Wearable assistance device with offset features

Abstract

A wearable assistance device that has an upper-body interface and a lower-body interface, and the upper-body interface includes a support frame. One or more offset features are provided on the outer surface of the support frame of the upper-body interface extending in a direction away from the wearer. An elastic member couples the upper-body interface to the lower-body interface and provides the assistive force to the back of the wearer. The at least one offset feature has a height that defines a space from the outer surface of the support frame of the upper-body interface that is configured to accommodate the elastic member.

Description

WEARABLE ASSISTANCE DEVICE WITH OFFSET FEATURESGOVERNMENT FUNDING

[0001] This invention was made with government support under United States Army Grant No. W91 1NF2120078. 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 / 450,563 filed on March 7, 2023, and entitled “Wearable Assistance Devices and Systems with Offsets for Use Under Body-Worn Gear or Personal Protective Equipment,” the content of which is relied upon and incorporated herein by reference in its entirety.BACKGROUND

[0003] This disclosure relates generally to wearable assistance devices and systems, such as occupational wearable tools and exosuits, and methods of use.

[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, be compatible with body worn uniforms and equipment, 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 can include incompatibility of the exo with required tasks or gear. If user needs are not met, an exo will not be used and thus will not contribute to a safer work environment. Existing exos are generally not designed to be worn with other body-worn gear (e.g., backpacks, fall protection harnesses, body armor). Different types of body-worn gear or equipment may interfere with an exo’ s function or comfort, or vice versa, an exo may interfere with the other body- worn gear or equipment. As one example, body armor worn as outerwear (i.e., worn over an exo) may impinge upon elements of the exo that need to move in order for it to function, thus renderingthe exo ineffective or impeding the wearer’s ability to move freely. Therefore, individuals in certain jobs or who are required to use certain types of body -worn gear are not served by existing occupational exos due to these incompatibility issues.SUMMARY

[0006] The present disclosure provides a wearable assistance device that comprises an upper-body interface and a lower-body interface. The upper-body interface may include a support frame that has inner and outer surfaces. The inner surface of the support frame can be configured to face a back of the wearer of the wearable assistance device. At least one offset feature can be provided on the outer surface of the support frame of the upper-body interface. The offset feature extends in a direction away from the inner surface of the support frame of the upper-body interface. An elastic member couples the upper-body interface to the lower-body interface. The elastic member is configured to provide an assistive force to the back of the wearer. The offset feature has a height that defines a space from the outer surface of the support frame of the upper-body interface, and the space being configured to accommodate the at least one elastic member.

[0007] In an embodiment, a clutch mechanism (or any other actuating mechanism, such as a motor or other powered actuation unit) is provided that is associated with the elastic members. The clutch mechanism is configured for selectively adjusting the assistive force provided by the elastic members.

[0008] In certain embodiments, the offset feature has an end surface that faces away from the wearer, and the end face surface is adapted to abut outerwear worn over the upper-body interface; the outerwear is body armor; the offset feature is attached to the outer surface of the support frame of the upper-body interface; the offset feature and the support frame form a unitary one-piece member; and / or the clutch mechanism is located on the outer surface of the support frame, and the height of the at least one offset is equal to or greater than a height of a housing of the clutch mechanism; and / or the offset is made of plastic, metal, dense foam, or a combination thereof.

[0009] In other embodiments, the offset feature includes one or more projections extending from the outer surface of the support frame; the one or more projections are one or more fasteners; the one or more projections are wall projections that form a shape of the offset feature; and / or the shape of the offset feature is square, rectangular, or hexagonal.

[0010] In some embodiments, the support frame is made of plastic or composite materials, the elastic member has first and second elements coupled to the upper and lower body interfaces, respectively, and the second element is configured to extend along the back of the wearer; the clutch mechanism operates between the first and second elements of the elastic member; the upperbody interface includes one or more shoulder straps coupled to the support frame; and / or the lower- body interface is one or more thigh sleeves.

[0011] 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 can include a support frame and at least one shoulder strap. The support frame has inner and outer surfaces. The inner surface of the support frame is configured to face a back of wearer of the wearable assistance device. A plurality of offset features can be provided on the outer surface of the support frame of the upper-body interface. Each of the offset features extends in a direction away from the inner surface of the support frame of the upper-body interface. One or more elastic members couple the upper-body interface to the lower-body interface. The one or more elastic members are configured to provide an assistive force to the back of the wearer. Each of the offset features has a height that defines a space from the outer surface of the support frame of the upper-body interface that is configured to accommodate at least one of the one or more of elastic members.

[0012] In an embodiment, a clutch mechanism (or any other actuating mechanism, such as a motor or other powered actuation unit) is provided that is associated with the elastic members. The clutch mechanism is configured for selectively adjusting the assistive force provided by the elastic members.

[0013] In one embodiment, the at least one offset feature includes at least two offsets that define a channel therebetween, the channel being configured to receive one or more of the one or more elastic members. For example, in an embodiment with two offset features, these can be provided at or near the bottom -left and bottom -right of the back panel. Or alternatively, the two offset features can be near the top-left and top-right of the back panel. Or alternatively, the two offset features can be near the middle-left and middle-right of the back panel. In another embodiment, the support frame has four corner zones, and at least one of the plurality of offset features is positioned at each of the four comer zones. In yet another embodiment, the clutch mechanism is located on the outer surface of the support frame, and an actuator is located on the upper-body interface for actuating the clutch mechanism between engaged mode and disengaged mode.

[0014] 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 are exemplary and are intended to provide an overview or framework to understand the nature and character of the disclosure.BRIEF DESCRIPTION OF THE FIGURES

[0015] 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:

[0016] FIG. l is a rear view of a wearable assistance device, according to an example of the present disclosure;

[0017] FIGS. 2A and 2B are views of the wearable assistance device of the present disclosure incorporated into protective wear, such as body armor;

[0018] FIGS. 3 A and 3B are rear and front views, respectively, of a wearable assistance device;

[0019] FIG. 4 is a diagram of a cross-section of the wearable assistance device worn under protective gear, showing space created by offset features of the present disclosure;

[0020] FIGS. 5A-5C are various views of the wearable assistance device worn under protective gear, showing offset features of the wearable assistance device creating space to accommodate elastic members of the device;

[0021] FIGS. 6A-6C are various views of an exemplary upper-body support frame of an exemplary wearable assistance device of the present disclosure, showing the offset features;

[0022] FIG. 7 is an elevational view of an exemplary upper-body interface incorporating the support frame illustrated in FIGS. 6A-6C and showing a clutch mechanism located on the support frame;

[0023] FIGS. 8 A and 8B are various views of another exemplary upper-body interface of the wearable assistance device of the present disclosure, showing alternative offset features; and

[0024] FIG. 9 is an elevational view of yet another exemplary upper-body interface of the wearable assistance device of the present disclosure, showing alternative offset features.DETAILED DESCRIPTION

[0025] It is 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.

[0026] 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.

[0027] The present disclosure relates to wearable assistance devices or systems designed to assist the wearer (also referred to herein as the “user”) with physical assistance capabilities, e.g. lifting and bending, and can be worn underneath outerwear, such as body armor or other body -worn gearor personal protective equipment, without hindering the assist functioning of the device or the functioning of the outer-wear. The wearable assistance device or system can be an exosuit (also referred to herein as “exo”), or sub-system or sub-component of an exosuit, or any other kind of exoskeleton or wearable assist device. In one embodiment, for example, the device is a back exosuit that includes at least one or more offset features on a back panel thereof, which allow for certain elements of the exo (e.g., elastic members) extending along back of the user to move and function properly, even when the exo is worn underneath body armor or other gear. Thus, the wearable assistance device of the present disclosure is novel, unique, and useful because it can enable a back exo to function and assist properly even when the device is worn under body armor or other gear. The wearable assistance device is designed to fit comfortably under outerwear like body armor or other body worn protective gear. As such, the wearable assistance device and system of the present disclosure can enable users to benefit from physical assistance and musculoskeletal relief.

[0028] For purposes of this disclosure the term “exosuit” 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 (e.g. elastic), or quasi-passive (e.g. elastic with a clutch). For example, the wearable assistance device of the present disclosure can be a quasi-passive (i.e. using a mode-switching clutch) back exosuit used under a uniform or armor, such as tactical vests by soldiers, for wearers who perform strenuous lifting or bending. Or for example, a quasi-passive exosuit might also include sensors for measuring body motion via an IMU or accelerometer, or load cells to measure the assistive force provided by the exosuit. Or, for example, the clutch may be replaced with a motor (or another actuation unit) that directly or indirectly controls the assistive force provided by the elastic member. Or, for example, the exo may be passive such that it only contains elastic or other materials and mechanical mechanisms. In some embodiments, a clutch or another actuating mechanism may be located on the outer surface of the support frame. In other embodiments, a clutch or another actuating mechanism may be located on other sides of the upper-body interface or lower-body interface, or mechanically coupled to other body -worn gear of equipment (e.g. belts, harnesses, body armor). The exosuit can include high-tech, breathable fabric, padding, or slipresistance features in the right places to comfortably conform to the wearer’s body.

[0029] FIG. 1 is a rear view of an exemplary wearable assistance device 10 of the present disclosure shown worn without outerwear, such as a body armor vest. FIGS. 2 A and 2B are viewsof the wearable assistance device as worn by a wearer, such as a solider, showing the wearable assistance device incorporated into the clothing and outerwear, e.g. body armor vest 12, of the soldier. As seen in FIGS. 1, 2A, and 2B, wearable assistance device 10 of the present disclosure generally comprises an upper-body interface 20, a lower-body interface 30, one or more elastic members 40 connecting the upper-body and lower body -interfaces 20 and 30, an engageable and dis-engageable clutch mechanism 50, and one or more offset features 60 that accommodate the one or more elastic members 40, as seen in FIGS. 1, 2 A and 2B. The one or more elastic members 40 are configured to provide the assistive force to the back of the wearer, such as when the wear bends or lifts. For example, the elastic members 40 may stretch when a user bends forward, which creates an assistive force on (and torque about) the back of the wearer that reduces musculoskeletal loading. The one or more offset features 60 each have a height H (FIG. 4) that defines a space S or receiving area from the upper-body interface 20, that is configured to accommodate the one or more elastic members 40, as seen in FIG. 7. That space S allows the elastic members 40 to deform (e.g. stretch, extend) and move (e.g. slide, translate) along the back of the wearer without hinderance from the device or any outerwear worn over the device. FIGS. 5A, 5B, and 5C show the wearable assistance device 10 worn on the user with body armor worn over the device 10 and show the support frame 22 with the offset features 60 creating the space S for accommodating the elastic members 40.

[0030] The upper-body interface 20 can be in the form of a harness that is comprised of a support frame 22, such as a back panel, (hereinafter referred to as a “support frame” or “support panel” or “back panel”) and one or more shoulder straps 24 (e.g. backpack style shoulder straps or harness) that cover at least a portion of the shoulders. The support frame 22 has inner and outer surfaces 26 and 28 where the inner surface 26 of the support frame 22 is configured to face a back of the wearer (also referred to as the user) of the wearable assistance device and the outer surface 28 is configured to face away from the wearer, as seen in FIG. 4. The support frame 22 can be flexible to accommodate the comfort of the wearer while retaining some rigidity to support the exo. The support frame 22 is flexible but also strong enough to bear the loads it experiences during user movement. For example, the support frame 22 can be made of plastic or composite materials, such as ABS plastic, Kydex, Delrin, or carbon fiber. Alternatively, the upper-body interface (including the support frame 22) may be comprised primarily of softer materials such as foams and fabrics. The upper-body interface 20 can be a separate accessory worn over the wearer’s clothing, such as seen in FIG. 1. Or the 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 upperbody, such as a shirt. The upper-body interface 20 can also include one or more optional chest straps for additional comfort of the wearer. The upper-body interface 20 may come in various other shapes, sizes, and materials that are configured to attach to the wearer’s trunk and / or over their shoulders and to apply forces from the exo to the wearer.

[0031] The lower-body interface 30 can be one or more leg or thigh sleeves that are configured to wrap around each leg. They may be comprised of soft goods (fabric, foam, and elastic materials). The sleeves can be attached or integrated into the wearer’s clothing, or they can be separate accessories worn on the legs, on top of or under pants. The leg sleeves 30 can also be supported by straps (e.g., webbing) that connect up to a waist belt, fabric loop, or to the loops or pockets of pants, or to the upper-body interface 20 itself. Or the lower-body interface 30 may be a pair of pants or shorts that cover at least a portion of the legs and waist.

[0032] 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.

[0033] The one or more elastic members 40 couple the upper-body interface 20 to the lower-body interface 30 and are configured to provide an assistive force to the back of the wearer. The elastic members 40 can run down along the back and over the buttocks of the user to the lower-body interface 30. Each elastic member 40 can be a single stiffness along its length, or alternatively can be sub-divided into two or more elastic elements, e.g. a first elastic element 42 (FIGS. 7, 8A or 9) and second elastic element 44 (FIGS. 3A and 7). The first and second elastic elements 42 and 44 can be of different stiffness or materials. And there may be additional elastic elements included in the elastic member that mechanically couples, and provides a mechanical load path between, the upper-body and lower-body interfaces.

[0034] The one or more elastic members 40 and the first and second elements 42 and 44 thereof may be comprised of springs, elastic bands, bungee cords, webbing, straps, or any other component or material containing any amount of elasticity or viscoelasticity. In one embodiment, the first elastic element 42 is a power spring or retractable reset spring (Fig. 7) and the second elastic element 44 is an elastic band (also referred to herein as an “assistive band”, FIGS. 3A and 7). There may also be more than two elements of each elastic member 40, such as an intermediate element (e.g. piece of strand or rope or webbing or spool), in between the first and second elements42 and 44. A strand or rope (intermediate element) can be provided that connects the first elastic element 42 and the second elastic element 44. The clutch mechanism 50 can be positioned between two of these elastic elements.

[0035] The elastic member 40 can be comprised of a single elastic stiffness. Or the elastic member can be segmented into multiple elastic elements in series or in parallel, of different stiffness. The first elastic element 42 may be less stiff than the second elastic element 44. In other embodiments, the elastic elements 42 and 44 are the same stiffness. In yet other embodiments, the first elastic element 42 can be stiffer than the second element 44 of the elastic member, such as when the first elastic element 42 is only affixed at one end.

[0036] A motor or other actuating mechanism may also be placed in series with one or more of the elastic members to further control the force or displacement of the elastic member, for instance, to adjust different levels of assistance, adjust elastic spring set points, or switch between engagement (assistance) and disengagement (non-assi stance) behaviors. A motor or other actuating mechanism may replace the clutch mechanism in the embodiments described. Or alternatively, a motor or other actuating mechanism may be used in addition to and in combination with the clutch mechanism. The motor and clutch may be co-located or alternatively may be located on different parts of the wearable assist device or body.

[0037] In one example, each first elastic element 42 can be a rotary spring housed inside the clutch mechanism 50, as seen in FIG. 7, and loaded in series with the second elastic element 44 when the clutch mechanism 50 is disengaged. Each second elastic element 44 can be an elastic band or other elastic or viscoelastic element configured to provide an assistive (or resistive) 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 44 stretch, creating an extension torque about the lumbar spine that reduces strain on the back musclesand discs, and an extension torque about the hips which further assists with lifting or standing upright. The elastic assistive bands 44 essentially act as an artificial set of back and hip extensor muscles.

[0038] Although the first elastic element 42 is shown inside of the clutch mechanism 50, the first elastic element 42 does not have to be inside or part of the clutch mechanism 50. For example, the elastic member 40 can run through a friction cam type clutch, such that the first elastic element 42 would be the portion of the elastic member 40 on one side of the clutch mechanism, and the second elastic element 44 would be the portion of the elastic member 40 on the other side of theclutch mechanism, and thus would not need to be inside the housing 52 of the clutch mechanism 50.

[0039] The clutch mechanism 50 can be associated with each elastic member 40 and is configured for selectively adjusting the assistive force provided by the elastic members 40. The clutch mechanism 50 can be positioned on the upper-body interface 20, such as near the top or middle of the support frame 22, or on another part of the upper-body interface 20, such as on one or more the shoulder straps 24. The clutch mechanism 50 can be operate between the elastic elements 42 and 44 of the elastic members 40. The housing 52 of the clutch mechanism 50 can be attached to the outer surface 28 of the support frame 22 of the upper-body interface 20, as seen in FIGS. 1 and 3A. The clutch mechanism may alternatively be located on the lower-body interface. There may be one clutch per elastic member 40, multiple clutches that each may adjust the assistive force provided by one or more elastic members 40, or a single clutch may adjust the assistive force provided by one or more elastic members 40.

[0040] 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 actuating mechanism, such as a switching mechanism) and / or based on movement from the user. Alternatively, a clutch mechanism may be powered such that a motor or other actuating mechanism 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.

[0041] The clutch mechanism 50 can be located between the first and second elastic elements 42 and 44 of the elastic members 40. The clutch mechanism 50 is configured to change the load path between the upper and lower-body interfaces 20 and 30 through the one or more elastic members 40, when the clutch mechanism 50 is engaged, i.e. changes from disengaged to engaged. For instance, when the clutch mechanism 50 is disengaged (also referred to as “disengaged mode”),the load path may go through the first and second elastic elements 42 and 44, but when the clutch mechanism 50 is engaged (also referred to as “engaged mode”), it may change the load path to go through only the second elastic element 44. In one embodiment, that would allow for unrestricted user movement when the clutch mechanism 50 is disengaged due to minimal force generated by displacement of a less-stiff first elastic element 42. And it would allow for larger assistive forces to be generated by the displacement of the stiffer second elastic element 44 when the clutch mechanism 50 is engaged.

[0042] The clutch mechanism 50 can be attached to the upper-body interface 20, or alternatively to the lower- body interface 30. In an embodiment, the clutch mechanism 50 can be designed to behave like a lockable keychain retractor. The clutch mechanism 50 can be a rotary type clutch, for example, comprised of a geared spool 46 and spring-loaded pin 48 (or pawl), associated with the first elastic element 42, which may be rotary spring, as seen in FIG. 7. A rope can be wrapped around the spool and connected to the second elastic element 44, which may be an elastic band. The spring or first elastic element 42 is inside the spool and causes it to reel in the rope when the clutch mechanism 50 is disengaged and helps keep the elastic member 40 taut or lightly tensioned. When engaged, the pin inserts into the gear teeth 46 on the spool. That prevents rotation of the spool and locks it in its current orientation.

[0043] Referring to FIGS. 1, 4, and 6A-6C, each offset feature 60 is configured as a physical spacer and is attached to or built into the support frame 22. FIG. 4 is a diagram of a partial crosssection of the wearable assistance device 10 worn under outerwear 12, such as protective gear. As seen in FIG. 4, each offset feature 60 serves to create a space, gap, or receiving area S through which the one or more elastic members 40 can extend and move freely, even when the device 10 is worn underneath outerwear 12, such as body armor. Each of the one or more offset features 60 extends from the outer surface 28 of the upper-body interface’s support frame 22 in a direction away from the wearer (or away from the inner surface 26 of the support frame 22). Each of the one or more offset features 60 has an end surface 62 that faces away from the wearer. Each end face surface 62 is adapted to abut the outerwear 12, e.g. body armor, worn over the upper-body interface 20.

[0044] Each offset feature 60 can include one or more projections with an end surface 62 extending from the outer surface 28 of the support frame 22 in a direction away from the wearer. The one or more projections with the end surfaces 62 can be wall projections that form a shape of the offset feature. The wall projections can be substantially straight (FIG. 1) or curved (FIG. 3 A). The shapeof the offset features 60 can be any shape, such as square, rectangular (FIGS. 1 and 6A), circular, triangular, hexagonal (FIGS. 8A and 9), and the like. The offset features 60 can be substantially solid (FIG. 1) or substantially hollow (FIGS. 6A-6C). Alternatively, the one or more projections can be one or more fasteners, as seen in FIG. 8B.

[0045] In other embodiments, there can be two offset features 60, for example, one near or at the bottom left and one near or at the bottom right of the support frame 22. Two or more of the offset features can be positioned on the support frame 22 to create a channel through which the one or more elastic members 40 pass. Alternatively, one offset feature 60 could be near the top or middle of the support frame 22 and the second could be at the bottom of the support frame 22. Or one offset feature 60 could be at or near the top right and top left of the back panel, as seen in FIG. 1. In addition to providing space for the elastic member 40, certain embodiments, such as this, may also enhance the comfort and stability of body armor or other body-worn gear over the exo. In another embodiment, four offset features, for example, can be provided at or near the top-left, topright, bottom -left, and bottom-right of the back panel, as seen in FIGS. 6 A and 6B.

[0046] In some embodiments, offset features 60’ can create a honeycomb-like feature that ends along part of the outer surface of the support frame, as seen in FIG. 8A, or along the length of the support frame 22, as seen in FIG. 9, with an open area provided for receiving the clutch mechanism 50. There can also be dozens of narrow offset features, which can have the appearance like a bed of nails or wet brush. The offset features can be distributed across part or all of the support frame of the upper-body interface. Various embodiments allow for the offset function while also allowing airflow channels to enhance the wearer’s thermal comfort by enabling sweat evaporation and reducing heat retention. Various embodiments also allow for the support frame to be flexible to accommodate the comfort of the wearer while retaining some rigidity to support the exo.

[0047] As seen in FIGS. 6A-6C, in one example, the wearable assistance device 10 has four separate offsets 60 along the outer surface 26 of the support frame 22 (i.e., back side) of the upperbody interface 20, located near the top-left, top-right, bottom-left, bottom-right of the support frame 22. The offset features 60 can be molded into the support frame 22 via injection molding during manufacturing, for example, such that the support frame 22 and the offset features form a unitary one-piece member. These offset features 60 protrude outwardly away from the support frame to keep the outerwear 12 (e.g. external body armor / safety gear) from impinging on the elastic members 40 that reside in the space or receiving area S between the support frame 22 and the body armor / safety gear. In this embodiment, the four offset features 60 are provided in four distinctoffset zones of the support frame 22. The height H of each offset feature 60 is approximately 20 mm (as measured from the back panel). Each offset feature 60 can be approximately 40-60 mm long (vertical) and approximately 20 mm wide. These offset zones allow sufficient space for the elastic members 40 to slide up and down vertically on the upper-body interface 20 without being impinged upon by the outer body armor. The offset features 60 are also designed such that the upper-body interface can still flex and conform to the body of the user during use. The precise dimensions of the offset feature 60 can vary (e.g. be larger or smaller than the dimensions in this exemplary embodiment) and may depend on the type of elastic member 40 or the height of the clutch 50.

[0048] The offset features 60 can be designed to match or substantially match the height of the housing 52 of the clutch mechanism 50 located on the support frame 22, such as seen in FIG. 6C. That is, the height H of the offset features can be the same or greater than the height of the housing 52 of the clutch mechanism 50.

[0049] The support frame 22 can have fewer or more offset features, for instance, such as ranging from 1-8 offset features 60. In one example, the offset features are approximately 1-5 cm in height H to provide space S for the elastic members 40 to move. The offset features 60 can be made of rigid or semi-rigid materials such as plastic, metal, or dense foam. The offset features 60 must be structurally strong enough to bear the weight of the body worn gear above it, and also to prevent breaking or substantial buckling under loads when someone sits in a high-backed chair or leans against a wall.

[0050] The wearable assistance device 10 can incorporate mode switching (between the engaged and disengaged modes) using an actuator 70 that controls the clutch 50. The actuator 70 can be a one-handed mode switching to allow for many real-life scenarios in which a user / wearer, such as a workman or soldier, may only have one hand available. Alternatively, the wearable assistance device 10 can be designed to mode switch with two hands or no hands (handsfree), such as by using voice-activation or electronic sensors or microcontrollers to control an actuator that performs the mode-switching of the clutch 50, or alternatively that generates or adjusts force along the elastic members 40. In some embodiments, there may not be a clutch or another actuator, but the offset features 60 would still serve to prevent outerwear from impinging on the elastic members 40.

[0051] The actuator 70 is associated with the clutch mechanism 50 for engaging and disengaging the same. The actuator 70 can be a manual actuator, such as a switch, or a powered actuator, such as a motor. A transmission 72 (e.g. a Bowden cable) of the actuator 70 couples to the clutch mechanism 50 to control engagement or disengagement of the clutch mechanism 50. The actuator 70 can be located on either the upper-body interface 20 or lower-body interface 30. In one embodiment, the actuator 70 is located at the front of the wearer, as seen in FIGS. 2A and 3B with the transmission 72 connecting the actuator 70 to the clutch mechanism 50 located at the back of the wearer.

[0052] In some embodiments, the wearable assistance device 10 is configured to allow a natural range of motion while disengaged (e.g. when the clutch mechanism 50 is disengaged but the wearer is still wearing the device 10). And the device 10 is designed to be comfortable during typical tasks, such as walking, running, bending, squatting, climbing, entering / exiting a vehicle, and sitting. The wearable assistance device 10 may include physical assistance and mode-switching capabilities. The wearable assistance device 10 can provide back assistance torque (e.g., 10-50 Nm) during bending and lifting when engaged, which has been found to be sufficient to reduce back muscle activity and fatigue.

[0053] 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 actuator. Thus, motors and / or sensors can optionally be included in certain embodiments. The wearable assistance devices and systems of the present disclosure can be used to create an exosuit that functions under body armor or other body -worn gear or equipment.

[0054] Other embodiments can be designed to assist other body joints, such as the neck, shoulder, elbow, foot, ankle, knee, hip, or thigh. For instance, in one embodiment assistance is provided about the hip but not the back by using a waist belt or similar attachment to the user’ s pelvis as the upper-body interface, rather than a shoulder harness. In some embodiments, the upper-body interface and lower-body interface attach to body segments that are distal and proximal (or proximal and distal) to the body joints being assisted. Elastic elements may contain any amount of elasticity (e.g., could be viscoelastic). One or both elements of the elastic member could also be replaced with or put in series with any other type of actuator, such as a damper or electric motor. For example, the reset spring (first elastic element) could be replaced with an electric motor powered by a battery and controlled by a microcontroller. The motor could be inside or connectedto the base component of the clutch housing, or connected to the upper-body interface or lower- body interface through other attachments.

[0055] Different elastic or viscoelastic elements can be used, such as linear and rotational springs and different materials for the springs (e.g., elastomer, fabric, metal). Different methods of clutching, mode-switching or actuation can also be used. Offsets could be added to the upperbody interface, or lower-body interface, or both, as needed, to accommodate body-worn gear on top, and to ensure proper function of the exo.

[0001] 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.

[0002] 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.

[0003] 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 the description 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.

[0004] It is noted that the description and claims may use geometric or relational terms, such as such as right, left, above, below, upper, lower, top, bottom, linear, arcuate, elongated, parallel, perpendicular, etc. These 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 exactlyperpendicular 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 wearable assistance device, comprising: an upper-body interface and a lower-body interface, the upper-body interface including a support frame that has inner and outer surfaces, the inner surface of the support frame being configured to face a back of the wearer of the wearable assistance device; at least one offset feature provided on the outer surface of the support frame of the upperbody interface, the at least one offset feature extending in a direction away from the inner surface of the support frame of the upper-body interface; and 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, wherein the at least one offset feature has a height that defines a space from the outer surface of the support frame of the upper-body interface, the space being configured to accommodate the at least one elastic member.

2. The device of claim 1, wherein a clutch mechanism is 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.

3. The device of claim 2, wherein the clutch mechanism is a motor.

4. The device of claim 2, wherein the clutch mechanism is located on the outer surface of the support frame, and the height of the at least one offset is equal to or greater than a height of a housing of the clutch mechanism.

5. The device of claim 2, wherein the at least one offset feature has an end face surface that faces away from the wearer, the end face surface being adapted to abut outerwear worn over the upper-body interface.

6. The device of claim 5, wherein the outerwear is body armor.

7. The device of claim 1, wherein the at least one offset feature is attached to the outer surface of the support frame of the upper-body interface.

8. The device of claim 1, wherein the at least one offset feature and the support frame form a unitary one-piece member.

9. The device of claim 1 , wherein the at least one offset is made of plastic, metal, dense foam, or a combination thereof.

10. The device of claim 1, wherein the at least one offset feature includes one or more projections extending from the outer surface of the support frame.

11. The device of claim 10, wherein the one or more projections are one or more fasteners.

12. The device of claim 10, wherein the one or more projections are wall projections that form a shape of the offset feature.

13. The device of claim 12, wherein the shape of the offset feature is square, rectangular, or hexagonal.

14. The device of claim 1, wherein the support frame is made of plastic or composite materials.

15. The device of claim 2, wherein the at least one elastic member has first and second elements coupled to the upper and lower body interfaces, respectively, and the second element is configured to extend along the back of the wearer.

16. The device of claim 15, wherein the clutch mechanism operates between the first and second elements of the elastic member.

17. The device of claim 1, wherein the upper-body interface includes one or more shoulder straps coupled to the support frame.

18. The device of claim 1, wherein the lower-body interface is one or more thigh sleeves.

19. A wearable assistance device, comprising: an upper-body interface and a lower-body interface, the upper-body interface including a support frame and at least one shoulder strap, the support frame having inner and outer surfaces, the inner surface of the support frame being configured to face a back of wearer of the wearable assistance device;a plurality of offset features provided on the outer surface of the support frame of the upperbody interface, each of the plurality of offset features extending in a direction away from the inner surface of the support frame of the upper-body interface; and one or more elastic members coupling the upper-body interface to the lower-body interface, the one or more elastic members being configured to provide an assistive force to the back of the wearer, wherein each of the offset features has a height that defines a space from the outer surface of the support frame of the upper-body interface, that is configured to accommodate at least one of the one or more of elastic members.

20. The device of claim 19, wherein the at least one offset feature includes at least two offsets that define a channel therebetween, the channel being configured to receive at least one of the one or more elastic members.

21. The device of claim 19, wherein the support frame has four comer zones, and at least one of the plurality of offset features is positioned at each of the four corner zones.

22. The device of claim 19, wherein a clutch mechanism is associated with the one or more elastic members, the clutch mechanism being configured for selectively adjusting the assistive force provided by the one or more elastic members.

23. The device of claim 22, wherein the clutch mechanism is located on the outer surface of the support frame, and wherein an actuator is located on the upper-body interface for actuating the clutch mechanism between engaged mode and disengaged mode.

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