Abstract: A versatile orthopaedic walker includes a high strength engineered plastic base with spaced upper and lower surfaces and upwardly extending slotted strut supports. The base may be laterally and vertically cored, and an outer sole is provided which extends upward over the core openings, with the upper edges of the outsole being ridged to fit into a peripheral groove in the base to provide a smooth exterior surface. Struts of different lengths are provided, and all of the struts have identical arrangements for interlocking with the base. All of the struts may be provided with a three pronged construction to triply lock the struts into the base. The struts may have areas of reduced cross-section providing pivot points or areas of flexibility to accommodate different size patients, and limiting stops may be provided to assure adequate orthopaedic support. Fully integrally molded pivoting D-rings may hold walker straps in place.

Abstract: An ankle brace has first and second semi-rigid shell members for extending over the ankle and the lower leg on the inner and outer sides of the ankle. A sealed bladder pad is mounted to each of the shell members on the side of the shell member facing the ankle. Each bladder pad includes three small-interconnected bladders wherein a first larger bladder is mounted at the lower end of the shell, and two side-by-side upper bladders are mounted on an upper portion of the associated shell member. The three bladders having restricted openings permitting limited flow of air between the bladders. When a patient wearing the ankle brace walks, the lower bladder is compressed, and air is directed through the restricted openings to the upper bladders, thereby intermittently varying the pressure on the ankle and lower leg, and promoting circulation.

Abstract: A technique for forming orthopaedic splints or supports includes the steps of impregnating the edges of casting material with non-rigid bonding material and subsequently impregnating the casting material with water hardenable material such as urethane. The edge treatment keeps the edges in a relatively cushioning or non-rigid state to avoid irritation of the skin of the patient. The blanks may be formed using a mold having a groove defining the outline of the casting blank, and a ridge for implementing the impregnation of a bead of bonding material into the casting fabric. The casting blank material may be formed of spacer or double knit type material, or may be formed of several layers of fabric including high strength filaments, and may have padding material as one layer.

Abstract: An orthopaedic support (50) or product is formed of a doubleknit type fabric material with spaced interwoven layers formed of high strength materials, and an open-work matrix of filaments or threads interconnecting the layers. The fabric may be impregnated with water hardened urethane. Hydroxy propyl methyl-cellulose (HPMC) will also be applied to the doubleknit type material or other casting fabric in sufficient amount to reduce the stickiness of the water hardened urethane. The HPMC may be mixed in with the water surfaces of the doubleknit type material. The orthopaedic support (50) or product is packaged in a water-vapor impermeable package; and is opened. Water is supplied to the fabric when it is applied to the part of the anatomy requiring support. The fabric may be included in a soft goods' support including a water distribution network, and straps (74) to hold the support in place.

Abstract: A technique for forming orthopaedic splints or supports includes the steps of impregnating the edges of casting material with non-rigid bonding material and subsequently impregnating the casting material with water hardenable material such as urethane. The edge treatment keeps the edges in a relatively cushioning or non-rigid state to avoid irritation of the skin of the patient. The blanks may be formed using a mold having a groove defining the outline of the casting blank, and a ridge for implementing the impregnation of a bead of bonding material into the casting fabric. The casting blank material may be formed of spacer or double knit type material, or may be formed of several layers of fabric including high strength filaments, and may have padding material as one layer.

Abstract: An orthopaedic support assembly is formed of a double-knit type fabric material with spaced interwoven layers formed of high strength materials and an open-work matrix of filaments or threads interconnecting the layers. The fabric preferably includes high strength stiff filaments of fiberglass, carbon fibers, or aramids and thermoplastic material to facilitate heat bonding of cut edges. The fabric is impregnated with a water-hardenable material. The support material or product is packaged in a water-vapor impermeable package; and is opened and water is supplied to the fabric when it is applied to the part of the anatomy requiring support. The fabric may be included in a soft goods support including a water distribution network and straps to hold the support in place. The double-knit type material may be variable in thickness and may be three dimensional in its configuration.

Abstract: An orthopaedic support is formed of a double knit type fabric material with spaced interwoven layers formed of high strength materials and an open-work matrix of filaments or threads interconnecting the layers. The fabric is impregnated with a water hardenable material. The support material or product is packaged in a water-vapor impermeable package; and is opened and water is supplied to the fabric when it is applied to the part of the anatomy requiring support. The fabric may be included in a soft goods support including a water distribution network and straps to hold the support in place.

Abstract: The present invention pertains to an orthopedic support having a flexible inner member and an exo-skeleton that is molded directly onto the flexible inner member. In one particular embodiment, a versatile, multi-medium orthopedic ankle support assembly has an inner fabric support for extending at least partially around an injured part of the anatomy and for providing basic support for the injury. A plastic exo-support is injection molded into said fabric support and supplies supplemental support for resisting motion of the injured part in undesired directions. The fabric support has a main body portion for extending at least part way around the injured part of the anatomy and has edges to be secured together after the fabric support is fitted to the injured part. The invention is not limited to ankle braces, of course, as the general principle of molding an exo-skeleton onto a flexible inner member may be used in conjunction with numerous different supports.

Abstract: An orthopaedic support or product is formed of a doubleknit type fabric material with spaced interwoven layers formed of high strength materials and an open-work matrix of filaments or threads interconnecting the layers. The fabric may be impregnated with water hardenable urethane. Hydroxy propyl methyl-cellulose (HPMC) will also be applied to the doubleknit type material or other casting fabric in sufficient amount to reduce the stickiness of the water hardenable urethane. The HPMC may be mixed in with the water hardenable urethane prior to impregnation, or may be applied to at least one of the outer surfaces of the doubleknit type material. The orthopaedic support or product is packaged in a water-vapor impermeable package; and is opened and water is supplied to the fabric when it is applied to the part of the anatomy requiring support. The fabric may be included in a soft goods support including a water distribution network and straps to hold the support in place.

Abstract: An improved ankle brace that is easily adjustable for improved comfort and use. The ankle brace includes a pair of relatively rigid side supports to fit about a lower leg of a patient, and the lower area of the side supports may be adapted to position an assembly of heel straps. The assembly may include at least two straps, which are coupled at the ends and adapted to adjust the effective length of the assembly, so that it may be accommodated for different heel widths of different patients. Alternatively, the assembly may include three pieces, an intermediary member for linking the other two straps. The assembly may be attached to the side supports through a pin mechanism that may be either capped (as by heat staking) or welded at the end to hold it in position. Alternatively, a cap with protruding plastic pin may be molded directly onto the strap, effectively making them one piece to be assembled as such.

Abstract: An improved ankle brace may have two relatively rigid side supports, the outer edge portion of the lower area of the side supports, adjacent to the ankle being covered with a flexible or resilient material. The flexible resilient material may be permanently secured to the side supports by bonding, mechanical interlocking, or by any other suitable arrangements. Additional resilient flexible material may be placed on the interior surface of the side supports to improve the fit and comfort of the brace around the user's lower leg. The rigid side supports may be of an open type with the resilient flexible material extending across the side supports and beyond the edges thereof. The lower area of the side supports may include a pivoting mechanism to adjustably receive heel straps. Each of the side supports may include a structural frame that surrounds but does not cover the ankle or malleolus.

Abstract: An orthopaedic brace for supporting a selected portion of the anatomy including a unitarily molded support having substantially flexible areas, substantially rigid portions for providing splinting action and a support coupling unitarily molded with the support for holding the opposed edges toward one another and for adjustably and removably securing the support onto the selected portion of the anatomy.

Abstract: An orthopaedic support includes a sheet of foam material that has been compression molded in specific areas. These areas have a thickness and density that is different from other areas of the support and serve to better fit the support to the body. The support may include compression molded grooves or cavities to accommodate straps, struts, gel-filled pads, inflatable bladders, pumps, and other accessories. The support may also include compression molded grooves that reduce bunching when the support is bent, and may include molded edges to minimize skin irritation during activity. The brace may also be a back brace or an ankle brace having compression molded components. A method of compression molding an orthopaedic support includes compression molding at least one sheet of resilient foam material in selected areas to reduce the thickness and increase the density of the material in those areas.

Abstract: An improved ankle brace may have two relatively rigid side supports, the outer edge portion of the lower area of the side supports, adjacent to the ankle being covered with a flexible or resilient material. The flexible resilient material may be permanently secured to the side supports by bonding, mechanical interlocking, or by any other suitable arrangements. Additional resilient flexible material may be placed on the interior surface of the side supports to improve the fit and comfort of the brace around the user's lower leg. The rigid side supports may be of an open type with the resilient flexible material extending across the side supports and beyond the edges thereof.

Abstract: In an orthopedic support pad with semi-permanent relief zones, an airtight bladder is filled with a material which retains its shape when air is evacuated from the bladder during the formation process. The afflicted areas of an appendage are temporarily covered with padding and the support pad is then conformed to the wearer's particular anatomy. When the padding is subsequently removed, areas of pressure relief for the afflicted areas are maintained in the support pad.

Abstract: A pneumatic ankle brace having a pair of relatively rigid side supports with inflatable main bladders attached to their inside surfaces. The inflatable main bladders are coupled to an interconnected foot pump. Additional support and back-up bladders may be placed distally upon the main bladders to provide further cushioning and support. The foot pump is activated through normal use, such as walking or running, whereby entrapped fluid is displaced back and forth between the main bladders and the pump. This creates a pulsing action which provides a massaging compression effect which helps reduce swelling and increase venous and lymphatic return.