Abstract: A method of preparing a breathable, custom-molded liner for an artificial limb socket includes the steps of providing a liner comprising an open-celled foam material impregnated with a curable resin, activating the curable resin, and deforming the foam material by positioning a residual limb on one of opposing surfaces of the liner, and positioning the artificial limb socket on a second opposing surface of the liner until curing is substantially complete to create and retain an impression of the residual limb in the foam material. A liner blank useful for preparing an artificial limb socket, comprising a foam material impregnated with a curable resin and sewn into the shape of a sock for an artificial limb, is also described.

Abstract: An orthopedic casting material is disclosed comprising a water-curable, isocyanate-functional prepolymer. The prepolymer comprises the reaction product of a polyisocyanate and a polyol having an HLB number per hydroxy group less than zero.

Abstract: An orthopedic casting material is disclosed comprising a water-curable, isocyanate-functional prepolymer. The prepolymer comprises the reaction product of a polyisocyanate and a polyol having an HLB number per hydroxy group less than zero.

Abstract: A protective covering of nonwoven fabric for an orthopedic cast, wound dressing or other bandage is disclosed. The covering is adapted to fit loosely about the bandage to be protected and is capable of being heat-shrunk at a relatively low temperature to closely cover the bandage. The covering is permeable to water vapor and air, it may be treated with a surface active agent to provide superior water and soil repellency, and it may be provided in various colors or with various decorative designs.

Abstract: The present invention relates to a method of dressing a wound using an open-celled foam pad prepared from a foam sheet impregnated with a water curable, isocyanate functional, polyurethane prepolymer resin. The pad can concurrently function as an orthotic pad. The pad exhibits the ability to wick wound exudate from the site of the wound, and also exhibits desirable conformability and comfort in use.

Abstract: A kit for use in preparing a last, i.e., an anatomical model of the human foot for use in the contruction of custom footwear, as well as a method of preparing lasts, the lasts prepared by such a method, and the custom footwear constructed by the use of such lasts. The kit includes a hardenable, shell-forming fabric that can be conformed to the shape of the foot, hardened in its conformed shape, and removed from the foot in a manner that does not substantially destroy its conformed shape. The resultant shell, being sufficiently smooth and being of substantially the same size and shape as the foot, can be used directly as a positive model of the foot.

Abstract: The present invention relates to a method of dressing a wound using an open-celled foam pad prepared from a foam sheet impregnated with a water curable, isocyanate functional, polyurethane prepolymer resin. The pad can concurrently function as an orthotic pad. The pad exhibits the ability to wick wound exudate from the site of the wound, and also exhibits desirable conformability and comfort in use.

Abstract: The present invention relates to an orthotic blank comprising an open-celled foam sheet impregnated with a water curable, isocyanate functional, polyurethane prepolymer resin. The orthotic blank can be used according to the method of this invention to prepare an orthotic pad bearing the impression of a body part to be supported and/or cushioned. The resultant orthotic pad exhibits both proper weight-bearing strength and cushioning properties for effective and comfortable use.

Abstract: A method of immobilizing a body part with an improved orthopedic cast or splint having a padding that has been treated with a fluorochemical or silicone. The padding has an apparent surface tension of less than 60 dynes per centimeter and a porosity of less than about 15 seconds. The padding is able to shed water rapidly, thereby providing more comfort for the user.

Abstract: An orthotic knee brace is custom fit to the user's leg without requiring any separate casting steps. The brace includes a thigh cuff which is hinged to a calf cuff. Straps can provide support to at least a portion of the leg. A pad is removably disposed on the interior surface of both the thigh cuff and the calf cuff and contacts the user's leg. The pad is initially pliable when placed around the user's leg and conforms to the leg shape. After a predetermined time the pad cures to maintain the leg shape even after the brace is removed.

Abstract: The present invention relates to an orthotic blank that includes an open-celled foam sheet impregnated with a water curable, isocyanate functional, polyurethane prepolymer resin. The orthotic blank can be used according to the method of this invention to prepare an orthotic pad bearing the impression of a body part to be supported and/or cushioned. The resultant orthotic pad exhibits both proper weight-bearing strength and cushioning properties for effective and comfortable use.

Abstract: An improved orthopedic cast or splint includes a padding that is treated with a fluorochemical or silicone. The padding has an apparent surface tension of less than 60 dynes per centimeter and a porosity of less than about 15 seconds. The padding is able to shed water rapidly, thereby providing more comfort for the user.

Abstract: The present invention relates to orthopedic splinting articles and methods for forming orthopedic splints at least part way around an animal body part. The splinting articles comprise a unitary blank formed of an open-celled foam sheet impregnated with a water curable, isocyanate functional, polyurethane prepolymer resin. The blank is dimensioned to extend the length of the body part to be immobilized and to partially, but preferably not completely, extend around the circumference of the body part. Upon activation of the resin impregnated foam sheet and molding the same around the body part, an orthopedic splint is formed.

Abstract: The present invention relates to orthopedic splinting articles and methods for forming orthopedic splints at least part way around an animal body part. The splinting articles comprise a unitary blank formed of an open-celled foam sheet impregnated with a water curable, isocyanate functional, polyurethane prepolymer resin. The blank is dimensioned to extend the length of the body part to be immobilized and to partially, but preferably not completely, extend around the circumference of the body part. Upon activation of the resin impregnated foam sheet and molding the same around the body part, an orthopedic splint is formed. The present invention further relates to the use of such resin-impregnated foam materials as walking heels or laminates betweeen casts and walking heels, as supports for orthotic devices such as arch supports for foot orthotics, and as protective coverings for animal hoofs.

Abstract: The present invention relates to orthopedic casting materials having reduced tack and methods for preparing and using such orthopedic casting materials, wherein the materials comprise a nonwoven, stretchable fabric which is impregnated with a curable prepolymer resin. The nonwoven fabric comprises fiber bundles and apertures between the fiber bundles, with each of the fiber bundles comprising a plurality of fibers having interstices therebetween. The curable prepolymer resin is impregnated into the nonwoven fabric such that the interstices between the fibers receive the resin, while leaving the apertures between fiber bundles substantially unoccluded. Such orthopedic casting materials are relatively inexpensive and exhibit improved properties.

Abstract: A curable resin coated sheet useful as an orthopedic bandage which has reduced tack is provided. The resin coated sheet is pre-lubricated with a lubricant which is (a) bonded to the resin, (b) added to the resin or applied to the surface of the coated sheet, or (c) a combination of (a) and (b). The lubricant is present in an amount to reduce the kinetic coefficient of friction of a surface of the coated sheet to less than 1.2.

Abstract: An ophthalmic lens and a method for providing a thin coating thereon is disclosed. The coatings render the surfaces of the devices resistant to abrasion and have an SEB abrasion resistance to at least 20 psi. They are optically clear, aberration-free, and provide essentially exactly an optical surface having the desired surface configuration. The coating compositions employed contain reactive ethylenically unsaturated groups and are applied to a mold face and partially reacted. The coated mold is then used to cast the ophthalmic device.

Abstract: A casting article and method for forming an orthopedic cast around an animal body part. The article comprises a unitary blank having first and second lateral free edges. The blank is dimensioned and the free edges are shaped to extend the length of the body part and to at least circumferentially envelop the body part. The blank includes a pliant, extensible layer of a foam member, an extensible fabric bonded to the foam member and a curable resin which, upon activation of the resin and closure of the lateral free edges of the blank around the body part, results in the orthopedic cast.

Abstract: A curable resin coated sheet useful as an orthopedic bandage which has reduced tack is provided. The resin coated sheet is pre-lubricated with a lubricant which is (a) bonded to the resin, (b) added to the resin or applied to the surface of the coated sheet, or (c) a combination of (a) and (b). The lubricant is present in an amount to reduce the kinetic coefficient of friction of a surface of the coated sheet to less than 1.2.

Abstract: An ophthalmic lens and a method for providing a thin coating thereon is disclosed. The coatings render the surfaces of the devices resistant to abrasion and have an SEB abrasion resistance of at least 20 psi. They are optically clear, aberration-free, and provide essentially exactly an optical surface having the desired surface configuration. The coating compositions employed contain reactive ethylenically unsaturated groups and are applied to a mold face and partially reacted. The coated mold is then used to cast the ophthalmic device.