Abstract: The process for fabricating an orthotic joint of the present invention involves creating a casting mold of the anatomical joint for which the brace is being fitted. Then layers of nylon and cross-link carbon composite grade and the PVA bag are placed over the mold as is done in typical laminating processees for such braces. Then, a series of reinforcing strips of nylon and composite are attached to the layup in the same location where the sidebars would normally be located. The bottom layer which is typically a layer of nylon stockinette is the longest of the layers and the nylon strips are alternated with the composite strips with each successive strip being shorter than the strip immediately below it. A dummy disk is then provided at the joint. A second set of strips is then positioned where the upper sidebar would be located. Additional laminating substrate materials of nylon and cross-link carbon composite braid and a PVA bag are then placed over the structure.

Abstract: Disclosed is an orthotic joint for an orthotic knee, hip or other similar brace that would eliminate the use of sidebars and would automatically lock upon full extension. The locking mechanism could also be fixed in an unlocked position if desired. Instead of a lock, one of a series of barrels of different diameters could be used as stops. The diameter of the barrel would determine the degree of stop. The locking mechanism or barrel would be vacuum-formed into the knee section of a typical custom-made knee orthosis or knee ankle foot orthosis. A round disk with a range-of-motion cutout and a locking hole is positioned between the thigh and calf portions of the brace. In one embodiment, a plunger mounted through the locking mechanism would roll on a cutout in the disk until reaching the tapered hole and then be forced in by a spring to lock the joint. Barrels, instead of a plunger, could be used if a stop, instead of lock, is desired. The locking mechanism could be unlocked by pulling or turning the plunger.