Enhanced comfort exosuit

Abstract

An enhanced comfort exosuit to be worn by a user for assisting with lifting a load, comprises a first vest having a front surface, a body surface, and a zipper, a second vest having a second front surface, a second body surface, and a second zipper, wherein the body surface and second body surface are adapted to face the user when worn, and a back operatively connected to the first vest and second vest, and adapted to be positioned on a backside of the user when worn. A spacer corresponds to the vest and is positioned on the body surface, and a second spacer element corresponds to the second vest and is positioned on the second body surface. The spacer extends along at least a majority of the length of the vest, and the second spacer extends along at least a majority of the second length of the second vest.

Description

ENHANCED COMFORT EXOSUITThis patent application claims priority benefit of US Provisional Patent application # 63 / 652,271 , filed on May 28, 2024.FIELD OF THE INVENTION

[0001] This invention relates to exosuits, and more particularly to exosuits suitable for use for shifting load on a user with enhanced user comfort.BACKGROUND OF THE INVENTION

[0002] Exosuits are design for load adjustment by users. Exosuits may be used for medical, military, logistics and other industrial applications. An exosuit helps transfer load away from one part of a body to another, usually stronger part of the body. For example, an exosuit may be used to transfer load from the upper body to the legs, and thereby assist with lifting loads help to prevent excess loading on the back of a user. It is also desirable in some instances to provide an exosuit which acts to remind a user of proper form.

[0003] PCT Patent Publication WO 2020 / 231344 to Yeow et al discloses an exoskeleton having a series of pneumatic actuator elements. This advantageously helps shift load away from the upper body. It would be desirable to provide an exosuit which is lightweight, easy to use, which transfers load effectively, which has increased useful life, and which has enhanced user comfort.SUMMARY OF THE INVENTION

[0004] In accordance with a first aspect, an enhanced comfort exosuit to be worn by a user for assisting with lifting a load, comprises a first vest having a front surface, a body surface, and a zipper, a second vest having a second front surface, a second body surface, and a second zipper, wherein the body surface and second body surface are adapted to face the user when worn, and a back operatively connected to the first vest and the second vest, and adapted to be positioned on a backside of the user when worn. A spacer corresponds to the vest and is positioned on the body surface, and a second spacer element corresponds to the second vest and is positioned on the second body surface. The spacer extends along at least a majority of the length of the vest, and the second spacer extends along at least a majority of the second length of the second vest.

[0005] From the foregoing disclosure and the following more detailed description of various embodiments it will be apparent to those skilled in the art that the present invention provides a significant advance in the technology of exosuits. Particularly significant in this regard is the potential the invention affords for providing a lightweight, and easy to use exosuit which provides a user with enhanced comfort. Additional elements and advantages of various embodiments will be better understood in view of the detailed description provided below.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Fig. 1 is an isometric view of an enhanced comfort exosuit in accordance with one embodiment provided with a left vest, a right vest and a back.

[0007] Fig. 2 shows a view of one of the vests unzipped, partially exposing an air rail extending along an interior of one of the vests.

[0008] Fig. 3 is a close-up view of the vest of Fig. 2 showing air supply tubes adapted to inflate corresponding bladders extending along a length of the vest.

[0009] Fig. 4 shows the enhanced comfort exosuit with a central zipper unzipped, showing body surfaces of the vests and a detachable back.

[0010] Fig. 5 shows a thigh strap attached to one of the vests and provided with a high friction surface to resist relative movement of the exosuit with respect to a user’s thigh.

[0011] Fig. 6 shows a close-up view of a release valve mounted generally parallel to a length of one of the vests, pointing towards a top of the vest, and a port for supplying air to the air bags.

[0012] Fig. 7 shows a portion of a front surface of one of the vests having an area which can receive a removable patch for customization.

[0013] Fig. 8 shows a view protective covers for air bladders with rounded corners.

[0015] Fig. 9 shows a schematic stack up of several elements of the enhanced comfort exosuit, showing the position of the elements with respect to one another in accordance with one embodiment.

[0016] Fig. 10 shows an embodiment of the enhanced comfort exosuit from the body surface, showing the vests, spacers and a mesh covering each spacer.

[0017] Fig. 11 shows an isolated isometric view of one of the spacers in accordance with one embodiment.

[0018] It should be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various features illustrative of the basic principles of the invention. The specific design features of the enhanced comfort exosuit as disclosed here, including, for example, the specific position of each rail in the interior of each corresponding vest, will be determined in part by the particular intended application and use environment. Certain features of the illustrated embodiments have been enlarged or distorted relative to others to help provide clear understanding. In particular, thin features may be thickened, for example, for clarity of illustration. All references to direction and position, unless otherwise indicated, refer to the orientation illustrated in the drawings.DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

[0019] It will be apparent to those skilled in the art, that is, to those who have knowledge or experience in this area of technology, that many uses and designvariations are possible for the enhanced comfort exosuit disclosed here. The following detailed discussion of various alternate elements and embodiments will illustrate the general principles of the invention with reference to an exosuit especially useful for enhanced comfort, that is, enhanced comfort in terms of heat and / or irritation when a user is wearing the suit. Other embodiments suitable for other applications will be apparent to those skilled in the art given the benefit of this disclosure.

[0020] Turning now to the drawings, Fig. 1 shows an enhanced comfort exosuit 10 in accordance with one embodiment. The enhanced comfort exosuit disclosed herein accomplishes several things simultaneously. First, some load is transmitted from a user’s upper body to the lower body. Second, the enhanced comfort exosuit has sufficient rigidity to encourage proper posture. Third, the exosuit has been designed to help enhance user comfort when worn. These advantages help reduce the risk of injury to people tasked with carrying relatively heavy items and make it so a person will wear the suit and not feel it is uncomfortable and take it off prematurely. The enhanced comfort exosuit 10 has at least one vest and is shown here having a first vest and a second vest, that is, a right vest 140 and a left vest 130. Vest 130 has a length and vest 140 has a second length. Typically, the length and the second length are equal to each other, as shown. The suit 10 may be generally symmetrical on either side of a sagittal plane 200. Vest 130 has a front surface 32, and second vest 140 has a second front surface 42, respectively, facing away from the wearer. Vest 130 has a body surface, and second vest has a second body surface, are opposite each corresponding front surface and face the body of the wearer. Thebody surfaces are shown in Fig. 4, for example, and discussed in greater detail below.

[0021] The exosuit is also provided with a back 94. The back 94 is positioned on a backside of a user when worn, and is connected to the vests 130 and 140. The vests 130, 140 cooperate with the back 94 and shoulder harness to define a gap 23 for a person’s head. The back is connected to vest 140 by straps 22 and 26, and to vest 130 by straps 21 and 24. These elements act as s shoulder harness operatively connecting the front vests to the back. The back is also connected to the vests by chest straps 50, 52 in a manner similar to the shoulder harness. The straps can be connected by buckles or by hook and loop (Velcro) fasteners, for example.Advantageously the back may be easily removed from the rest of the exosuit and can be machine washable. Also, in certain embodiments all of the exosuit (back, vests, straps) is machine washable. An additional waist strap 68 is shown which extends around the waist of a user of the exosuit and releasably connects vest 130 to vest 140. A thigh strap 55 operatively connects the exosuit to one of the user’s thighs. A comparable second thigh strap 65 operatively connects the exosuit to a second leg of the user. Some of the load a person my encounter lifting items can be transferred away from the person’s upper body to the lower body via the thigh straps.

[0022] In addition to the straps, zippers are used to hold several elements together and to define spaces for additional elements. Zipper 70 connects vests 140 and 130, Zipper 80 for vest 130 unzips to reveal on opening in the vest (shown in Fig. 2), and zipper 90 for vest 140 unzips in a similar manner as zipper 80 to reveal an opening in the other vest. As noted above the vests are generally symmetrical oneither side of the sagittal plane 200. However, vest may provide an access port 127 for introducing air into tubing in the vests, and one vest may provide a release valve 125 to allow air to escape from the tubing in the vests. In the embodiment of Fig. 1 , the access port 127 and release valve 125 are positioned on vest 130.

[0023] While being worn when a user bends over or squats, the vests have a tendency to bunch in the middle, that is, the act of bending over biases the vests toward the sagittal plane 200. This can be uncomfortable for the user. To compensate for this motion, and in accordance with a highly advantageous element, the vest shape has been modified. As shown in Fig. 1 , vest 140 has a second upper portion 141 and a second lower portion 143. Vest 130 has an analogous upper portion 131 and analogous lower portion 133. The shape of the vests combined is in the form of an “A-frame” shape or an upside-down Y. As shown, upper portions 131 and 141 are generally parallel to one another, such that the distance between edges of the vests (where zippers 80 and 90 are located) stays roughly the same. Lower portions 133 and 143 each extend at an acute angle away from the sagittal plane to steadily increase distance between the edges of the vests. Typically, the transition from the upper portion of each vest to the lower portion of each vest occurs near the waist. Although the transition may be curved, as shown the portions are linear sections, to keep materials reduced and help to ensure a lightweight design. Central portions and bottom portions of the vests cooperate to complete the “A- Frame” shape. That is, central portion of the first vest cooperates with second central portion, to complete the bottom of a generally linear central section of the A, and bottom portion and second bottom portion cooperate to define bottom sections of the A. An advantage of this shape is that people tend to open their legs whenthey squat down, and when the vest is shaped in this manner there is more space to accommodate this motion.

[0024] Figs. 2 and 3 focus on one vest 130 with zipper 80 unzipped to reveal an interior 91. The vest is provided with a rail 135 and a series of air supply tubes 34 extending from the rail towards a corresponding bladder or inflatable air bag (with the bladders shown in more detail in Fig. 8) positioned in the interior 91. The air rail 135 receives air transmitted at port 127. In the embodiment of Figs. 2-3 connection to the port 127 is through the upper segment 136. A corresponding rail, air supply tube, series of inflatable air bags, are positioned in an analogous vest interior (not shown) provided in vest 140. Optionally, connection between air rails on either side may be made near the port so that inflation and deflation occur to both sides essentially simultaneously. The air rail can comprise a lightweight flexible or bendable tubing such as a plastic which allows for bending around the waist as the vest transitions from the upper portion to the lower portion (which extends away from vertical at an angle 0 which can be an acute angle of about 5-15 degrees. As shown in Fig. 2, air rail 135 has an upper segment 136 and a lower segment 137. Since the air rail is flexible the air rail bends at the transition between the upper portion and the lower portion. Use of the A-frame vest shape with flexible / bendable rails biases the rails away from the center and towards the outside of the legs, and thereby reduces user discomfort when squatting.

[0025] Fig. 2 also shows a highly advantageous element where an interior surface 57 of thigh strap 55 which faces a leg of the user when worn has a high friction material 56 to help resist relative movement of the thigh strap with respect to the leg of theuser. A comparable high friction material surface may be used on the other thigh strap 65. The high friction material on the thigh straps has the effect of enhancing user comfort while wearing the exosuit. The straps and zippers cooperate to secure the exosuit 10 to the user in a position suitable for enhanced beneficial effect. The straps pulls the vests into the user (the bladders / bags are preferably as close to the user as possible. Meanwhile, the zippers apply tension to the protective covers, which in turn applies compression to the bags, effectively pushing them onto the body.

[0026] Fig. 4 shows a view where the central zipper 70 is unzipped, revealing back surfaces 232 and 242 of vests 130 and 140, respectively. Further, the shoulder harness has been separated, such that the back 94 is only connected to the vests as chest straps 50, 52. As noted the back 94 can be removable and machine washable. In accordance with a highly advantageous element, positioned on the back of the vests is a corresponding spacer: first spacer 230 for vest 130 and second spacer 240 for vest 140. The spacers advantageously and separate the vests from direct contact with the user. It has been found that the spacers impressively help keep the user comfortable, especially in hot and humid environments. As shown the spacers extend most of the way along the vest, at least a majority of a length of each corresponding vest. The spacers may be made of a lightweight material such as a plastic. Optionally a net-like material or mesh may be used with each spacer: 250 for spacer 230 and 260 for spacer 240, as shown.

[0027] Fig. 5 is a close up showing the high friction material of the interior surface 57 of thigh strap 55 for vest 130, which faces a leg of the user. The high frictionmaterial 57 helps resist relative movement of the thigh strap with respect to the leg of the user. The high friction material on the thigh straps has the effect of enhancing user comfort while wearing the exosuit. As shown, the high friction material can comprise silicone rubber strips to help the leg section from moving too much with respect to the corresponding leg, helping to make the exosuit more stable.

[0028] Fig. 6 is a close-up of the air access port 127 and air release valve 125. Of note, the opening of the port 127 faces away from the sagittal plane to make it easier to access for inflation. The opening for the release valve faces upward toward the top of vest in a direction generally parallel to the front surface of the vest to reduce interference with other things which might be encountered while using the suit. That is, while the suit is being used it is expected that a user may lift relatively heavy and / or bulky items, and positioning the release valve in this manner helps to avoid having the release valve catch on the bulky item which could damage the release valve or the item, or otherwise interfere with the movement of the bulky item. In the embodiment shown in the Figs., only one port and one release valve are used and as such there is no port and release valve in the other vest. The valve and port can be on either vest and a connecting tube may be provided operatively connecting the rails such that both vests are inflated or deflated simultaneously. Fig. 7 shows a section 31 of the front surface of the vest 130 adapted to releasably receive a patch 33. The section can be positioned on the front so as to be relatively conspicuous, and may be made as a hook and loop (Velcro) to easily attach and remove the patch. The patch may be an identifier such as a company logo, for example.Alternatively, but in a similar manner, the 31 section may extend across much of thefront surfaces 32, 42 of the vests, as well as on the back, and the patch may be an extended covering, such as a reflective material to enhance user safety.

[0029] Fig. 8 shows a series of inflatable air bags 36 each surrounded by protective covers 166. The protective covers 166 have openings to receive a corresponding air supply tube 34, which connects to a corresponding inflatable air bag 36. The protective covers are further provided with a zipper 60 to allow for access to an opening 92 which each contains one of the air bags. The protective covers, inflatable air bags and the rail 135 are typically positioned inside the vest 130, and exposed by pulling down the vest zipper 80. The protective cover 166 operatively surrounds its corresponding air bag, protecting the air bag. Application of air pressure (such as by connecting a pump to the port) inflates all of the air bags on both vests such that the air bag / protective cover advantageously abuts against any adjacent air bag / protective covers. It has been found that isolating each air bag in an individual mesh in this manner significantly extends the useful life of these exosuits by preventing wear and tear of the inflatable bags. In accordance with a highly advantageous element, the corners 81 of the protective covers 166 have been rounded, as shown. Pointy corners of the protective covers can abut into the user. Elimination of pointy corners by rounding the corners reduces this problem and thereby helps enhance user comfort. Advantageously the exosuit components may be made of relatively lightweight materials. Further, increasing the comfort of the user wearing the exosuit increases the likelihood of compliance where the exosuit is required.

[0030] Fig. 9 is a schematic stackup showing the order of elements. From left to right - the front surface 42 of second vest 140, following by a series of second air supply tubes 34 / air rail 135 operatively connected to second inflatable airbags with second protective covers similar to the inflatable airbags and protective covers of vest 130 shown in Fig. 8 (and operatively connected to the air port and release valve), the second body surface 242 of the back of the second vest 140, followed by the second spacer 240, the second mesh 260. The user and the back (not shown) would be further to the right from the drawing.

[0031] Fig. 10 shows an isolated back side view of the vests 130 and 140. Body surfaces 232 and 242 are visible, along with spacers 230 and 240, as well as mesh 250 and second mesh 260. The spacers are positioned on corresponding body surfaces to create a gap between the body surfaces 232, 242 and the user, advantageously allowing for dissipation of heat and movement of air between the vest and the user. The meshes cooperate with corresponding vest body surfaces to secure the corresponding spacer in place with respect to the other elements. As shown, mesh 250 is attached to the body surface 232 of vest 130, securing spacer 230 against the body surface 232. In a similar manner, second mesh 260 at attached to second body surface 242 of second vest 140, securing the second spacer 240 against the second body surface 242.

[0032] An isolated isometric view of an embodiment of the spacer 240 is shown in Fig. 11. The second spacer 240 can be a unitary or one-piece construction extending along most of the length of the second length of the second vest 140. In this embodiment, the spacer 240 can be ladder shaped as shown, with side lengths241 and 243 connected by a sequential series of cross rails 244. Spacer 230 for the other vest is formed as a mirror image of second spacer 240. The spacer has a thickness which acts to space the vest apart from the user by a distance. One weight saving design is to have a series of rises 245 on the side rails, and increases 247 on the cross rails 244. The rises 245 may be hemispherical-shaped with a gap 246 between the rise and the corresponding side length. The increases 247 may also have an opening 248 between the increase and the corresponding cross rail. The rises and the increases may be on the same side of the spacer (as in Fig. 11 , facing toward the mesh and the user) and have the same height. Other spacer shapes will be readily apparent to those skilled in the art given the benefit of this disclosure. For example, while it is important that the spacer extend along at least a majority of the length of the vest, and preferably extends along most of the length (with the second spacer acting the same for the second vest, extending along at least a majority of a second length of the second vest) as shown in the drawings, the spacer need not necessarily form a unitary element.

[0033] From the foregoing disclosure and detailed description of certain embodiments, it will be apparent that various modifications, additions and other alternative embodiments are possible without departing from the true scope of the invention. The embodiments discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to use the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of theinvention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.

Claims

CLAIMSWhat is claimed is:

1. An enhanced comfort exosuit to be worn by a user for assisting with lifting a load, comprising, in combination: a first vest having a front surface, a body surface, and a zipper; a second vest having a second front surface, a second body surface, and a second zipper, wherein the body surface and second body surface are adapted to face the user when worn; a back operatively connected to the first vest and the second vest, and adapted to be positioned on a backside of the user when worn; and a spacer corresponding to the vest and positioned on the body surface, and a second spacer element corresponding to the second vest positioned on the second body surface, wherein the spacer extends along at least a majority of the length of the vest, and the second spacer extends along at least a majority of the second length of the second vest.

2. The enhanced comfort exosuit of claim 1 wherein the spacer is ladder shaped, having a pair of side rails and a plurality of cross rails connecting the side rails.

3. The enhanced comfort exosuit of claim 2 wherein spacer has rises on the side rails, and increases on the cross rails, with the rises defining gaps with the side rails and the increases defining openings with the cross rails.

4. The enhanced comfort exosuit of claim 1 further comprising a mesh attached to the body surface of the vest, and cooperating with the body surface of the vest to secure the spacer to the vest.

5. The enhanced comfort exosuit of claim 1 wherein the vest has an upper portion and a lower portion, and the second vest has a corresponding second upper portion and a second lower portion, wherein distance between the zipper and the second zipper between the upper portions stays the same, and distance between the zipper and the second zipper increases between the lower portion and the second lower portion.

6. The enhanced comfort exosuit of claim 5 wherein the upper portion and the second upper portion are linear, and the lower portion and the second lower portion are linear.

7. The enhanced comfort exosuit of claim 1 further comprising: an air rail extending along an interior of the vest; a plurality of inflatable air bags, with each air bag operatively connected to the air rail such that each air bag may be inflated and deflated; and a plurality of protective covers, one protective cover for each inflatable air bag, wherein the protective covers each has an opening sized to receive a corresponding inflatable air bag; wherein the protective covers have rounded corners.

8. The enhanced comfort exosuit of claim 7 further comprising: a second rail extending along an interior of the second vest; a plurality of second inflatable air bags, with each second air bag operatively connected to the second air rail such that each second air bag may be inflated and deflated; and a plurality of second protective covers, one second protective cover for each second inflatable air bag, wherein the second protective covers each have an opening sized to receive a corresponding second inflatable air bag; wherein the second protective covers have rounded corners.

9. The enhanced comfort exosuit of claim 8 wherein the interior of the vest is accessible by the zipper, and the interior of the second vest is accessible by the second zipper.

10. The enhanced comfort exosuit of claim 8 further comprising a central zipper positioned along a sagittal plane and connecting the vest to the second vest; an air access port, wherein the air access port opens away from the central zipper; and an air release valve, wherein the air release valve opens parallel to the central zipper.11 . The enhanced comfort exosuit of claim 9 wherein the air release valve opens in an upward direction generally parallel to the front surface of the vest.

12. The enhanced comfort exosuit of claim 1 further comprising a thigh strap operatively connected to the vest, having an interior surface adapted to face a leg of the user, wherein the interior surface of the thigh strap has a high friction material to resist relative movement of the thigh strap with respect to the leg of the user; and a second thigh strap operatively connected to the second vest, having an interior surface adapted to face a second leg of the user, wherein the interior surface of the second thigh strap has a high friction material to resist relative movement of the second thigh strap with respect to the second leg of the user13. An enhanced comfort exosuit to be worn by a user for assisting with lifting a load, comprising, in combination: a first vest having a front surface, a body surface, and a zipper; a second vest having a second front surface, a second body surface, and a second zipper, wherein the body surface and second body surface are adapted to face the user when worn; a back operatively connected to the first vest and the second vest, and adapted to be positioned on a backside of the user when worn; and the vest has an upper portion and a lower portion, and the second vest has a corresponding second upper portion and a second lower portion, wherein distance between the zipper and the second zipper between the upper portions stays the same, and distance between the zipper and the second zipper increases between the lower portion and the second lower portion.

14. The enhanced comfort exosuit of claim 13 further comprising:an air rail extending along an interior of the vest; and a second air rail extending along an interior of the second vest; wherein the air rail is bendable at a transition between the upper portion and the lower portion, and the second air rail is bendable at a transition between the second upper portion and the second lower portion.

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