Welded back brace

Abstract

A welded orthopedic back brace is disclosed. In an embodiment, at least one belt member is coupled to a spinal support element. The materials of the belt member are thermally fused to form a unitary segment. In another embodiment, an anterior portion of a posterior pad of the spinal support element includes thermally fused materials to provide a user with an added degree of comfort.

What is claimed is: 
     
         1 . A orthopedic back brace, comprising:
 a spinal support element comprising a frame having a plurality of perforations defining at least one flap aligned over a spinal column region, the at least one flap configured to open outward from the region in response to pressure applied to the region when the brace is worn; and   at least one belt member coupled to the spinal support element for securing the spinal support element to a user.   
     
     
         2 . The back brace of  claim 1 , wherein the spinal support element further comprises a foam pad affixed to a side of the frame facing the spinal column region. 
     
     
         3 . The back brace of  claim 1 , wherein the plurality of perforations comprise a first perforation intersecting a second perforation aligned in a first different direction along the frame than the first perforation, to form at least a portion of the flap. 
     
     
         4 . The back brace of  claim 1 , wherein the second perforation further intersects a third perforation aligned in a second different direction than the second perforation to form the flap. 
     
     
         5 . The back brace of  claim 4 , wherein the first and second directions are the same. 
     
     
         6 . The back brace of  claim 1 , wherein the at least one flap comprises a pair of flaps arranged at opposing sides of the spinal column region. 
     
     
         7 . The back brace of  claim 6 , wherein the pair of flaps are arranged evenly relative to one another along a vertical axis. 
     
     
         8 . The back brace of  claim 6 , wherein the pair of flaps is arranged in the center of the frame in a horizontal direction. 
     
     
         9 . The back brace of  claim 6 , wherein each of the pair of flaps comprises rectilinear perforations on three sides. 
     
     
         10 . The back brace of  claim 6 , wherein the pair of flaps are configured to open outward from stitching or an injured area on the spinal column region. 
     
     
         11 . The back brace of  claim 1 , wherein the at least one flap comprises a plurality of flaps staggered vertically along opposing sides of the spinal column region. 
     
     
         12 . The back brace of  claim 1 , wherein the at least one flap comprises a generally rectangular shape. 
     
     
         13 . The back brace of  claim 1 , wherein the at least one flap comprises one or more of an elliptical, triangular, oblong, and asymmetrical shape. 
     
     
         14 . The back brace of  claim 1 , wherein the frame comprises a semi-rigid plastic material. 
     
     
         15 . A spinal support element for an orthopedic back brace, comprising:
 a frame having a plurality of perforations defining at least one flap aligned over a spinal column region, the at least one flap configured to open outward from the region in response to pressure applied to the region when the back brace is worn.   
     
     
         16 . The spinal support element of  claim 15 , wherein the frame comprises a rigid or semi-rigid plastic. 
     
     
         17 . The spinal support element of  claim 15 , wherein the spinal support element further comprises a foam pad affixed to a side of the frame facing the spinal column region. 
     
     
         18 . The spinal support element of  claim 15 , wherein the at least one flap comprises a pair of flaps arranged at opposing sides of the spinal column region. 
     
     
         19 . The spinal support element of  claim 18 , wherein the pair of flaps are arranged evenly relative to one another along a vertical axis. 
     
     
         20 . The spinal support element of  claim 18 , wherein each of the pair of flaps comprises rectilinear perforations on three sides. 
     
     
         21 . The spinal support element of  claim 18 , wherein the pair of flaps are configured to open outward from stitching or an injured area on the spinal column region. 
     
     
         22 . The spinal support element of  claim 15 , wherein the at least one flap comprises a generally rectangular shape. 
     
     
         23 . The spinal support element of  claim 15 , wherein the at least one flap comprises one or more of an elliptical, triangular, oblong, and asymmetrical shape.