FR3159509A1 - Knitted orthosis comprising at least one protuberance - Google Patents

Abstract

Knitted orthosis comprising at least one protrusion The knitted orthosis (1) comprises a body (2) having a substantially tubular shape and at least one protrusion (4) extending projecting from at least one face of the body (2), said body (2) and said protrusion (4) being knitted from at least two knitting yarns (12, 14) and one weft yarn (16), the two knitting yarns (12, 14) being knitted together to form the body (2), the weft yarn (16) being deposited in said body (2). The knitting yarns (12, 14) are knitted separately and are spaced apart from each other to form the protrusion (4), the weft yarn (16) being deposited in said protrusion (4) so as to pad said protrusion (4). Figure for abstract: 2

Description

Knitted orthosis comprising at least one protuberance

The present invention relates to a knitted orthosis, of the type comprising a body having a substantially tubular shape and at least one protuberance extending projecting from at least one face of the body, said body and said protuberance being knitted from at least two knitting yarns and one weft yarn, the two knitting yarns being knitted together to form the body, the weft yarn being deposited in said body.

Orthoses, such as a knee brace or an ankle brace, comprising a tubular body made of textile material and one or more inserts, forming one or more protrusions in the orthosis, are known. Such orthoses are for example described in standard NF S97-117 (May 2022) entitled “Medical compression orthoses – Technical specifications”. The insert, for example a patellar insert in the case of a knee brace or malleolar inserts in the case of an ankle brace, for example made of silicone, thermoplastic elastomer (TPE) or foam, makes it possible for example to improve the support and/or orient the joint of the limb receiving the orthosis.

Such orthoses are complex to produce because the insert(s) must be integrated into the orthosis, for example during the making or knitting of the orthosis or by inserting the insert(s) between two textile layers which are then assembled together to ensure the maintenance of the insert(s).

One of the aims of the invention is to propose an orthosis comprising one or more protuberances which can be integrated simply into the orthosis.

To this end, the invention relates to a knitted orthosis of the aforementioned type, in which the knitted threads are knitted separately and are spaced apart from each other to form the protuberance, the weft thread being deposited in said protuberance so as to pad said protuberance.

Thus, in the knitted orthosis according to the invention the protrusion(s) are directly formed by the yarns constituting the knitted orthosis so that it is not necessary to provide additional elements to be fixed on or in the knitted orthosis. A finished knitted orthosis can thus be obtained in a single knitting step with a single knitting machine. Furthermore, the shape, dimensions, location and/or number of protrusions can be simply adjusted by a setting of the knitting machine or by means of a control program of the knitting machine for changing the number of needles and/or the number of knitting rows, which makes it possible to change the size of the protrusion(s) in the knitted orthosis.

• le fil de trame est élastique ;
• le fil de trame est déposé de façon tendue dans ledit corps et de façon libre et lâche dans la protubérance ;
• au moins l’un des deux fils de tricot est élastique ;
• la protubérance s’étend selon une forme allongée sur au moins une des faces du corps ;
• la forme de la protubérance s’étend selon un contour fermé s’étendant autour d’une partie du corps ou d’une ouverture traversant l’orthèse tricotée selon une direction d’épaisseur, ledit contour fermé étant entouré au moins en partie par une partie du corps ;
• la protubérance forme au moins un insert rotulien ou au moins un insert malléolaire ;
• la protubérance présente une dureté, sur au moins une des faces de la protubérance, comprise entre 25 sh 00 et 85 sh 00 ;
• un premier fil de tricot des fils de tricot est tricoté selon une structure en cote 1 et 1 et un deuxième fil de tricot des fils de tricot est tricoté selon une structure en jersey envers ou selon une structure en cote 1 et 1 pour former le corps ;
• le premier fil de tricot est tricoté selon une structure en jersey envers et le deuxième fil de tricot est tricoté selon une structure en jersey endroit dans la protubérance ; et
• l’orthèse tricotée comprend en outre un troisième fil de tricot, ledit troisième fil de tricot étant tricoté avec les deux fils de tricot dans le corps et étant tricoté avec seulement l’un des fils de tricot dans la protubérance ou étant déposé avec le fil de trame pour rembourrer la protubérance.

The knitted orthosis according to the invention may further comprise one or more of the following characteristics, taken individually or in any technically conceivable combination:

• the weft thread is elastic;
• the weft thread is laid tautly in said body and freely and loosely in the protuberance;
• at least one of the two knitting yarns is elastic;
• the protuberance extends in an elongated shape on at least one of the faces of the body;
• the shape of the protrusion extends along a closed contour extending around a part of the body or an opening passing through the knitted orthosis in a thickness direction, said closed contour being surrounded at least in part by a part of the body;
• the protuberance forms at least one patellar insert or at least one malleolar insert;
• the protuberance has a hardness, on at least one of the faces of the protuberance, of between 25 sh 00 and 85 sh 00;
• a first knitting yarn of the knitting yarns is knitted in a 1 and 1 rib structure and a second knitting yarn of the knitting yarns is knitted in a reverse stockinette structure or in a 1 and 1 rib structure to form the body;
• the first knitting yarn is knitted in a reverse stockinette stitch structure and the second knitting yarn is knitted in a front stockinette stitch structure in the protrusion; and
• the knitted orthosis further comprises a third knitting yarn, said third knitting yarn being knitted with both knitting yarns in the body and being knitted with only one of the knitting yarns in the protrusion or being laid with the weft yarn to pad the protrusion.

Other aspects and advantages of the invention will appear more clearly on reading the description which follows, given solely by way of non-limiting example, and made with reference to the appended drawings in which:

FIG. 1 there FIG. 1 is a schematic representation from above of a knitted orthosis according to the invention,

FIG. 2 - there FIG. 2 is a schematic cross-sectional representation of part of the knitted orthosis of the FIG. 1 according to a first embodiment of the invention showing a protuberance,

FIG. 3 - there FIG. 3 is a schematic representation of the knitting of the knitted orthosis of the FIG. 2 in a part forming the body of the knitted orthosis,

FIG. 4 - there FIG. 4 is a schematic representation of the knitting of the knitted orthosis of the FIG. 2 in a part forming a protuberance of the knitted orthosis,

FIG. 5 - there FIG. 5 is a schematic sectional representation of a portion of a knitted orthosis according to a second embodiment of the invention showing a protuberance,

FIG. 6 - there FIG. 6 is a schematic representation of the knitting of the knitted orthosis of the FIG. 5 in a part forming a protuberance of the knitted orthosis,

FIG. 7 - there FIG. 7 is a schematic sectional representation of a portion of a knitted orthosis according to a third embodiment of the invention showing a protuberance,

FIG. 8 - there FIG. 8 is a schematic representation of the knitting of the knitted orthosis of the FIG. 7 a part forming the body of the knitted orthosis, and

FIG. 9 - there FIG. 9 is a schematic representation of the knitting of the knitted orthosis of the FIG. 7 in a part forming a protuberance of the knitted orthosis.

In reference to the FIG. 1 , a knitted orthosis 1 is described comprising a body 2 and at least one protuberance 4. According to the embodiment shown in the FIG. 1 , the knitted orthosis forms a knee brace. It is however understood that the invention can be applied to any type of orthosis, such as an ankle brace, a wrist brace, an elbow brace or other.

The body 2 comprises at least one part having a generally tubular shape so as to form a sleeve capable of surrounding the part of a user's limb on which the knitted orthosis 1 is to be worn. The body 2 defines a reverse face 6, intended to be applied against the user's skin and a front face 8, opposite the reverse face 6 and facing outwards. The thickness of the knitted orthosis 1 is defined in the direction from the reverse face 6 to the front face 8, called the thickness direction, as being the distance separating the reverse face 6 and the front face 8.

It is understood that the body may comprise other parts made in one piece with the tubular part of the body 2, for example other tubular sections whose opening opens into the opening of the tubular part of the body 2. It may thus be one or more tubular sections to receive the thumb and/or the other fingers of a user in the case of a wrist orthosis or a glove.

The protrusion 4 is arranged to form a functional insert of the knitted orthosis 1, for example a patellar insert in the case of a knee brace, a malleolar insert in the case of an ankle brace, a thumb support insert in the case of a wrist orthosis or other.

The protrusion 4 projects from the body 2 in the thickness direction. More particularly, as seen in Figs. 2, 5 and 7, the protrusion projects from the reverse face 6 and/or the front face 8 of the body 2.

In the case of a knee brace, shown in the FIG. 1 , the protuberance 4 has for example an elongated shape and a closed contour extending in projection towards the outside of the knitted orthosis so as to form a patellar insert. Thus, in this case, the protuberance 4 extends mainly in projection on the right side 6 of the knitted orthosis 1. The protuberance 4 has for example a substantially ovoid or ellipsoidal shape surrounded at least in part by a part of the body 2. The protuberance 4 surrounds an opening 10 passing through the body 2 in the direction of thickness, the opening 10 being intended to receive the kneecap of a user having put on the orthosis. It is understood that the protuberance 4 can have another shape and have varied dimensions adapted to different sizes of orthoses. It is also understood that such an orthosis may have other protuberances to form other types of inserts and/or that the closed contour of a protuberance 4 may surround a part of the body 2 of the knitted orthosis 1, instead of an opening 10. Thus, according to one embodiment, a part of the body 2 surrounds the opening 10 and the protuberance surrounds this part of the body 2.

In the case of an ankle brace, several protuberances 4 are for example provided to form malleolar inserts extending in projection on the reverse face 6 of the knitted orthosis 1 around the ankle of a user having put on the orthosis. Such protuberances have for example an elongated shape. More particularly, the protuberances are for example in the form of ribs extending in projection from the reverse face 6 of the knitted article in order to be applied against the skin of a user, the ribs being surrounded and connected together by one or more parts of the body 2 of the knitted orthosis 1.

In the case of a wrist orthosis, the protrusion is, for example, arranged to maintain a gap between the thumb and index finger of a user who has put on the orthosis. The protrusion 4 has, for example, a pad shape that fits the shape of the neckline between the thumb and index finger.

It is understood that other forms of protrusions may be envisaged, for example a form of cushion intended to replace a gel insert or other. It is also understood that the same knitted orthosis may have several different types of protrusions, for example by combining the embodiments relating to different types of orthoses described above. When several protrusions are provided, these do not necessarily have the same shape or the same dimensions.

The body 2 has, for example, a thickness substantially between 0.5 mm and 3 mm and the protuberance(s) has, for example, a thickness substantially between 5 mm and 25 mm.

In addition, the or each protuberance 4 has a hardness, on the reverse side 6 and/or on the right side 8, of between 25 sh 00 and 85 sh 00, in accordance with standard NF S97-117 of May 2022.

Several embodiments of the knitted structure of the knitted orthosis according to the invention will now be described with reference to Figs. 2 to 9.

Generally, the knitted orthosis according to the invention is obtained by knitting at least two knitting yarns, namely a first knitting yarn 12 and a second knitting yarn 14, and a weft yarn 16. More particularly, the body 2 is obtained by knitting together the first and second knitting yarns 12, 14 and depositing the weft yarn 16 in this knitting, and the protuberance(s) 4 are obtained by knitting separately the first and second knitting yarns 12, 14 so that they are spaced apart from each other and depositing the weft yarn 16 in the protuberance 4 thus formed so as to form a padding of the protuberance 4. By knitted together, it is meant that the first and second knitting yarns 12, 14 cross in the body. At a protrusion 4, the first knitting yarn 12 forms the reverse side 6 of the protrusion 4 and the second knitting yarn 14 forms the right side 8 of the protrusion 4.

In the figures, the first knitting yarn 12 is shown in regular lines, the second knitting yarn 14 in dotted lines and the weft yarn 16 in bold lines.

The first knitting yarn 12 may be an elastic or non-elastic yarn having a count, for example, between 17 dtex and 680 dtex. By elastic, we mean a yarn that can be stretched under the effect of an external stress intended to lengthen the yarn and regaining its initial length when this stress ceases to be applied. An elastic yarn has, for example, a maximum elongation before breaking greater than or equal to 300%. By non-elastic, we mean a yarn that is substantially inextensible under the effect of an external stress intended to stretch the yarn. A non-elastic yarn has, for example, a maximum elongation before breaking less than or equal to 100%.

• Fibres en matière naturelle, telle que du coton, de la laine, du lin, du chanvre, etc. ;
• Fibres en matière artificielle, telle que de la viscose, etc. ;
• Fibres en matière synthétique, telle que du polyamide, du polyester, du polypropylène, etc.

A non-elastic thread is, for example, a thread made from one or more of the following textile materials:

• Natural fibers, such as cotton, wool, linen, hemp, etc.;
• Fibers made of artificial materials, such as viscose, etc.;
• Synthetic fibers, such as polyamide, polyester, polypropylene, etc.

An elastic yarn is, for example, a single-spun yarn, a double-spun yarn or a “core spun yarn” type structure.

• Fibres en matière naturelle, telle que du coton, de la laine, du lin, du chanvre, etc. ;
• Fibres en matière artificielle, telle que de la viscose, etc. ;
• Fibres en matière synthétique, telle que du polyamide, du polyester, du polypropylène, élasthanne, etc.

In the case of a single or double covered yarn, the covering operations are carried out by a spiral winding technique around an elastic core yarn, or by intermingling by air jet around an elastic core yarn. The core yarn is for example made of one or more elastane or latex filaments, the count of which is for example between 17 dtex and 475 dtex. The covering yarn(s) are made of one or more of the following textile materials:

• Natural fibers, such as cotton, wool, linen, hemp, etc.;
• Fibers made of artificial materials, such as viscose, etc.;
• Synthetic fibers, such as polyamide, polyester, polypropylene, elastane, etc.

• Fibres en matière naturelle, telle que du coton, de la laine, du lin, du chanvre, etc. ;
• Fibres en matière artificielle, telle que de la viscose, etc. ;
• Fibres en matière synthétique, telle que du polyamide, du polyester, du polypropylène, etc.

In the case of a "core spun yarn" type structure, the core yarn is, for example, made of an elastane or latex filament, with a yarn count between 17 dtex and 475 dtex. The fiber layers surrounding the core are, for example, made of one or more of the following textile materials:

• Natural fibers, such as cotton, wool, linen, hemp, etc.;
• Fibers made of artificial materials, such as viscose, etc.;
• Synthetic fibers, such as polyamide, polyester, polypropylene, etc.

The second knitting yarn 14 may also be an elastic or non-elastic yarn, examples of which are given above.

According to various embodiments, the first and second knitting yarns 12, 14 may be the same or different from each other. However, it should be noted that at least one of the first and second knitting yarns 12, 14 is an elastic yarn.

The weft yarn 16 is an elastic yarn. The weft yarn 16 has, for example, a count substantially between 300 dtex and 1500 dtex. More particularly, the weft yarn 16 is, for example, a double-wrapped yarn, comprising a core formed from an elastane monofilament having a count of 1280 dtex and two polyamide wrapping yarns.

According to various embodiments, in particular those shown in Figs. 2 to 6, the knitted article further comprises at least one third knitting yarn 18, which may or may not be elastic. In the case of a non-elastic third knitting yarn 18, the third knitting yarn 18 is, for example, a non-elastic yarn as described previously for the first and second knitting yarns 12 14. In the case of an elastic yarn, the third knitting yarn 18 is, for example, an elastic yarn as described previously for the first and second knitting yarns 12 14. In the figures, the third knitting yarn 18 is shown in thin lines.

As previously indicated and as shown in Figs. 3 and 8, in the body 2 is in the form of a tubular sheet formed by knitting the first and second knitting yarns 12, 14 together. Optionally, when present, the third knitting yarn 18 is also knitted with the first and second knitting yarns 12, 14 to form the body 2, as shown in the FIG. 4 . As shown in Figs. 3 and 8, in the body 2, the weft yarn 16 is laid tautly in the sheet, being more particularly held in place in the sheet by the first knitting yarn 12, as will be described in more detail later.

In the protrusion(s) 4, the first and second knitting yarns 12, 14 are knitted separately from each other and spaced apart from each other, so as to define between them a pocket 20, receiving the weft yarn 16. More particularly, the first knitting yarn 12 forms the reverse side 6 of the knitted orthosis 1 in the or each protrusion 4 and the second knitting yarn 14 forms the front side 8 of the knitted orthosis 1 in the or each protrusion 4. In the pocket 20, the weft yarn 16 is received freely and loosely so as to form a padding of the pocket 20, as shown in Figs. 2, 5 and 7. By "free and loose manner" is meant that the weft yarn 16 fills the pocket 20 by forming folds inside this pocket 20, the length of weft yarn 16 present inside the pocket 20 making it possible to adjust the thickness and flexibility of the pocket 20. In this way, the knitted orthosis 1 comprises a pad in the protuberance 4, this pad being able to form an insert for a joint, as described previously.

When a third knitting yarn 18 is provided, this is, according to a first embodiment shown in Figs. 2 and 4, knitted with the first knitting yarn 12 in the or each protuberance 4 so as to form with the first knitting yarn 12 the reverse side 6 of the knitted orthosis 1 in the or each protuberance 4. According to a second embodiment, shown in Figs. 5 and 6, the third knitting yarn 18 is received freely and loosely with the weft yarn 16 in the pocket 20 so as to form a padding of the pocket 20 with the weft yarn 16 in the or each protuberance 4 of the knitted orthosis 1.

The knitting of the different threads of the knitted orthosis will now be described according to different embodiments.

According to a first embodiment, the knitting of which is shown in Figs. 3 and 4, the knitted orthosis 1 comprises three knitting threads 12, 14 and 18, the third knitting thread 18 forming the reverse side 6 of the knitted article in the or each protuberance 4 with the first knitting thread 12 as described previously.

According to this embodiment, in the body 2 whose knitting is shown on the FIG. 3 , the first knitting yarn 12 is knitted according to a 1 and 1 rib structure and the second knitting yarn 14 is knitted according to a reverse stockinette structure. The third knitting yarn 18 is also knitted according to a reverse stockinette structure. This structure is produced by means of a knitting machine using n needles of the front needle bed and n needles of the rear needle bed. "n" corresponds to an integer number of needles and the choice of this number makes it possible to adjust the body 2. As indicated previously, the weft yarn 16 is laid taut in the sheet thus formed taut by being laid between the front and rear needle beds of the knitting machine.

In the or each protuberance 4 whose knitting is shown on the FIG. 4 , the first knitting yarn 12 is knitted in a reverse stockinette structure and the second knitting yarn 14 is knitted in a front stockinette structure. The third knitting yarn 18 is knitted in a back stockinette structure and forms with the first knitting yarn 12 the reverse side of the knitted orthosis 1 in the or each protuberance 4. In the or each protuberance 4, the first knitting yarn 12 and the third knitting yarn 18 are knitted using n' needles of the back bed and the second knitting yarn 14 is knitted using n' needles of the front bed. "n'" corresponds to an integer number of needles different from n and the choice of number makes it possible to adjust the width of the or each protuberance 4. The length of the or each protuberance 4 depends on the number of successive knitting rows. As previously indicated, the weft yarn 16 is deposited freely and loosely in the or each pocket 20 thus formed by being deposited between the front and rear needle beds of the knitting machine.

Such an embodiment allows the size of the protrusions on one side to be varied thanks to the presence of an elastic knitted yarn. In addition, when three knitted yarns are provided, it is possible to have yarns of different colors in order to give a particular appearance to the knitted orthosis.

According to a second embodiment, the knitting of a protuberance 4 is shown in the FIG. 6 , the knitted article 1 comprises three knitting yarns 12, 14 and 18, the third knitting yarn 18 forming the padding of the pocket 20 in the protrusion 4 with the weft yarn 16 as previously described.

According to this second embodiment, the knitting of the body 2 is identical to that of the body 2 of the first embodiment described previously.

In the or each protrusion 4, the first knitting yarn 12 is knitted in a reverse stockinette stitch structure and the second knitting yarn 14 is knitted in a front stockinette stitch structure. The third knitting yarn 18 is laid freely and loosely with the weft yarn 16 in the pocket 20 thus formed by being laid between the front and rear needle beds of the knitting machine. In the or each protrusion 4, the first knitting yarn 12 is knitted using n’ needles of the rear needle bed and the second knitting yarn 14 is knitted using n’ needles of the front needle bed. The choice of n’ makes it possible to adjust the width of the or each protrusion 4. The length of the or each protrusion 4 depends on the number of successive knitting rows.

Such an embodiment makes it possible to increase the thickness of the protuberance(s), or even their hardness.

According to a third embodiment, shown in Figs 7 to 9, the knitted orthosis 1 comprises only the first knitting yarn 12, the second knitting yarn 14 and the weft yarn 16. In other words, the knitted orthosis 1 does not comprise the third knitting yarn 18 described previously.

According to this embodiment, in the body 2 whose knitting is shown on the FIG. 8 , the first knitting yarn 12 and the second knitting yarn 14 are knitted according to a 1 and 1 dimension structure. This structure is produced by means of a knitting machine using n needles of the front needle bed and n needles of the rear needle bed. The choice of n makes it possible to adjust the width of the body 2. As indicated previously, the weft yarn 16 is laid taut in the sheet thus formed taut by being laid between the front and rear needle beds of the knitting machine.

In the or each protuberance 4 whose knitting is shown on the FIG. 9 , the first knitting yarn 12 is knitted in a reverse stockinette stitch structure and the second knitting yarn 14 is knitted in a front stockinette stitch structure. The first knitting yarn 12 is knitted using n' needles of the back needle bed and the second knitting yarn 14 is knitted using n' needles of the front needle bed. The choice of n' allows the width of the or each protrusion 4 to be adjusted. The length of the or each protrusion 4 depends on the number of successive knitting rows. As previously indicated, the weft yarn 16 is deposited freely and loosely in the pocket 20 thus formed by being deposited between the front and rear needle beds of the knitting machine.

Having only two knitting threads makes it possible to reduce the thickness of the sheet forming body 2 and to lighten the resulting knitted orthosis.

The knitted orthosis 1 according to the invention can therefore be obtained by knitting on a single knitting machine, the number, shape and dimensions of the one or more protuberances 4 relative to the body 2 being adjustable simply by varying the number of needles and the number of knitting rows to produce the body 2 and the protuberance(s) 4.

Claims (11)

Knitted orthosis (1) comprising a body (2) having a substantially tubular shape and at least one protuberance (4) extending projecting from at least one face of the body (2), said body (2) and said protuberance (4) being knitted from at least two knitting yarns (12, 14) and one weft yarn (16), the two knitting yarns (12, 14) being knitted together to form the body (2), the weft yarn (16) being deposited in said body (2), characterized in that the knitting yarns (12, 14) are knitted separately and are spaced apart from each other to form the protuberance (4), the weft yarn (16) being deposited in said protuberance (4) so as to pad said protuberance (4). A knitted orthosis according to claim 1, wherein the weft yarn (16) is elastic. Knitted orthosis according to claim 1 or 2, wherein the weft yarn (16) is laid tautly in said body (2) and freely and loosely in the protuberance (4). Knitted orthosis according to any one of claims 1 to 3, wherein at least one of the two knitted yarns (12, 14) is elastic. Knitted orthosis according to any one of claims 1 to 4, in which the protuberance (4) extends in an elongated shape on at least one of the faces of the body (2). Knitted orthosis according to claim 5, wherein the shape of the protuberance (4) extends according to a closed contour extending around a part of the body (2) or an opening (10) passing through the knitted orthosis in a thickness direction, said closed contour being surrounded at least in part by a part of the body (2). Knitted orthosis according to any one of claims 1 to 6, in which the protuberance (4) forms at least one patellar insert or at least one malleolar insert. Knitted orthosis according to any one of claims 1 to 7, in which the protuberance (4) has a hardness, on at least one of the faces of the protuberance (4), of between 25 sh 00 and 85 sh 00. A knitted orthosis according to any one of claims 1 to 8, wherein a first knitting yarn (12) of the knitting yarns is knitted in a 1 and 1 rib structure and a second knitting yarn (14) of the knitting yarns is knitted in a reverse jersey structure or in a 1 and 1 rib structure to form the body (2). A knitted orthosis according to claim 9, wherein the first knitting yarn (12) is knitted in a reverse jersey structure and the second knitting yarn (14) is knitted in a front jersey structure in the protrusion (4). A knitted orthosis according to any one of claims 1 to 10, further comprising a third knitting yarn (18), said third knitting yarn (18) being knitted with both knitting yarns (12, 14) in the body (2) and being knitted with only one of the knitting yarns (12, 14) in the protuberance (4) or being laid with the weft yarn (16) to pad the protuberance (4).