric with one another.

14. The hinge of claim 13 , wherein the second cover plate defines a bearing surface extending from a first surface of the second cover plate about the at least one recess, and having substantially a same diameter as the bearing surface of the first cover plate and is generally concentric with the at least one recess.

15. The hinge of claim 14 , wherein the first and second cover plates define a clearance located between the first surfaces thereof for permitting free rotation of the first and second hinge arms relative to the first and second cover plates.

16. A hinge for an orthopedic device, consisting:
a first hinge arm defining a hole at a gear end thereof;
a second hinge arm defining a hole at a gear end thereof;
first and second cover plates for hingedly joining the first and second hinge arms;
wherein the first cover plate defines first and second bearings extending from a first surface thereof and the second cover plate defines first and second recesses extending into the second cover plate from a first surface of the second cover plate for receiving a first portion first and second bearings, a second portion of the at least one bearing extending between the first surface of the first cover plate and the first surface of the second cover plate to maintain a predetermined distance therebetween, the first and second bearings passing through one of the holes of the first and second hinge arms, respectively, to enable rotation of the second hinge arm within the predetermined distance and about the second bearing relative to the first hinge arm.

17. The hinge of claim 16 , wherein the the first and second bearings define a bearing surface adjacent the first surface of the first cover plate and has a diameter greater than a diameter of the second portion extending from the bearing surface, the bearing surface and the second portion being substantially concentric with one another.

18. The hinge of claim 17 , wherein the first portion has a diameter smaller than the second portion, the first and second recesses have a diameter substantially the same as the second portion, the first and second portions being substantially concentric with one another.

19. The hinge of claim 18 , wherein the second cover plate defines a bearing surface extending about the first and second recesses, and having substantially a same diameter as the bearing surface of the first cover plate.

20. A method of manufacturing a hinge, the method comprising steps of:
providing polymeric first and second cover plates of the hinge, the first cover plate including first and second bearings and the second plate defines first and second recesses, the first and second bearings being receivable within a corresponding one of the first and second recesses when the first and second cover plates are positioned over one another;
positioning a first hinge arm including a hole at a gear end thereof over the first bearing of the first cover plate;
positioning a second hinge arm including a hole at a gear end thereof over the second bearing, the first and second bearings maintaining the first and second hinge arms in an orientation so that gear teeth at the gear ends of the first and second hinge arms mesh together;
positioning the cover plates over one another so as to encase the gear ends of the first and second hinge arms between the first and second cover plates, hingedly connecting each of the first and second hinge arms to the first and second bearings; and
securing the first and second cover plates together.

Assignees

• Ossur Iceland Ehf

Inventors

• Hsu Henry
• Ingimarsson Gudni

Classifications

• A61F2005/0155

  with actuating means · CPC title

• A61F2005/0167

  adjustable · CPC title

• A61F5/0125

  the device articulating around a single pivot-point · CPC title

• A61F2005/0165

  with limits of movement · CPC title

• F16C11/04

  Pivotal connections (hinges for doors, windows or wings E05D) · CPC title