Abstract: An apparatus and method for creating and using a lightweight custom-molded orthopedic appliance are disclosed. The orthopedic appliance is made up of an inner and an outer bladder containing components which, when combined by rupturing the inner bladder, react to form a rigid foam substance which may be conformed to the shape of the body part or surface in need of support, cushioning, or immobilization, and which quickly cures to form a firm, supportive brace for the affected body part.

Abstract: An orthopedic casting material comprises a support layer made of thermoplastic material in the form of a sheet repeatedly formable for wrapping round a body member to be immobilized, and a buffer layer made of compressibly elastic thermoplastic material and bonded to one side of the support layer for buffering between the support layer and the body member to be immobilized.

Abstract: An Orthopaedic Plaster of Paris bandage (10) comprising a water resistant layer of material (50; 60) on at least one face of the bandage (10) which allows the bandage (10) to be cured by water but once the bandage (10) is set, the bandage (10) is water resistant against disintegration.

Abstract: An orthopedic casting material made from layers of resin impregnated fiberglass fibers that are shaped, cut, and formed into a skeletal hexagonal cellular mesh array. The material forms a sheet with an array of aligned apertures that permit the flow of air. The size of the apertures may vary but is generally large in comparison to the fiberglass sections that define the sides of the apertures. The mesh may optionally include reinforcing strands and a lining. The material may be cut and trimmed in both its pliable and rigid states. The apertures additionally serve to receive the fingers or toes of the individual receiving the cast. The apertures also serve to allow continuous monitoring of the condition of the patient's skin. The skeletal structure of the material reduces the weight of the cast without sacrificing strength and protection.

Abstract: A knee pad assembly for relieving the symptoms of patellar tendinitis, including a pad adapted for being positioned against and molded onto a lower leg in the region of the knee for lying in closely-conforming relation against and applying radially-directed pressure to the attachment site of the patellar tendon to the patella, to the knee joint, and to at least one epicondyle of the tibia. The pad is hardened into a rigid structure for therapeutic use and includes an initially flexible inner substrate impregnated or coated with a reactive system. The system remains stable when maintained in substantially moisture-free conditions and hardens upon exposure to moisture to form a rigid, self-supporting structure having a shape conforming to the lower leg to which the pad is molded during curing. A flexible cover encloses the substrate, and cooperates with the pad for maintaining the pad in its closely-conforming position against the lower leg.

Abstract: The present invention is directed, to an improved orthosis and posterior plantar flexion stop for the orthosis, as well as to methods of making and using the orthosis and posterior stop, plus components used to make the orthosis and stop. The ankle-foot orthosis and plantar flexion stop of the present invention improve on the function and performance of the orthosis, while also making the orthosis attractive and easier to use than prior devices.

Abstract: The present invention relates to a bent splint used to wrap affected parts such as a fractured part and a ligament fractured part so that they do not move, and method of manufacturing the same. More particularly, the present invention relates to a bent splint that can facilitate a surgical operation by shaping the bent splint similar to an operation shape of a bent portion such as an elbow at a bent shape in which the wrinkles are not formed in the bent splint and that can increase an effect of a medical treatment by closely fixing the bent splint to the affected parts so that the splint does not float, and method of manufacturing the same.

Abstract: The present invention provides a composite material for use in making orthopedic elastic braces for supporting a body part by compression. One embodiment of the invention is a compression brace material (400) having an elastic outer layer (410), a first fabric layer (420), a spacer fabric layer (425), and a second fabric layer (430). The spacer fabric layer permits and promotes airflow laterally through the brace material. The outer layer may have a plurality of slits (550) therethrough to permit and promote airflow transversely through the composite material. The plurality of slits may be arcuate to further improve transverse airflow through the composite brace material.

Abstract: A synthetic rigid bandage especially for splinting and/or supporting a diseased or injured limb of the human or animal apparatus of locomotion, comprising a curable core which is formed by one or more synthetic resin-impregnated layers of longitudinal strips of a textile fabric, is covered at the one side thereof with a pad and on the other side thereof with a water vapour-pervious, longitudinally and/or transversally elastic film or sheet cover, and is to be stored in a moisture-proof package, said core being mouldable in its ready-for-application state, is characterized in that the said film or sheet cover is separated from the said resin-impregnated layers by means of a spacer.

Abstract: A splint product for forming a hard structure about a body portion is provided. The splint product includes a unitary assembly of moisture-impervious outer and inner layers with an outer substrate layer, a resin impregnated substrate that hardens when exposed to moisture, and an inner substrate layer disposed between these moisture-impervious layers. Padding is adhered to the moisture-impervious inner layer opposite said resin impregnated substrate so that the padding is in contact with a patient's skin. Another aspect of the present invention is a method for activating the splint product by exposing the outer substrate layer and/or the resin impregnated substrate to moisture. This may be done by removing the moisture-impervious outer layer and spraying water on the outer substrate layer or by holding the moisture-impervious inner and outer layers together to form a pouch and pouring water into this pouch.

Abstract: A knee immobilizer for being custom-formed to the shape of a knee while flexible and upon hardening providing a rigid, knee-supporting custom fit. The knee immobilizer includes an elongate splint with a substrate impregnated or coated with a reactive system. The system hardens upon exposure to moisture to form a rigid, self-supporting structure. A flexible cover overlies the substrate for forming an integrated splint structure for being molded while flexible to an aspect of the knee. A bandage extends around the knee for holding the splint in a supporting position on the knee. A splint support cooperates with the splint and the bandage for maintaining the splint on the bandage in a conforming shape against the knee and substantially immobilizing the knee in a predetermined position.

Abstract: The present invention relates to an orthotic for correction of foot pronation and a method to fabricate the foot orthotic. The orthotic includes a thin formable body having pliable medial and lateral side walls and a pliable bottom, and a securing mechanism to draw the side walls about a foot so as to create a hydrostatic pressure of the soft tissue of the foot within the orthotic. The securing mechanism includes hook and loop straps attached to the pliable body and looping rings attached to the pliable body for wrapping the straps therethrough. The pliable body is vacuumed formed plastic wherein the plastic is chosen form the group consisting essentially of polypropylene, polyethylene or copolymer. The orthotic has a heel post attached to the bottom thereof to provide stability for standing or walking. The heel post is formed from a semi circular piece of material chosen from the group consisting essentially of polypropylene, polyethylene, or copolymer.

Abstract: An inflatable cast system for immobilizing a lower extremity of a human. The system includes a pair of outer shell members shaped to conform to the lateral and medial sides of the lower extremity, respectively. A base member is fastened to the shell members to form a substantially U-shaped stirrup member. The upstanding sidewalls of the shell members are maintained in position relative to the lower extremity by a plurality of elongated, circumferentially extending, longitudinally spaced, flexible fastening straps. A pair of inflatable air bags are attached to inside surfaces of the shell members. The air bags include at least one chamber and a valve that is sealed along one edge of the air bag and is adapted to allow the chamber to be automatically sealed once the brace is attached to the extremity of the user. A unidirectional air pump is provided to allow the chamber of the air bag to be selectively inflated and deflated.

Abstract: An orthopedic support assembly has a shape which is well-suited to be reliably positioned on a patient's anatomical structure, e.g., a limb or other extremity. Designs in accordance with certain embodiments include two or more lobes joined by one or more narrower joining region.

Abstract: An elongate medical bandaging product for being dispensed in lengths suitable for a given medical use, including an elongate sleeve of a predetermined length formed of a moisture-impervious material and sealable to prevent entry of moisture, and an elongate medical material having substantially the same predetermined length as the elongate sleeve and positioned within the sleeve in substantially moisture-free conditions and sealed therein against moisture until use.

Abstract: The present invention provides improved hardenable orthopaedic supports and methods of making the same. One embodiment provides a support which includes a blank made of a permeable, flexible material and including a structural region impregnated with a hardenable material and a peripheral region which will remain flexible after the hardenable material is hardened. Another embodiment provides a method of manufacturing an orthopaedic support in which a permeable, flexible material is positioned adjacent a recess of a molding element; the flexible material is contacted with a hardenable material; and the hardenable material is placed under pressure in the molding element to impregnate the section of the flexible material with the hardenable material.

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: A tennis elbow pad assembly product for relieving the symptoms of lateral epicondylitis is disclosed. The tennis elbow pad assembly product includes an outer pouch formed of a moisture-impervious material. A pad is positioned in the pouch in substantially moisture-free conditions and sealed therein against entry of moisture until use. The pad is adapted for being positioned against and molded onto a forearm in the region of the elbow for lying in closely-conforming relation against and applying radially-directed pressure to the common tendon attachment and grasping and supination muscles associated with the radial-humeral joint and the lateral epicondyle of a forearm and hardened into a rigid structure for therapeutic use. The pad includes an initially flexible substrate impregnated or coated with a reactive system.

Abstract: A medical bandaging product having a moisture curable hardening agent and a flexible liquid-permeable braided and/or tubular fabric substrate for casting or splinting, a method of manufacture of such a medical bandaging product, and a bandaging system comprising such a bandaging product within a moisture impervious package with means for resealing the package.

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 ventilated neck brace that provides support to the wearer's neck while providing improved ventilation and breathability. Most embodiments of the neck brace are comprised of an elongate member that defines a neck support, a transition section, and an elongate shoulder rest. Most configurations of the neck brace allow the wearer to adjust the width and length of the neck brace.

Abstract: A medical bandaging product in roll form for being dispensed in predetermined lengths suitable for a given medical use, and including an elongate sleeve formed of moisture-impervious material and sealable to prevent entry of moisture, and an elongate medical bandage material substantially the same length as the sleeve and positioned in the sleeve in a single length along the length of the sleeve and sealed therein against entry of moisture until use. The medical bandage material includes a substrate and a reactive system impregnated into or coated onto the substrate. The system remains stable when maintained in substantially moisture-free conditions and hardens upon exposure to sufficient moisture to form a rigid, self supporting structure. A protective liner sheet encloses the substrate along its length and forms a barrier between the substrate and the sleeve during storage, and is optionally removable after removal of the medical bandage material from the sleeve and prior to application to a patient.

Abstract: A cushioning sole for use in contact with a foot, the foot being characterized by a specific shape relief and pressure map. The cushioning structure comprises a central layer of a rubber-like thermoplastic material having an upper surface devised to be in contact with the foot and having a shape relief conforming the specific shape relief of the foot, and a bottom surface opposite the upper surface. The cushioning sole further comprises a layout of space-apart anatomical pressure-receiving fingers made integrally with the central layer and protruding from at least one of the upper surface and bottom surface. Each of the pressure-receiving fingers has a predetermined height and diameter. The layout, the height and the diameter of the pressure-receiving fingers are determined in function of the physical characteristics of the rubber-like thermoplastic material and the specific pressure map of the foot, whereby the overall pressure-receiving fingers suit the specific pressure map of the foot.

Abstract: The present invention provides a portable heating pad capable of transferring heat to an anatomical region of a subject by means of a removable gel pack member which is releasably attached to a heat pad member with a detachable electrical power cord. The present invention can also include an inflatable bladder having an integrally formed pump. The portable heating pads of the present invention are useful for the rapid and convenient treatment of various muscular and orthopedic aches and pains of a mobile subject.

Abstract: A formable cushion is produced by providing a mold having a first cavity and the second cavity in a fluid communication with one another, with the first cavity having a greater depth than the second cavity. A first volume of foam/gel is deposited into the first and second cavities in an amount providing a level surface of foam/gel. The level surface is covered with a formable sheet and the second volume of foam/gel is disposed onto the formable sheet. Thereafter, heat and pressure applied to the first and second volume of foam/gel within the mold in order to provide a cushion having a relatively firm back pliable layer, a relatively firm mouse pad and a conjoining relatively soft compressible cushion.

Abstract: An elongate medical bandaging product for being dispensed in lengths suitable for a given medical use, including an elongate sleeve of a predetermined length formed of a moisture-impervious material and sealable to prevent entry of moisture, and an elongate medical material having substantially the same predetermined length as the elongate sleeve and positioned within the sleeve in substantially moisture-free conditions and sealed therein against moisture until use.

Abstract: The invention relates to a thermoplastic casting material, especially a thermoplastic casting material for orthopedic and other medical applications for immobilization of extremities and/or joints, that comprise a first textile fabric, a thermoplastic polymer applied to the first textile fabric and at least one second textile fabric applied to this composite. Additionally, the invention relates to a method for the production of this thermoplastic casting material that comprises the following steps: a) application of a thermoplastic polymer on a first textile fabric and b) application of at least one second textile fabric on the first textile fabric from step a) provided with the thermoplastic polymer.

Abstract: An orthopedic bandage with a curable resin applied to a substrate with the cut ends of the substrate bound together with a binder-detackifier composition. The bandage is constructed by applying stripes of the binder-detackifier agent to the substrate. The substrate is then cut within a stripe of the binder-detackifier composition so that the binding aspect of the composition will stabilize the cut ends of the substrate. A curable resin is also to be applied to the substrate. The detackifying aspect of the composition allows handling of the curable resin while minimizing or eliminating the sticky or tacky feelings normally associated with resins during the curing process. The end placement of the stripes of binder-detackifier allow the user to control the amount of detackifier transferred to the gloves used by the user while applying the bandage both during cast construction and during the final formation.

Abstract: An orthotic device developed and customized to control the desired movement of the patient's defective lower limb. The device incorporates a footplate made of a rubber-like elastomeric material and a proximal segment that encompasses the foot at the metatarsophalangeal joints and the shin portion of the leg. This proximal segment is made of a rubber-like elastomeric material laminated into multiple layers of fabric throughout the proximal segment. Additional strips of fabric are positioned within the proximal segment of the device to limit or promote certain motions within the foot and ankle. This device incorporates a continuous closure from the foot to the proximal segment, creating total contact and hydrostatic containment of the foot and lower leg.

Abstract: A therapeutic ankle support brace bladder pad member having a pair opposed surfaces defining an inflated air support pocket and a second support pocket containing gel material and filler apparatus materials, is disclosed. An overlay fabric material is integrally attached to the bladder, provides additional support and enables removable attachment of the bladder to side support members of a therapeutic brace.

Abstract: An elongate medical bandaging product for being dispensed in lengths suitable for a given medical use, including an elongate sleeve of a predetermined length formed of a moisture-impervious material and sealable to prevent entry of moisture, and an elongate medical material having substantially the same predetermined length as the elongate sleeve and positioned in a continuous layer which coextends within the sleeve in substantially moisture-free conditions and sealed therein against moisture until use.

Abstract: An orthopedic device comprises a shaft capable of at least partially encircling at least a lower part of a leg, a foot part, a cup-shaped heel part connecting the foot part to the shaft, a continuous bearing surface arranged between the front end of the foot part and the heel part, the bearing surface constituting a lower closure of the orthopedic device and having a side facing the interior of the orthopedic device, which is flat and symmetrical with respect to a central longitudinal axis, and an arch support affixable to said bearing surface side. A portion of the arch support running along an outside of a foot capable of being supported by the arch support extends substantially horizontally, and a portion of the arch support running along an inside of the foot has a shape of a rising arc, a flank of the arc near the heel rising substantially perpendicularly from the bearing surface to an apex and extending from the apex to the foot part.

Abstract: A batter's lower leg protector product, including a lower leg protector for being custom-formed to the shape of a batter's lower leg while flexible and upon hardening providing a rigid, supporting custom fit. The lower leg protector product includes an outer container formed of moisture-impervious material. A flexible lower leg protector is positioned in the container in substantially moisture-free conditions and sealed therein against entry of moisture until use. The lower leg protector includes a leg portion shaped to provide, when in place on a batter's leg, protection to the front, lateral and medial aspects of the leg above the ankle and optionally-detachable ankle flap portions integrally formed with a bottom edge of the leg portion and shaped to provide protection to the lateral and medial ankle bones.

Abstract: A thumb spica splint for being custom-fitted to the thumb portion of the hand for immobilizing the thumb while permitting continued unrestricted use of the other fingers of the hand, and including an elongate, flexible inner cushion layer, an initially flexible intermediate layer overlying the inner cushion layer, the intermediate layer formed of a fabric impregnated or coated with a moisture-curable resin which hardens upon curing to form a rigid structure of the fabric which retains a shape into which it is molded during curing. A flexible protective outer layer overlies the intermediate layer and is attached to the inner cushion layer for enclosing the intermediate layer and forming the inner layer, intermediate layer and outer layer into a single, integrated splint structure. The splint is shaped to extend along and conform to the medial aspect of the lower arm and thumb to the distal joint thereof.

Abstract: Process for the production, transport and storage of a therapeutic system which is in the form of a plaster and has an active layer supersaturated with active ingredient and containing the active ingredient in homogeneous dispersion or in solution, characterized in that it is carried out avoiding process parameters which favour or induce crystallization of active ingredient, and any type of pressure operating on the plaster and, in particular, on the active layer is avoided while it is carried out.

Abstract: A custom-fitted hand protector product, including a multi-layer protective pad for being custom-fitted onto the back of the hand to protect the hand of the wearer between the wrist and the fingers. The protective pad comprises a flexible inner cushion layer for being placed closest to the hand and an initially flexible intermediate layer overlying the inner layer, said intermediate layer comprised of a fabric impregnated with a moisture-curable resin which hardens upon curing to form a rigid structure of the fabric which retains a hand-molded shape into which it is molded during curing, thereby also holding the flexible inner cushion layer in the same hand-defined shape. Releasable attachment devices are attached for retaining the protective pad in an exposed, exterior position on the back of the hand. The product is packaged in a moisture-proof package until immediately prior to use.

Abstract: An orthopedic bandage with a curable resin applied to a substrate with the cut ends of the substrate bound together with a binder-detackifier composition. The bandage is constructed by applying stripes of the binder-detackifier agent to the substrate. The substrate is then cut within a stripe of the binder-detackifier composition so that the binding aspect of the composition will stabilize the cut ends of the substrate. A curable resin is also to be applied to the substrate. The detackifying aspect of the composition allows handling of the curable resin while minimizing or eliminating the sticky or tacky feelings normally associated with resins during the curing process. The end placement of the stripes of binder-detackifier allow the user to control the amount of detackifier transferred to the gloves used by the user while applying the bandage both during cast construction and during the final formation.

Abstract: A septal splint that does not require surgical removal after implantation. The septal splint is designed to be dissolvable over a period of time, thereby eliminating the need to surgically remove the splint. Preferably, the splint dissolves within four weeks after placement. The dissolvable splint of the invention allows surgeons that provide services to rural and small medical facilities at infrequent intervals, such as once per month, to perform septoplasty procedures without requiring the surgeons to make special arrangements for follow-up visits to remove the splints. Furthermore, the dissolvable splint eliminates the need for a splint removal procedure, which is particularly difficult to perform with children.

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: A body part protector for being custom-fitted to a body part, including at least two protective pad inserts, each of the pad inserts having an initially flexible protective layer formed of a support material impregnated with a moisture-curable resin which hardens upon curing to form a rigid structure which retains a body part-defined shape into which it is molded during curing. The protective pad inserts are stored in moisture-proof conditions until use to prevent hardening. A pad encloses the at least two protective pad inserts, and is conformable to the molded shape of the pad inserts. A hard shell outer protector is adapted for receiving and carrying on an inner, concave surface thereof the pad and the at least two protective pad inserts positioned therein in protective position on the leg between the leg and the outer protector, the outer protector and the pad having complementary fastening elements for releasably securing the pad to the outer protector.

Abstract: A custom ankle brace which is made to compensate for debilitating conditions of an individual patient's ankle area. The brace is custom made by creating a negative cast of the patient's foot/ankle/lower-leg; and then prescribed markings are included on the negative cast by the castmaker to indicate the desired geometry of support. The markings are transferable to a positive cast to inform the bracemaker. The custom brace has inner and outer material layers with a stiffening element within, all fitted to the shape of a built-up positive cast, the stiffening element having a unitary horizontal partial sole portion and vertical back-and-sides-of-leg portion. The stiffening element, made from a thin polymeric sheet, is vacuum and heat fitted to the built-up positive cast.

Abstract: A custom-fitted athletic body protective product such as a shin guard, including a storage package formed of moisture-impervious material and sealable to prevent entry of moisture, a flexible protective guard positioned in the storage package and sealed therein against entry of moisture, and for being custom-formed to the shape of a body part to be protected while flexible and upon hardening providing a rigid, supporting custom fit to the body part. The protective product includes a low density core defining first and second major surfaces and first and second sheets positioned in overlying relation on respective first and second major surfaces of the core. The core and the first and second overlying sheet materials collectively defining a laminated substrate.

Abstract: A copolymer thermoplastic natural foot orthosis for supporting and controlling the movement of a lower extremity and method for manufacturing the same. The orthosis is fabricated by forming a positive mold of the lower extremity, and modifying the positive mold in predetermined locations to accomplish the type of lower extremity control desired. A strip of heated thermoformable copolymer material is strategically positioned around predetermined locations on the positive mold for providing increased support for the natural foot orthosis at these predetermined locations. A sheet of heated thermoformable copolymer material is then drape mold around the positive mold and copolymer strip, wherein the copolymer sheet is vacuum sealed to conform to the shape of the positive mold. During the vacuum formation process, the copolymer sheet and copolymer strip combine together so that the copolymer sheet and copolymer strip are integrally formed into a single supporting structure.

Abstract: A method and appliance for treating carpal tunnel syndrome has a splint with dorsal, thenar and hypothenar portions for applying pressure to the respective dorsal aspect of the hand and to thenar and hypothenar areas of a palmar aspect of the hand to induce stretching of the carpal ligament and flexor retinaculum. The thenar and hypothenar portions of the splint are connected to opposite sides of the dorsal portion and are spaced from the dorsal portion to allow for the insertion of the hand to be treated. The splint is preferably formed from a unitary piece of substantially rigid material and is sized and shaped to closely receive the hand with the dorsal, thenar and hypothenar portions substantially aligned with and covering the respective dorsal aspect, and thenar and hypothenar areas of the palmar aspect of the hand.

Abstract: A lower limb orthotic brace to control the movement of the lower limb of a patient comprising a contoured orthotic contact shell and an integral load-bearing frame, the contoured orthotic contact shell comprises at least one layer of fabric impregnated with a hardened structural resin forming an inner orthotic contact surface conforming to the outer surface of the lower limb of the patient and the integral load-bearing frame comprises at least one reinforcing member extending along the contoured orthotic contact shell including a plurality of bundled continuous composite fibers woven in a multidirectional tubular braid impregnated with a hardened structural resin with at least one side of the braid in contact with the contoured orthotic contact shell along the entire length of the braid such that the hardened resins impregnating the fabric of the contoured orthotic contact shell combine with the resins impregnating the braid thereby forming a continuous integral structural matrix encapsulating both the braid

Abstract: A body protector for being custom fitted to a body part to be protected formed of a flexible garment member shaped to lie over the body part to be protected. The garment member is made with two spaced, inner and outer sheets of material forming an inner pocket between the layers. An opening for access into the pocket is formed along at least one of said edges and includes a closure fastener for opening and closing the opening. An insert made with a moisture curable, resin impregnated material is shaped to fit into and dimensionally conform to the pocket to provide a rigid barrier for the body part when the resin is hardened. Straps are provided to secure the protector to the user.

Abstract: A thumb wrist splint with a main body portion which includes a plurality of straps for encircling the wrist and securing the same firmly to the wrist with desirable palmar and dorsal stays. A sewn thumb spica/splint is fabricated, and finished by normal binding around the periphery. The thumb strap loop is fixed to the splint and a removable securable anchor is also applied to the spica/splint. The spica/splint is a VOLARA.RTM. grade polyolefin closed foam material which is desirably laminated to nylon cloth on one side. The sewn thumb spica is secured to the main body portion. Thereafter, the entire blank, as just described, is positioned over an anvil intended to form a curvilinear pattern to the thus encapsulated VOLARA.RTM. so that it will conform to the upper portion of the wrist. Once secured in place on the wrist by means of the straps around the wrist portion, the thumb strap is secured.

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: An athletic body protective product such as a shin guard with enhanced protection against direct impact to bone structure shin. The guard includes a storage package formed of moisture-impervious material and sealable to prevent entry of moisture, a flexible protective guard positioned in the storage package and sealed therein against entry of moisture for being custom-formed to the shape of the shin while flexible and upon hardening providing a rigid, supporting custom fit. The guard includes a reactive system impregnated into or coated onto a substrate, the system remaining stable when maintained in substantially moisture-free conditions and hardening upon exposure to sufficient moisture to form a rigid, self supporting structure. A flexible pad is positioned on one side of the substrate along its length to provide a cushioning barrier between the hardened substrate and the protected bone of the athlete when the protective guard is in use.

Abstract: An injection-molded thermoplastic device having a field of injection-molded hooks integrally formed in predetermined areas on the device during the injection-molding of the device for releasable attachment to a strap with loops.