Body conforming interfaces for wearable assistance device

Abstract

A body interface for a wearable assistance device that comprises a flexible ventilated back panel that has inner and outer surfaces, and the inner surface includes an inner offset feature configured to face a back of a wearer of the wearable assistance device. The flexible ventilated back panel has a plurality of openings and a plurality of ribs. Primary straps are connected to an upper portion of the ventilated back panel. Secondary straps are coupled to a lower portion of the ventilated back panel but spaced a discrete distance from a bottom end of the back panel. Each of the secondary straps is adjustably coupled to one of the primary straps. The flexible ventilated back panel is configured to operatively connect to one or more elastic members that are configured to provide an assistive force to the back of the wearer.

Description

BODY CONFORMING INTERFACES FOR WEARABLE ASSISTANCE DEVICEGOVERNMENT FUNDING

[0001] This invention was made with government support under United States Army Grant No. W911NF2120078. The government has certain rights in the invention.CROSS-REFERENCE TO RELATED APPLICATION

[0002] This application claims the benefit of priority of U.S. Provisional Application Ser. No. 63 / 450,568, filed on March 7, 2023, and entitled “Body Conforming Interfaces for Wearable Assistance Devices and Systems” the content of which is relied upon and incorporated herein by reference in its entirety.BACKGROUND

[0003] The disclosure relates generally to wearable assistance devices and more particularly to body interfaces of those wearable assistance devices that are designed for the comfort of the user.

[0004] Exos (e.g. rigid exoskeletons and soft exosuits) are wearable devices that assist, support, enable or augment human movement, posture, or physical activity through mechanical interaction with the body. Occupational exos are used to provide physical relief and assistance to workers in demanding jobs and to reduce musculoskeletal injury risks and fatigue. For instance, shoulder exos support the arms during overhead work and back exos assist lifting and bending. However, for users to accept and adopt exos, the devices must also be sufficiently comfortable, practical to use, and not interfere with other critical job tasks or movements.

[0005] Commercially available occupational exos do not fully meet the needs of some users. Barriers to exo adoption include incompatibility of the exo with required tasks or gear, poor fit, discomfort, time to don and doff, or the need for a device to be worn discreetly. Providing for the user’s comfort is a particular challenge due to different body shapes, and because a person’s body changes shape as they move dynamically or adopt different postures. Furthermore, physical comfort needs of a user often must be balanced against thermal comfort needs; for instance, body interfaces that spread over larger areas of the body can benefit physical comfort but simultaneously hurt thermal comfort, and vice versa. Existing ways that exos interface with the body have limitations, which can negatively affect wearer comfort (e.g. physical or thermal) and adoption of wearable technology.SUMMARY

[0006] The present disclosure provides a body interface for a wearable assistance device that comprises a flexible ventilated back panel that has inner and outer surfaces, and the inner surface may include an inner offset feature configured to face a back of a wearer of the wearable assistance device. The flexible ventilated back panel has a plurality of openings and a plurality of ribs. Primary straps are connected to an upper portion of the ventilated back panel. Secondary straps are coupled to a lower portion of the ventilated back panel but spaced a discrete distance from a bottom end of the back panel. Each of the secondary straps is adjustably coupled to one of the primary straps. The flexible ventilated back panel is configured to operatively connect to one or more elastic members that are configured to provide an assistive force to the back of the wearer. In an embodiment, each primary strap may have an adjustable length.

[0007] In certain embodiments, the plurality of openings include central and lateral openings, and the central openings are smaller than the lateral openings; the plurality of ribs include at least one longitudinal rib and at least one transverse rib; the flexible ventilated back panel includes opposite sides each having a concave shape; a bottom edge of the outer surface of the flexible ventilated back panel is rounded; and / or each of the primary straps is a shoulder strap with an s-shape.

[0008] In other embodiments, a neck panel is coupled between the upper portion of the back panel and the primary straps, the neck panel having a stiffness that is less than a stiffness of the flexible ventilated back panel and greater than a stiffness of the primary straps; the inner offset feature is a cushion layer attached to the inner surface of the flexible ventilated back panel, and the cushion layer has cut-out sections that leave exposed the plurality of openings for ventilation; the cushion layer comprises foam and an adhesive backing, and may include an outer fabric covering the foam; and / or each of the primary straps includes upper and lower attachment points, and a ladder attachment (also referred to as a ladder lock buckle or ladder lock) accessory (or other attachment method such as hook and loop, snap, buttonjcouples each of the secondary straps to one of the upper and lower attachment points of one of the primary straps.

[0009] In some embodiments, the primary strap and secondary straps have extendable portions in addition to the adjustable coupling between the primary and secondary strap. In these embodiments, each of the primary straps includes a pocket, buckle, or mechanism for adjusting the length of the primary or secondary strap; each of the primary straps may include webbing that scrunches the primary straps when pulled, or adjusts telescoping inner and outer sleeves; anextendable yoke between the upper portion of the back panel and the primary straps; the secondary straps may include a panel extension is coupled between the back panel and each of the secondary straps.

[0010] The present disclosure may also provide a wearable assistance device that comprises an upper-body interface and a lower-body interface. The upper-body interface includes a flexible ventilated back panel that has inner and outer surfaces. The inner surface may have an inner offset feature configured to face a back of the wearer of the wearable assistance device. At least one elastic member couples the upper-body interface to the lower-body interface and is configured to provide an assistive force to the back of the wearer. One or more clutch mechanisms can be provided that are associated with the at least one elastic member and is configured for selectively adjusting the assistive force provided by the at least one elastic member. The lower-body interface may be one or more thigh sleeves.

[0011] In one embodiment, the upper-body interface includes primary straps connected to an upper portion of the ventilated back panel, each primary strap has an adjustable length, and secondary straps are coupled to a lower portion of the ventilated back panel but spaced a discrete distance from a bottom end of the back panel, and each of the secondary straps is adjustably coupled to one of the primary straps.

[0012] In another embodiment, the clutch mechanism is supported on the outer surface of the back panel. An actuator for switching the clutch mechanism between engaged and disengaged modes can be provided which can be located on a shoulder strap of the upper-body interface.

[0013] In yet another embodiment, the flexible ventilated back panel includes a plurality of central and lateral openings wherein the central openings are smaller than the lateral openings, and includes a plurality of ribs comprising at least one longitudinal rib and at least one transverse rib, and includes opposite sides each having a concave shape.

[0014] In an alternative embodiment, the inner offset feature is a cushion layer attached to the inner surface of the flexible ventilated back panel, and the cushion layer has cut-out sections that leave exposed the plurality of openings for ventilation.

[0015] This summary is not intended to identify essential features of the claimed subject matter, nor is it intended for use in determining the scope of the claimed subject matter. It is to be understood that both the foregoing general description and the following detailed description areexemplary and are intended to provide an overview or framework to understand the nature and character of the disclosure.BRIEF DESCRIPTION OF THE FIGURES

[0016] The accompanying drawings are incorporated in and constitute a part of this specification. It is to be understood that the drawings illustrate only some examples of the disclosure and other examples or combinations of various examples that are not specifically illustrated in the figures may still fall within the scope of this disclosure. Examples will now be described with additional detail through the use of the drawings, in which:

[0017] FIGS. 1A and IB are front or inner elevational views of an exemplary body interface according to the present disclosure;

[0018] FIG. 2A is a rear or outer elevational view of the body interface of FIGS. 1A and IB, showing the body interface worn by a user;

[0019] FIG. 2B is a partial enlarged view of a back panel of the body interface illustrated in FIGS. 1 A and IB;

[0020] FIGS. 3 A and 3B are a side elevational view of the body interface of FIGS. 1A and IB, showing the body interface worn by a user that is in a bent over position and showing force vectors as applied to the body interface;

[0021] FIG. 4 is a view of an exemplary wearable assistance device according to the present disclosure, showing the device worn by users;

[0022] FIG. 5 A is a view of a neck portion of the body interface of FIGS. 1 and IB, and FIG. 5B shows the neck portion integrated into shoulder straps of the body interface;

[0023] FIG. 6 shows partial top and views of the body interface, illustrating ventilation gaps provided by the body interface;

[0024] FIG. 7 is a partial view of the body interface, showing an actuator attached to a shoulder strap of the body interface and showing an engagement mechanism for connecting a clutch to the body interface;

[0025] FIG. 8 A shows a ladder attachment accessory for use with the body interface, FIGS. 8B and 8C show the ladder strap accessory used with an exemplary shoulder strap of the body interface for adjusting the length (i.e. extending or shortening) of the shoulder strap, and FIG. 8D shows a pocket integrated into the shoulder strap for receiving a loose end of an adjustment strap;

[0026] FIGS. 9A-9C are side elevational views of exemplary shoulder and back straps of a body interface of the present disclosure, showing upper and lower attachment locations for adjusting the straps of the body interface; this embodiment allows adjustment of the length of the shoulder straps by attaching the secondary strap to different locations on the primary shoulder strap.

[0027] FIGS 10A and 10B are elevational views of an exemplary shoulder strap of a body interface of the present disclosure, showing webbing used to adjust the length of the shoulder strap;

[0028] FIGS. 11A-11D are elevational views of an exemplary shoulder strap of a body interface of the present disclosure, showing inner and outer sleeves used to adjust the length of the shoulder strap;

[0029] FIGS. 12A and 12B are elevational views of exemplary adjustable attachment of a shoulder strap of a body interface of the present disclosure;

[0030] FIG. 13 is an elevational view of exemplary panel extensions of a body interface of the present disclosure with semi-rigid plastic construction;

[0031] FIG. 14 is a back elevational view an exemplary extendible yoke of a body interface of the present disclosure;

[0032] FIGS. 15A-15C are various views of a back panel of the body interface of the present disclosure, showing the back panel with an inner offset feature;

[0033] FIG. 16 is a diagram of the offset illustrated in FIGS. 15A-15C showing the layers of the inner offset feature and the position of the inner offset feature between the back panel and the back of the user of the wearable assistance device;

[0034] FIG. 17 is a partial enlarged view of the inner offset feature illustrated in FIGS. 15A-15C;

[0035] FIG. 18 is an elevational view of exemplary panel extensions of a body interface of the present disclosure with fabric and foam construction, in accordance with an exemplary embodiment of the present disclosure;

[0036] FIG. 19 is a perspective view of a portion of the inner offset features illustrated in FIGS. 15A-15C with fabric and foam construction and an adhesive backing in accordance with an exemplary embodiment of the present disclosure.DETAILED DESCRIPTION

[0037] It is to be understood that the figures and descriptions of the present disclosure may have been simplified to illustrate elements that are relevant for a clear understanding of the present disclosure, while eliminating, for purposes of clarity, other elements found in a typical wearable assistance device or typical method of using a wearable assistance device. Those of ordinary skill in the art will recognize that other elements may be desirable and / or required in order to implement the present disclosure. However, because such elements are well known in the art, and because they do not facilitate a better understanding of the present disclosure, a discussion of such elements is not provided herein. It is also to be understood that the drawings included herewith only provide diagrammatic representations of the presently preferred structures of the present disclosure and that structures falling within the scope of the present disclosure may include structures different than those shown in the drawings. Reference will now be made to the drawings wherein like structures are provided with like reference designations.

[0038] Before explaining at least one embodiment in detail, it should be understood that the inventive concepts set forth herein are not limited in their application to the construction details or component arrangements set forth in the following description or illustrated in the drawings. It should also be understood that the phraseology and terminology employed herein are merely for descriptive purposes and should not be considered limiting. It should further be understood that any one of the described features may be used separately or in combination with other features. Other invented devices, systems, methods, features, and advantages will be or become apparent to one with skill in the art upon examining the drawings and the detailed description herein. It is intended that all such additional devices, systems, methods, features, and advantages be protected by the accompanying claims.

[0039] Wearable assistance devices apply forces to the user’s body via body interfaces. The present invention relates to wearable assistance devices and particularly body interfaces thereof. A body interface according to an embodiment of the present disclosure is an upper-body interface that is configured to exert these forces in a comfortable manner to wearer. The body interface of the present disclosure is also ventilated to be thermally comfortable. The body interface is alsodesigned to be flexible and conform to the body of the user based on the user’s particular body shape and also changes to the body’s shape that may occur as the user moves dynamically or adopts different postures. The features of this novel body interface enable it to be both thermally and physically comfortable in a wide range of body postures, which overcomes limitations of existing body interfaces for wearable assistance devices, which tend to sacrifice either physical or thermal comfort or comfort in different body postures.

[0040] For purposes of this disclosure, the term “body interface” refers to the component of the exosuit (e.g., a sleeve, strap, cuff, harness) that physically touches, attaches to, or applies force to the wearer’s body. The body interface may be positioned against the skin or inside or on top of the wearer’s clothing.

[0041] A wearable assistance device 10 of the present disclosure generally comprises an upperbody interface 20, a lower-body interface 30, and one or more elastic members 40 connecting the upper-body and lower body-interfaces 20 and 30, as seen in FIG. 4. The elastic members 40 (e.g. springs or elastic bands) are configured to provide assistive force to the back of the wearer, such as when the wear bends or lifts. Device 10 can also include a clutch mechanism 50 operatively coupled to elastic members 40 that can be actuated between engaged and disengaged modes for selectively adjusting the assistive force provided by the elastic members 40. For instance, such that the wearable assistance device 10 offloads the wearer’s back when the clutch mechanism 50 is engaged and they bend forward or lift, and such that the wearable assistance device 10 does not provide substantial assistance or impede or restrict the wearer’s movement when the clutch mechanism 50 is disengaged.

[0042] FIGS. 1 A and IB are front or inner views of upper-body interface 20 and FIG. 2A is a rear or outer view of upper-body interface 20 showing upper-body interface 20 worn on top of the wearer’s shirt. The upper-body interface 20 can be in the form of a harness that is comprised of a support frame or back panel 22, primary straps 24, and secondary straps 26. The lower-body interface 30 can be one or more leg sleeves, as seen in FIG. 4. The elastic members 40 mechanically couple the upper-body and lower-body interfaces 20 and 30.

[0043] The primary straps 24 of upper-body interface 20 can be shoulder straps (e.g. left and right backpack style shoulder straps or harness) that cover at least a portion of the shoulders, and the secondary straps 26 can be webbing straps. The back panel 22 has inner and outer surfaces 62 and 64 where inner surface 62 is configured to face a back of the wearer or user of the wearableassistance device 10 and the outer surface 64 is configured to face away from the wearer or user. The outer surface 62 of back panel 22 can include a rounded bottom edge 71 at the bottom end 70 thereof. The bottom edge 71 being rounded facilitates movement of the elastic members 40 along back panel 22 and reducing the potential for the elastic members 40 snagging on back panel 22.

[0044] For added comfort, an inner offset feature 60 can be provided on the inner surface 62 of back panel 22 to provide cushioning and ventilation between back panel 22 and the back of the wearer of device 10. The back panel 22 has an upper portion 66 that can couple to primary straps 24 (also referred to herein as “shoulder straps”) and a lower portion 68 that can couple to secondary straps 26 (also referred to herein as “back straps”). Primary and secondary straps 24 and 26 are adjustably coupled to one another at their respective opposite ends, which is remote from where each of the primary and secondary straps 24 and 26 are attached to the upper and lower portions 66 and 68, respectively, of the back panel 22. Any type of buckle or adjustable strap attachment (such as a ladder attachment accessory 106 in FIGS. 3 A and 8A, or hook and loop, snaps, magnets, buttons, zippers), can be used to adjustably couple the primary and secondary straps 24 and 26.

[0045] As seen in FIG. 3A, upper-body interface 20, and particularly back panel 22, is designed to be flexible as the user bends over. In an embodiment, secondary or back straps 26 may attach at the bottom end 70 of back panel 22. In other embodiments, the secondary or back straps 26 may attach near but not at the bottom end 70 of back panel 22, as seen in FIG. 1A. That is, although back straps 26 are connected to the lower portion 68 of a back panel 22, back straps 26 may be spaced from the bottom end 70 of back panel 22, as seen in FIG. 3 A, to better conform to the user’ s body. In other words, the attachment location L (FIGS. 1 A and 3A) where back straps 26 attach onto back panel 22 can be spaced a discrete distance D (FIG. 2A) away from the bottom end 70 of back panel 22 (rather than right at the panel’s bottom end 70). That discrete distance from bottom end 70 of back panel 22 to the attachment location L where back straps 26 attach to back panel 22 can be between about 20 to 80 mm, for example. It is non-obvious and beneficial to attach the back straps 26 a discrete distance above the bottom end 70 of the back panel 22 because if the straps 26 were attached at the very bottom, then under load (i.e., when the exosuit is assisting), back panel 22 could curl, pressing into the user’s lower back at the bottom edge of back panel 22, which could cause discomfort. By attaching a discrete distance D (FIG. 2A) above the bottom end 70 of the back panel 22, the back panel 22 better conforms to the user’s body when the device 10 is under load, smoothing out the pressure distribution across the back top to bottom and left to right in a "fishtail" pattern (FIG. 3A). This unique upper-body interface design overcomes the limitations of existing body interfaces related to physical comfort, particularly during bending.The combination of features, including where the back straps attach to the back panel, provides enhanced comfort during bending postures and reduces uncomfortable pressure points along the back relative to previous interfaces.

[0046] As seen in FIGS. 1A, IB, 2A, and 3B, back panel 22 has opposite sides 29 (i.e. left and right sides) that each have a concave curve shape to give space for the user’s shoulder blades. This shape is maintained and complemented in the profile of the primary straps 24 (FIGS. 1 A and 2A). That is beneficial because it enables the shoulders to freely move in all orientations, to ensure freedom of movement and comfort. The concave sides of the back panel 22 also help minimize surface area covered on the wearer’s back to enhance thermal comfort. The back panel 22 includes a plurality of openings that comprise central openings 74 generally positioned in the middle of back panel 22 and lateral openings 76 generally positioned along the side portions of back panel 22 (or on either side of central openings 74), as seen in FIGS. IB and 3B. The central openings 74 can be smaller than the lateral openings 76. The smaller central openings 74 provide thermal ventilation while also allowing elastic members 40 (or other exo components) to move without getting snagged. For instance, as seen in Fig. 3A, there is a carabiner and fabric attachment at the top of the elastic members 40, which slides up and down the back panel (i.e. toward and away from the clutch mechanism 50). If the central openings 74 are too large, then these parts of the elastic member or attachments to the elastic member may snag on the central openings 74. The benefit of the lateral openings 76 being larger is that they provide larger open areas for ventilation and airflow, and these are sufficiently lateral such that the elastic members do not slide or move over these areas of the back panel, thus the larger openings do not create a snag risk for the elastic members 40. Slots 78 may also be provided at various locations on back panel 22, such as along the perimeter thereof, for receiving straps or webbing, such as when attaching the primary or secondary straps 24 and 26 to back panel 22 (e.g. by looping the straps through the slots 78). At least two of the slots 78 are at the attachment locations L (FIG. 3 A) spaced the discrete distance D (FIG. 2) away from the bottom end 70 of back panel 22 for receiving one of the back straps 26.

[0047] Back panel 22 may also have one or more longitudinal ribs 80 (e.g. two to six longitudinal ribs) that generally run vertically between the top and bottom of back panel 22, and one or more transverse ribs 82 (e.g. one to four transverse ribs) that generally run horizontally between the left and right sides of the back panel 22. Each of the longitudinal ribs 80 and the transverse ribs 82 is configured to give stiffness along the appropriate lines to prevent buckling of back panel 22 or uncomfortable pressure concentrations applied to the wearer, for example, when the assistive force is applied by the one or more elastic members 40. Buckling of the back panel could impair devicefunction or wearer comfort. Thus, these ribs can play an important role in enabling the proper function of the wearable assistance device 10 and enabling physical comfort in the presence of openings on the back panel that enable thermal comfort. The longitudinal ribs 80 and the transverse ribs 82 also provide a surface for attachment of the inner offset feature 60. The longitudinal and transverse ribs 80 and 82 may be linear or curvilinear. The ribs 80 and 82 may span the entire length or height of the back panel 22, or only a portion of the length or height of the back panel 22.

[0048] The design of back panel 22 accounts for the forces applied to back panel 22 in all directions when the device 10 is in use. FIG. 3B illustrates the force vectors (labeled as vectors A-E) on back panel 22 when the device 10 is worn by a user, particularly when the user bends over. Force vectors A-C (shown as arrows A-C) are in tension and force vectors D and E (shown as arrows D and E) are in compression (i.e. normal to the view or toward the wearer).

[0049] The primary or shoulder straps 24 can be comprised of foam and fabric, similar to the backpack straps. The shoulder straps 24 may contain loops, pockets, or other buckles or attachment points 84 (FIGS. 1 A and 7), such as for attaching exo components or accessories or for capturing cables or other exo hardware to reduce snag risk and / or secure components. In an embodiment, the shoulder straps 24 may contain one or more sternum straps that connect across the chest (between the left and right shoulder straps), and which are connected using buckles, hooks, or other removeable fasteners. The sternum straps can be used to improve fit and comfort of the upper-body interface, for example, to pull the shoulder straps away from the armpit area of the wearer, which can improve comfort during reaching.

[0050] In an embodiment, primary or shoulder straps 24 are shaped like S curves, as seen in FIG. 5B, which better conforms to the wearer’s body compared to a single curve. That shape allows shoulder straps 24 to curve around the neck region, which prevents rubbing of the upper-body interface 20 on the neck. That shape also curves away from the armpit region, which prevents high pressures or discomfort on the pectoral tendon region during forward reaching. The S-shape of shoulder straps 24 helps maximize comfort and promote even pressure distribution of load on the upper-body. The shoulder straps 24 may also have other shapes, such as those commonly found on different backpacks, harnesses, or rucksacks.

[0051] The upper-body interface 20 can also incorporate a neck portion or panel 28 located between back panel 22 and shoulder straps 24. FIG. 5A shows the neck panel 28 and FIG. 5Bshows the neck panel 28 attached to shoulder straps 24. In an embodiment, a top end of back panel 22 connects to the bottom 86 of neck panel 28, and the top 88 of neck panel 28 connects to left and right shoulder straps 24 (as seen in FIG. 5B).

[0052] The neck panel 28 can be formed of a relatively thin flexible material (e.g., 0.4-2.0 mm), such as plastic. The neck panel 28 may or may not be covered in fabric and / or foam. The neck panel 28 is positioned near the neck area of the user when wearing the device 10. In some embodiments, the neck panel 28 can provide a transition between back panel 22 and shoulder straps 24 which can have different stiffnesses. That is, due to the back panel’s configuration and the plastic material which forms the back panel 22, the back panel 22 can have a stiffness that is greater than the stiffness associated with the shoulder straps 24 (which may be formed of softer materials, such as fabric and foam). In some embodiments, the neck panel 28 can be of an intermediate stiffness relative, i.e. in between the stiffness of back panel 22 and the stiffness of the shoulder straps 24 to thus serve as a transition material / component. That prevents excess folding and distortion in the soft goods. The neck portion 28 also helps create one or more ventilation gaps G (FIG. 6) for releasing heat from the neck region when the upper-body interface 20 is worn.

[0053] In an embodiment, there are more than one back panels or more than one neck panels. Those may be connected via fabric or webbing or other connectors (e.g., hook and loop).

[0054] In some embodiments, shoulder straps 24 are removeable from neck panel 28, for example, by using hook and loop, zippers, buckles, or buttons; or shoulder straps 24 are non-removably attached to neck panel 28, for example, via sewn fabric, adhesive, or rivets. In an embodiment, neck panel 28 is optional for upper-body interface 20, and shoulder straps 24 can be coupled directly to the upper portion 66 of back panel 22 without neck panel 28 in between.

[0055] As seen in FIGS. 8A-8C, in an embodiment, shoulder straps 24 can have adjustable lengths. At or near the bottom end of each shoulder strap 24 are upper and lower attachment points 102 and 104 that are spaced from one another. The upper and lower attachment points 102 and 104 can be loops, for example. An adjustable attachment accessory 106 can be connected to either the upper or lower attachment points 102 and 104. The adjustable attachment accessory 106 can be a ladder attachment, for example, through which one of the back straps 26 can be threaded (as seen in FIG. 3 A) for coupling the back strap 26 to the shoulder strap 24 in an adjustable manner. The attachment accessory 106 can include a clip 108 for coupling to the loops of the attachment points 102 and 104. When the attachment accessory 106 is connected to the upper attachment point 102of the shoulder strap 24, the shoulder strap 24 has a first length (also referred to herein as a “shortened length”), as seen in FIG. 8B. When the attachment accessory 106 is connected to the lower attachment point 104, the shoulder strap has a second length (also referred to herein as “extended length”) that is longer than the first length. A pocket 110 (FIG. 8D) can be provided on the shoulder straps 24 for receiving the loose or tail ends 112 of the shoulder strap 24 when the back strap 26 is coupled to the attachment accessory 106 at the upper attachment point 102. In an alternate embodiment, the loose or tail ends 112 of the shoulder strap 24 can instead be attached to shoulder strap 24 by means of buckles, snaps, hook and loop, or other attachment methods in addition to or instead of a pocket 110. The loose ends of the back straps 26 can also be folded and clipped to the shoulder straps 24.

[0056] FIGS. 9A-9C show side views of the shoulder and back straps 24 and 26 of upper-body interface 20 showing the locations of upper and lower attachment points 102 and 104 on the shoulder straps 24 for adjusting the straps of the body interface. With the back strap 26 threaded through the ladder attachment accessory 106, the clip 108 of the ladder attachment accessory 106 allows it to be easily connected at either location 102 and 104 per the choice of the user for a custom fit.

[0057] FIGS 10A and 10B illustrate an alternative shoulder strap 24’ of upper-body interface 20 that uses webbing 25’ to adjust the length of the shoulder strap. The webbing 25’ can be pulled such that the bottom portion of the shoulder strap 24’ scrunches or folds to adjust the length of the shoulder strap 24’ from an extended length (FIG. 10A) to a shortened length (FIG. 10B). In this embodiment, a webbing strap 27’ passes through a ladder lock buckle 28’. The webbing strap 27’ may be hidden within (e.g. passing inside) the shoulder strap 24’, or may alternatively be configured to be on the inside or outside of the shoulder strap 24’. When the webbing 25’ is pulled, the webbing strap 27’ shortens inside shoulder strap 24’, forcing the bottom portion of the shoulder strap 24’ to scrunch or fold to the shortened length. The ladder lock buckle 28’ locks the webbing length when tension is applied to shoulder strap 24’ to maintain the shortened length. The ladder lock buckle 28’ can then be loosened to lengthen the amount of webbing strap 27’ inside shoulder strap 24’ and return to the extended length.

[0058] FIGS. 11A-11D illustrate another alternative shoulder strap 24” of upper-body interface 20 that comprises separate inner and outer telescoping portions or sleeves 25” and 27” that are attached by a webbing 29” for adjusting the length of the shoulder strap to obtain a custom fit for the wearer. FIG. 11C shows the shoulder strap 24” in a shortened configuration or shortenedlength and FIG. 11D shows the shoulder strap 24” in an extended configuration or extended length. As seen in FIG. 11 A, the webbing 29” is attached to the strap’s outer sleeve 27”. The inner and outer sleeves 25” and 27” are configured such that the bottom portion of the shoulder strap 24” slides up or down when webbing 29” in a ladder lock 23” is adjusted. In this embodiment, webbing 29” (also referred to as a “pull strap”) passes through a ladder lock buckle 23”, for example, and is attached to an upper portion 28” of the inner sleeve 25”. When webbing or pull strap 29” is pulled, the webbing 29” in turn pulls on inner sleeve 25” and slides it inside of the outer sleeve 27”, thereby shortening the length of shoulder strap 24”, as seen in FIG. 11C. The ladder lock buckle 23” locks the length of webbing 29” when tension is applied to shoulder strap 24” to maintain the shortened length. The ladder lock buckle 23” can then be loosened to lengthen the webbing 29” inside shoulder strap 24” such that inner sleeve 25” retreats from outer sleeve 27”, thereby returning the shoulder strap 24” to its extended length.

[0059] FIGS. 12A and 12B are views of an alternative adjustable attachment 120 that can be used to connect each shoulder strap 24 to back panel 22 of upper-body interface 20. Adjustable attachment 120 includes an extendable panel 122, which may be a length of webbing, a mesh panel or fabric panel, and / or a telescoping sleeve. FIG. 12A shows shoulder strap 24 with the adjustable attachment 120 in the shortened configuration attached to an upper attachment point 123 on shoulder strap 24. FIG. 12B shows shoulder strap 24 with the adjustable attachment 120 in the extended configuration attached to a lower attachment point 124 on shoulder strap 24. The adjustable attachment 120 may be a buckle, hook and loop fastener, ladder lock, snap or other attachment method that interfaces with a mating connection at upper and lower attachment points 123 and 124, either directly connected, such as a buckle, or an adjustment mechanism, such as a webbing passing through a ladder lock. The mechanism for shortening and extending the length of shoulder strap 24 may be a webbing attachment similar to FIGS. 8A-8D, and / or FIGS. 9A-9C, or a folding or scrunching mechanism similar to FIGS. 10A-10B, or a telescoping sleeve configuration similarly to 11 A-l ID .

[0060] As seen in FIGS. 13 and 18, the upper-body interface 20 may include optional panel extensions 112 that can connect near or at the bottom of back panel 22 for additional comfort to the wearer of device 10. The panel extensions 112 can be designed to curve around the lower back of the user. The panel extensions 112 can be semi-rigid plastic (e.g., 0.4 - 2 mm), and may be ventilated with openings similar to other back panel embodiments described herein. Alternatively, the panel extensions 112 can be made of soft materials, such as foam or fabric, or a combination of semi-rigid plastic, foam and fabric. The panel extensions may be molded into the back panel22 and / or separately attached. Each panel extension 112 includes attachment points 114 for attaching to the back straps 26. The attachment points 114 can be provided at various locations on the panel extension 112. The spacing of the attachment points 114 can vary, allowing for adjustment of strap length by adjusting the attachment of a secondary strap 26 to any attachment point 114.

[0061] FIG. 14 is a back view of upper-body interface 20 showing an optional extendable yoke 116 added to the interface which can fit on or over part of the user’s shoulders. The extendable yoke 116 can be added to the upper portion 66 of back panel 22 (and / or added to a neck panel 28). The extendable yoke 116 may include one or many connectors 118 of adjustable length to extend the yoke length; examples include hook and loop fasteners, a number of ladder locks (or any other type of buckle) with associated webbing, and / or other fastener types including clips, buttons, snaps, zippers, and magnets. In the example embodiment in FIG. 14, the connectors 118 are ladder locks with associated webbing. The webbing of the ladder locks 118 can be pulled or loosened to adjust the length between the upper portion 66 of back panel 22 and the neck panel 28. The extendable yoke 116 allows the wearer to extend the total length of the upper-body interface 20 for a more customized fit. When the yoke is in the extended position it also provides additional ventilation to improve thermal comfort for the wearer of device 10 by providing an additional air gap-

[0062] Referring to FIGS. 15A-15C, back panel 22 can include the inner offset feature 60 for added comfort. The inner offset feature 60 can be a cushion layer designed to provide an offset for ventilation and cooling as well as cushioning for between the back of the wearer and back panel 22. The inner offset feature 60 (also referred to herein as the “cushion layer”) can be made of foam, for example, that is attached to the inner surface 62 of back panel 22 via an adhesive layer. The cushion layer 60 can have a pattern generally corresponding to the pattern of back panel 22. For example, the cushion layer 60 may comprise multiple struts 130 that extend along longitudinal and transverse ribs 80 and 82 of the back panel 22. The cushion layer 60 can also have central and lateral cut-out sections 132 and 134 to accommodate (i.e. leave exposed) the plurality of central openings 74 and lateral openings 76, respectively, in the back panel 22 to maintain ventilation and thermal comfort. FIG. 16 is a diagram of the inner offset feature 60 showing the layers of the inner offset feature 60 and the position of the offset feature 60 between the back panel and the back of the user of the wearable assistance device 10. In an embodiment, the cushion layer 60 comprises foam 136 and an adhesive backing 138; in another embodiment the cushion layer 60 comprises foam 136, an adhesive backing 138, and an outer fabric 140 covering the foam 136, as seen inFIGS. 16 and 19. The cushion layer 60 can include narrow lips 142 (FIG. 17) along the edges thereof to increase the adhesion to the back panel 22 (via adhesive backing 138) to reduce peeling when forces are applied to the cushion layer 60. This unique construction provides a benefit in terms of durability while allowing the other features of the back panel needed for physical and thermal comfort.

[0063] The protective fabric 140 can be added to the outer surface of the foam 136 of cushion layer 60. For example, the fabric 140 can be stretched over the foam’s outer surface to cover the same to provide a fabric encapsulated foam layer, and the fabric may be attached to the foam by adhesives, heat, molding, or other processes. The fabric 140 is designed to be an abrasive-resistant material that can easily slide against the wearer’s clothing. The fabric 140 also protects the foam 136 of the cushion layer 60. The foam can be, for example, 2 to 20 mm in height. The foam can be made from or replaced with any cushioned material. The foam stiffness is designed to minimize the distance the device 10 projects from the back of the user, while still providing sufficient cushioning to prevent discomfort from forces applied to the panel. The stiffness is also selected to prevent rigid components of the device 10 such as the clutch attachment mechanism 52 from pressing on the back of the user.

[0064] The pattern of the cushion layer 60 can include one or more divots or gaps 144 (5 to 50 mm wide, for example) in the center of back panel 22 to reduce pressure from back panel 22 on the spinal column or vertebrae. As seen in Fig. 15A and 15B, there is a gap 144 in the foam such that when this is against the back of the wearer and force is applied to push the back panel into the wearer’s back, there will be less force applied to the spinal vertebrae in the center of the back (because the foam is not in contact with the back) and instead the foam will transmit more force to the lateral sides of the wearer’s back on either side of the spine. This configuration improves the physical comfort of the wearer by lessening pressure directly against the spinal column. That divot 144 in the cushion layer 60 can be at the top, middle, bottom, or all along the back panel. These divots or gaps may also be placed at any locations on the cushion layer to reduce pressure at those points. In other embodiments the divots or gaps may be created by gradual slopes or curves rather than distinct discontinuities in the foam. In other embodiments the divots or gaps are instead created by shaped features in the back panel 22 and the foam remains a consistent thickness and / or contains divots or gaps.

[0065] Although upper-body interface 20 is shown as being a separate accessory worn over the wearer’s clothing, upper-body interface 20 can be attached or embedded into the user’s clothing,e.g. uniform, in any manner, such as by being sewed into clothing for the wearer’s upper body, such as a shirt. The upper-body interface 20 can also include one or more optional chest straps (also called sternum straps) for additional comfort of the wearer.

[0066] The back panel 22 is designed to be flexible to accommodate the comfort of the wearer while also being strong enough to bear the loads it experiences during user movement and assistive forces provided by the device 10. For example, the back panel 22 can be made of plastic or composite materials, such as ABS plastic, Kydex, Delrin, or carbon fiber. The back panel may also be constructed of other materials such as metal, rubber, foam, fabric and combinations thereof. The back panel 22 may be relatively thin (e.g. 1 mm - 5 mm).

[0067] For purposes of this disclosure, any connections between components of the body interface can be made in any known manner, for example, via sewn fabric or webbing, hook and loop (e.g., VELCRO), buttons, rivets, magnets, snaps or the like.

[0068] The upper-body interface 20 can be part of wearable assistance device 10, which can be an exo (exoskeleton or exosuit), to support the back or other body parts (e.g. neck, arms, legs). For purposes of this disclosure, the term “exosuif ’ refers broadly to a type of exo that is constructed, at least in part, from soft materials such as textiles and elastomers. An exosuit is also known as a soft exoskeleton or soft exo. An exosuit can be powered (e.g., motorized), passive, or quasipassive. For a powered exosuit, the clutch mechanism may be replaced with or used in combination with a powered actuator such as an electric motor that controls or exerts force on the elastic member (e.g. creates a tension force along the elastic member). For a quasi-passive exosuit, wearable sensors to detect joint angles, forces applied to the body or other signals may be included. The exosuit can include high-tech, breathable fabric, padding, or slip-resistance features in the right places to comfortably conform to the wearer’s body. The wearable assistance device 10 may include physical assistance and mode-switching capabilities. The wearable assistance device 10 can, for example, provide back assistance torque (e.g., 10-50 Nm) during bending and lifting, which reduces back muscle activity and fatigue. Alternatively, the body-conforming interface described here can be used as a component of a different type of wearable device, for example, to assist the shoulders or neck or other body joint or segment. In some embodiments, the upper-body interface detailed herein to be worn on the trunk of the user may be lower than or proximal to the lower-body interface (e.g., on the head or arms).

[0069] In one embodiment, the back panel 22 of the upper-body interface 20 supports the clutch mechanism 50 on its outer surface 64, as seen in FIG. 2A. The back panel 22 may include a clutch attachment mechanism 52 (FIG. 7) that can releasably attach clutch mechanism 50. The clutch attachment mechanism 52 can be a hot shoe or other quick connect and release type mechanism. For example, the quick release mechanism can be achieved with a pattern of bolts on the clutch that rotationally tightens into a pattern of cam-locking slots on the back panel. A spring-loaded pin may serve as an additional feature to lock the clutch mechanism 50 into place, or to unlock and remove the clutch mechanism 50 from back panel 22. In another embodiment, clutch mechanism 50 is affixed to the outer surface 64 of back panel 22 with fasteners, e.g. screws, bolts, rivets, or other permanent or removable fasteners.

[0070] The lower-body interface 30 can comprise thigh sleeves (or shorts or pants or other types of legs sleeves or attachments) that are configured to wrap around each leg, as seen in FIG. 4. The lower-body interface 30 may comprise soft goods (fabric, foam, and elastic materials). The thigh sleeves can be attached or integrated into clothing, or they can be separate accessories worn on the legs, on top of or under pants. The thigh sleeves can also be supported by a fabric loop (similar to a belt loop) that attaches to a belt around the wearer’s waist. These loops may be permanent or removable, and / or fixed in length and / or adjustable.

[0071] The one or more elastic members 40 may be comprised of springs, elastic bands, bungee cords, webbing, straps, or any other component or material containing any amount of elasticity or viscoelasticity. The one or more elastic members 40 can be comprised of a single elastic stiffness. Or each elastic member 40 can be segmented into multiple elastic elements in series, or in parallel, of different stiffness. There may be one or more clutch mechanisms 50 that are each configured to adjust the force of one or more elastic members 40. The clutch mechanism 50 can be positioned between two of these elastic elements. For example, each first elastic element can be a rotor spring housed inside the clutch mechanism 50 which is loaded in series with a second elastic element when the clutch mechanism is disengaged, and which loads only the second elastic element when the clutch is engaged (by bypassing the first elastic element). Each second elastic element can be an elastic band or other elastic or viscoelastic element configured to provide an assistive force to the back of the wearer, for instance, to provide lifting assistance when a user bends forward. During bending or lifting, these elastic bands stretch, creating an extension torque about the lumbar spine that reduces strain on the back muscles and discs, and an extension torque about the hips which further assists with lifting or standing upright. Different elastic or viscoelastic elements can be used, such as linear and rotational springs and different materials for the springs (e.g., metal,elastomer, fabric). Different methods of clutching and mode-switching can also be used to engage and disengage, or adjust assistance, of the wearable assistance device.

[0072] For purposes of this disclosure, the term “clutch” or phrase “clutch mechanism” may include any device that engages and disengages mechanical elements (e.g., elastic members) that bear or transmit force or mechanical power. A clutch mechanism may be unpowered such that it engages and disengages based on manual input (e.g., manual actuator, also referred to as a switch) and / or based on movement from the user. Alternatively, a clutch mechanism may be powered such that a motor or other actuator with its own power supply is used to control engagement and disengagement, or to control the position of clutch engagement relative to one or more mechanical elements (e.g., elastic members), or to control the set point of an elastic member relative to the position of clutch engagement, thereby adjusting or setting tension of, for example, elastic member(s). The clutch mechanism may be used in combination with additional motors or actuators that provide force parallel, transverse or perpendicular to elastic members. The engaging and disengaging by the clutch mechanism of a mechanical element may be achieved by any form of clutch or brake, for example, a ratchet, dog clutch, cam clutch, friction clutch, overrunning clutch, disc brake, drum brake, latch, or buckle. Each clutch mechanism 50 may be configured to adjust the force of one elastic member 40, or one clutch mechanism 50 may be configured to adjust the force of two or more elastic members 40, or multiple clutch mechanisms 50 may each be configured to adjust the force of one or more elastic members 40.

[0073] The device 10 may also include an actuator 90 (e.g., manual actuator also referred to as a switch, or a powered actuator such as a motor) and a switch transmission 92 (e.g. a Bowden cable) to control the engagement or disengagement of clutch mechanism 50. In one embodiment, actuator 90 is attached to one of the shoulder straps 24 via one of the strap’s attachment points 84, as seen in FIG. 7. Actuator 90 may also be collocated with the clutch mechanism 50 (e.g., attached directly via a lever or other mechanical coupling), or an actuator 90 may be located on each shoulder strap 24. The clutch mechanism 50 may be replaced with a powered actuator such as a motor. The clutch can be attached to the back panel using a quick-release mechanism 52. The actuator can also be attached to the shoulder straps or other parts of the upper-body or lower-body interfaces using a quick-release mechanism or any other attachment method.

[0074] The wearable assistance device can incorporate one-handed mode switching (between engaged and disengaged modes) using actuator 90 (e.g. a manual switch) to allow for many real- life scenarios in which a user / wearer may only have one hand available. Alternatively, the devicecould be designed to mode switch with two hands or no hands (handsfree), such as by using voiceactivation or electronic sensors or microcontrollers to control an actuator that performs the modeswitching, or by using an alternate body part to actuate the mode switching (e.g., elbow switch). The present disclosure can be applied to quasi-passive (mode-switching) exosuits that have a reset spring (first elastic element) and assistive spring (second elastic element) in series, or to powered exosuits that generate forces with a motor or other powered clutch mechanism. Thus, motors and / or sensors can optionally be included in certain embodiments.

[0075] The body interface design described herein may also be used for other wearable devices, including those used to assist other parts of the body (not only the back) or devices that are not used for assistance. For example, the body interface design may be used to hold wearable sensor systems that need to be comfortably affixed to the body, such as video cameras, inertial measurement units (IMUs) or electromyography sensors (EMG). Or the body interface described herein may be used to hold other equipment or gear. The embodiments detailed herein focus on how an upper-body interface with a ventilated back panel could be worn on user’s trunk. However, this analogous design could also be applied to other body parts such as a body-interface for the waist, thighs, shank, feet, arms, forearms, or head.

[0076] It will be apparent to those skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings that modifications, combinations, subcombinations, and variations can be made without departing from the spirit or scope of this disclosure. Likewise, the various examples described may be used individually or in combination with other examples. Those skilled in the art will appreciate various combinations of examples not specifically described or illustrated herein that are still within the scope of this disclosure. In this respect, it is to be understood that the disclosure is not limited to the specific examples set forth and the examples of the disclosure are intended to be illustrative, not limiting.

[0077] As used in this specification and the appended claims, the singular forms “a”, “an” and “the” include plural referents, unless the context clearly dictates otherwise. Similarly, the adjective “another,” when used to introduce an element, is intended to mean one or more elements. The terms “comprising,” “including,” “having” and similar terms are intended to be inclusive such that there may be additional elements other than the listed elements.

[0078] Additionally, where a method described above or a method claim below does not explicitly require an order to be followed by its steps or an order is otherwise not required based on thedescription or claim language, it is not intended that any particular order be inferred. Likewise, where a method claim below does not explicitly recite a step mentioned in the description above, it should not be assumed that the step is required by the claim.

[0079] It is noted that the description and claims may use geometric or relational terms, such as right, left, above, below, upper, lower, top, bottom, linear, arcuate, elongated, parallel, perpendicular, etc. Those terms are not intended to limit the disclosure and, in general, are used for convenience to facilitate the description based on the examples shown in the figures. In addition, the geometric or relational terms may not be exact. For instance, walls may not be exactly perpendicular or parallel to one another because of, for example, roughness of surfaces, tolerances allowed in manufacturing, etc., but may still be considered to be perpendicular or parallel.

Claims

WHAT IS CLAIMED IS:

1. A body interface for a wearable assistance device, comprising: a flexible ventilated back panel having inner and outer surfaces, the inner surface including an inner offset feature configured to face a back of a wearer of the wearable assistance device, the flexible ventilated back panel having a plurality of openings and a plurality of ribs; primary straps connected to an upper portion of the ventilated back panel; and secondary straps coupled to a lower portion of the ventilated back panel but spaced a discrete distance from a bottom end of the back panel, each of the secondary straps being adjustably coupled to one of the primary straps, wherein the flexible ventilated back panel is configured to operatively connect to one or more elastic members that are configured to provide an assistive force to the back of the wearer.

2. The body interface of claim 1, wherein each primary strap has an adjustable length.

3. The body interface of claim 1, wherein the plurality of openings include central and lateral openings, and the central openings are smaller than the lateral openings.

4. The body interface of claim 3, wherein the plurality of ribs include at least one longitudinal rib and at least one transverse rib.

5. The body interface of claim 4, wherein the flexible ventilated back panel includes opposite sides each having a concave shape.

6. The body interface of claim 5, wherein a bottom edge of the outer surface of the flexible ventilated back panel is rounded.

7. The body interface of claim 1, wherein each of the primary straps is a shoulder strap with an s-shape.

8. The body interface of claim 1, wherein a neck panel is coupled between the upper portion of the back panel and the primary straps.

9. The body interface of claim 8, wherein the neck panel has a stiffness that is less than a stiffness of the flexible ventilated back panel and greater than a stiffness of the primary straps.

10. The body interface of claim 1, wherein the inner offset feature is a cushion layer attached to the inner surface of the flexible ventilated back panel, and the cushion layer has cut-out sections that leave exposed the plurality of openings for ventilation.

11. The body interface of claim 10, wherein the inner offset feature has divots or gaps to reduce pressure on the wearer’s back.

12. The body interface of claim 10, wherein the cushion layer comprises foam and an adhesive backing.

13. The body interface of claim 10, wherein the cushion layer comprises foam and an adhesive backing, and an outer fabric covering the foam.

14. A wearable assistance device, comprising: an upper-body interface and a lower-body interface, the upper-body interface including a flexible ventilated back panel that has inner and outer surfaces, the inner surface having an inner offset feature configured to face a back of the wearer of the wearable assistance device; at least one elastic member coupling the upper-body interface to the lower-body interface, the at least one elastic member being configured to provide an assistive force to the back of the wearer; and a clutch mechanism associated with the at least one elastic member, the clutch mechanism being configured for selectively adjusting the assistive force provided by the at least one elastic member.

15. The device of claim 14, wherein the upper-body interface includes primary straps connected to an upper portion of the ventilated back panel, and includes secondary straps coupled to a lower portion of the ventilated back panel but spaced a discrete distance from a bottom end of the back panel, and each of the secondary straps is adjustably coupled to one of the primary straps.

16. The device of claim 14, wherein the clutch mechanism is supported on the outer surface of the back panel.

17. The device of claim 14, further comprising an actuator for switching the clutch mechanism between engaged and disengaged modes, the actuator being located on a shoulder strap of the upper-body interface.

18. The device of claim 14, wherein the flexible ventilated back panel includes a plurality central and lateral openings, the central openings being smaller than the lateral openings, and includes a plurality of ribs comprising at least one longitudinal rib and at least one transverse rib, and includes opposite sides each having a concave shape.

19. The device of claim 14, wherein the inner offset feature is a cushion layer attached to the inner surface of the flexible ventilated back panel, and the cushion layer has cut-out sections that leave exposed the plurality of openings for ventilation.

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