Abstract: An impact plate system is provided herein comprising a textile layer comprising at least a first surface and an elastically resilient material. The system further comprises a moldable plate coupled to the first surface of the textile layer. The moldable plate comprises a polymeric material having a tensile strength within the range of 40 MPa to 50 MPa, according to ASTM D638 standards.

Abstract: An electronically-activated, self-molding and re-shapeable load-bearing support structure system is provided that includes a first composite structure. The first composite structure includes a first layer of a first thermally-responsive polymer; one or more first heating elements positioned adjacent to the first layer on a first heating element side; a second layer of the first thermally-responsive polymer positioned adjacent to the first heating elements on a second heating element side; a temperature sensor communicating with at least the first layer or the second layer of the first thermally-responsive polymer; one or more electrical connectors electrically communicating with the heating elements; and an electrical controller detachably connectable to at least one of the electrical connectors of the composite for providing an electrical current to the heating elements. A method of molding the load-bearing support structure system is also provided.

Abstract: An integrated thermoformable splint and heater and method for manufacturing same includes a thermoplastic material and an oxygen activated heater operatively associated with the thermoplastic material. The integrated thermoformable splint and heater are sealed within an oxygen impermeable housing. Oxygen is allowed to activate the heater either by removing the assembly from the sealed housing, or, by displacement of a removable seal that will allow oxygen to penetrate a porous region in the housing, and, in turn, come into contact with the heater.

Abstract: A brace device for the support of a wearer. The brace device comprises a flexible smart fabric, operable to partially or substantially enclose and/or lie adjacent to one or more portions of the thoracic, lumbar and/or cervical portions of the spine of the wearer. Fabric hardening means are provided, operable to partially or substantially harden one or more regions of the smart fabric upon application of an activating stimulus, thereby to prohibit, restrict and/or resist movement of one or more portions of the spine of the wearer. One or more predetermined regions of the smart fabric are in a substantially flexible configuration when the fabric hardening means are not activated, facilitating positioning, fitment and/or adjustment of the device around the wearer.

Abstract: The invention provides a shape memory spacer fabric composite, being a spacer fabric coated with a shape memory polymer layer, wherein the spacer fabric comprises a first outer layer, a second outer layer and an intermediate spacing layer connecting the first outer layer and the second outer layer; the shape memory polymer layer is made from at least one block or random copolymer selected from the group consisting of the following: polyesters, polyurethanes, polyamides, polyols; the copolymer has at least one phase transition temperature in a range of 40˜80° C.

Abstract: A composite material 10 for forming custom fitted orthopedic and other products. The composite material is easily formable when heated to temperatures of about two hundred degrees Fahrenheit for a time of at least six to eight minutes and then is rigid at temperatures of about one hundred thirty degrees. The composite material can be sewn and formed in complex shapes when initially heated to about two hundred degrees. Closure attachments 60 can be secured to the composite material as needed on site rather than at the manufacturing facility. The composite material can be custom fitted to a patient in situ.

Abstract: A quick deployment cast comprises a flexible outer sleeve fitted for a human appendage. The cast has a bladder network within the sleeve, a fluid capable of expanding and hardening when in the presence of a curing agent, stored within the bladder network and a mechanism for exposing the fluid to the curing agent.

Abstract: A method of infusing, infiltrating, or impregnating a three dimensional printed, free-form fabricated or additive manufactured object having at least one of pores and voids in or between particles or sheets of material from which the object is manufactured may include immersing the object in a thermoplastics material such that the thermoplastics material penetrates the object. The method may further include controlling a frequency and an amplitude of pressure oscillation such that the thermoplastics material at least partially fills the at least one of pores and voids and bonds the particles or sheets of material from which the object is manufactured.

Abstract: A thermoformable medical member and heater and method for manufacturing same. A thermoplastic material is converted from a relatively rigid state to a formable state over a narrow temperature range, and, which reverts back to a clinically rigid state within a relatively short period of time, and, which remains in that state even at elevated ambient temperatures.

Abstract: A disposable housing including a single-use thermal exchange component can be configured to be mechanically, removably coupled to a receptacle on a cuff positionable around a joint to provide temperature-based therapy to the joint.

Abstract: Orthopedic braces and associated methods are described for treatment of lower back injuries and chronic back pain. An orthopedic brace may include a pair of back panels, a pair of front panels, and a closure system. A lateral end of each front panel is releasably coupleable to a lateral end of each back panel at a desired angle. A ventral end of each front panel includes an attachment provision configured to allow one of the front panels to releasably attach to the other of the front panels generally over an abdomen of a wearer. The brace also includes a pocket on the ventral end of at least one of the front panels, the pocket configured to temporarily receive a hand of the wearer to aid in donning the orthopedic brace.

Abstract: An integrated thermoformable splint and heater and method for manufacturing same includes a thermoplastic material and an oxygen activated heater operatively associated with the thermoplastic material. The integrated thermoformable splint and heater are sealed within an oxygen impermeable housing. Oxygen is allowed to activate the heater either by removing the assembly from the sealed housing, or, by displacement of a removable seal that will allow oxygen to penetrate a porous region in the housing, and, in turn, come into contact with the heater.

Abstract: The present invention relates to an immobilization device for immobilizing a body part, the immobilization device comprising a sheet of a thermoplastic material which has been shaped to conform to the body part to be immobilized. The thermoplastic material contains at least one nano filler material which is exfoliated.

Abstract: A physical rehabilitation device for the treatment of a medical condition of the foot known as plantar fasciitis includes a splint which is connected to the toe and ankle of a patient. The splint can be used in a method for treating plantar fasciitis known as “dynamic splinting”. This device allows the patient to bend the ankle and thus dynamically change the flexion in the foot of the patient. The device itself is unique, but the method of treatment made possible by this device is also unique.

Abstract: A bandaging material in the form of a linear structure. The material has a first layer formed by a composite containing a thermoplastic polymer selected from the group of polymers and mixtures thereof, and a woody material derived from platy or granular wood particles having a minimum average size in one dimension of 0.1 mm. The material further has a second layer of a textile material having a first and a second surface. The first layer is superposed on the second layer in such a way that the first layer is essentially attached only to the first surface of said second layer. In this way, a bandaging material is obtained which has a suitably small self-adhesion which allows for it being coiled to a roll without force during manufacturing process. The bandaging material can further be uncoiled smoothly by hand followed by subsequent applying of it around limb at application temperature without delamination.

Abstract: An improved thermoplastic material for orthoses and prostheses. This material comprises at least one resin layer of polymeric resin, optionally reinforced with multiple layers or internal fibers, designed to be compatible with vacuum thermoforming, with thickness between 3/64 inches and ¾ inches. The material additionally comprises at least one and optionally two extremely thin cap layers with thickness between 2/1000 and 12/1000 inches, at least one of which is intended for improved compatibility with human skin, and the other of which can be configured for various cosmetic or UV protection purposes. Methods of producing this material, and various orthotic and prosthetic devices using this material, are also taught.

Abstract: An apparatus is provided for mounting to a support for modifying an ankle-foot orthosis. The apparatus comprises a tooling device having a plurality of holes spaced over an outer surface of the tooling device. The tooling device includes a first portion having a longitudinal axis, and a second portion integral with the first portion and having a longitudinal axis substantially perpendicular to the longitudinal axis of the first portion. The second portion of the tooling device defines an opening for receiving the support. A peg is configured to be inserted into one of more holes of the tooling device. The peg comprises a body portion and a post depending from the body portion and configured to be received in the holes in the outer surface of the tooling device. In one embodiment, the body portion of the peg has a convex outer surface.

Abstract: Disclosed are ankle braces with heat moldable stays that provide inversion and eversion support. The stays include heat formable ankle regions to conform to the malleolus of the user's ankle.

Abstract: A custom brace and method for fabricating the custom brace includes marking a body with reference points and/or other indicators. Multiple images of the body from multiple angles are then obtained. The images are used to determine the contours of the body and the other markings are located and used to design the custom brace. Fenestrations can be added to the brace design. The custom brace can be fabricated with the fenestrations as a single piece structure or in multiple pieces that are assembled to complete the custom device.

Abstract: A therapeutic, supportive, or protective device is fabricated from a material capable of contracting in response to interacting with heat, cold, a chemical reagent, electromagnetic energy, or mechanical energy. The device is positioned over an anatomical joint or other body part and via a “shrink fit,” conforms to the part, providing a customizable fit.

Abstract: A composite material for forming custom fitted orthopedic and other products. The composite material is easily formable when heated to temperatures of about two hundred degrees Fahrenheit for a time of at least six to eight minutes and then is rigid at temperatures of about one hundred thirty degrees. The composite material can be sewn and formed in complex shapes when initially heated to about two hundred degrees. Closure attachments can be secured to the composite material as needed on site rather than at the manufacturing facility. The composite material can be custom fitted to a patient in situ.

Abstract: An undergarment for use with a cast tape to form a hip spica cast, such as a pantaloon-type hip spica cast. The cast includes at least one layer of a 3D spacer synthetic padding material formed into a fabric of monofilament yarns and fabricated into an anatomically correct undergarment structure for being positioned around a torso and residing directly against the skin of a hip spica cast patient.

Abstract: A conformable material for an orthotic device including a plurality of fibers each including a plurality of filaments encapsulated by a first thermoplastic material. A second thermoplastic material is configured to bind the plurality of fibers and form the conformable material.

Abstract: A packaged product, such as a thermo-formable splinting or bracing product adapted to be heated by microwave energy, which packaged product comprises a water laden absorbent material (5), optionally sealed in a first water-impervious container (6), wherein said absorbent material (5) is adapted to permit microwave energy to enter and heat the water held in the absorbent material (5), the first container (6) being microwave transparent and the product to be heated and the absorbent material are disposed adjacent each other but are separated by a water-impervious barrier.

Abstract: A composite material in the form of a linear structure having a width, a length and a thickness, comprising a composite material with a first component formed by a polymer and a second component formed by a reinforcing material, wherein the first component comprises a thermoplastic polymer selected from the group of biodegradable polymers and mixtures thereof, and the second component comprises a woody material derived from platy or granular wood particles. The composite material being formable at a temperature of about 50 to 70° C. and it can be used as a blank for an orthopedic splint.

Abstract: A low density fabric substrate for a medical bandaging product. The substrate has a plurality of longitudinally-extending voids formed in the fabric for permitting water penetration through the fabric thickness from one of the major faces to the other major faces. A reactive system is impregnated into or coated onto the substrate and remains stable when maintained in substantially moisture-free conditions and hardens upon exposure to sufficient moisture to form a rigid, self supporting structure. A soft, flexible protective material covers at least one of the major faces of the substrate along its length to provide a cushioning barrier between the substrate and the skin of a patient when the material is in use.

Abstract: A custom ankle brace system is disclosed which is constructed from a low temperature non-olefinic elastomeric blend material, and methods of fabricating and fitting the same. This material can be molded directly to a custom mold made from a casting of an affected body part. The final product will be an ankle brace that is able to be heated at low temperature (150° F.-200° F.) by use of an oven or equivalent, and custom molded directly on the patient. If necessary reheated, the ankle brace may be remolded to account for a change in the patient's anatomy or for an increase in comfort.

Abstract: A wrist support device includes a splint body having a central portion and a thumb extension. The central portion provides a protective shield which is located such as to overlie a carpal tunnel of a human wrist when the device is worn. The central portion is raised relative to surrounding sections of the splint body such that the central portion can be elevated from the carpal tunnel, does not contact the wearer, and provides a support surface which disperses external forces acting thereon to locations other than the carpal tunnel so as not to compress the carpal tunnel. The thumb extension section of the splint body confronts, supports and stabilizes a base of a thumb of the wearer. The device permits the wearer to rest the inner wrist on counters, keyboard surfaces, counter edges or sharp and irregular surfaces without compression of the carpal tunnel area.

Abstract: Shoulder braces for inhibiting secondary anterior shoulder dislocations that are configured to allow for a wide range of motion for mobility and stabilization, include a brace body with a single arm portion configured to reside about a shoulder of a user and a torso portion, a plurality of shoulder straps extending over the single arm portion shoulder, a substantially rigid thermoplastic insert releasably held by the arm portion of the brace body. The insert can have a user-specific custom shape that substantially conforms to shoulder anatomy of the shoulder of the user. The brace can also include at least one adjustable length laterally extending torso strap attached to the torso portion.

Abstract: Use of a sheet-like composite material for the manufacture of an immobilization element, wherein the sheet-like composite material is made from a material comprising a thermoplastic polymer containing carbon nanotubes as a fibrous reinforcing material, obtainable by dispersing carbon nanotubes in a dispersing liquid in which the thermoplastic polymer does not dissolve, subjecting the dispersion to an ultrasonic treatment, adding of particles thermoplastic polymer to the dispersion and mixing of the thermoplastic polymer with the dispersion of carbon nanotubes, removing of the dispersing liquid, forming of the thermoplastic polymer impregnated with carbon nanotubes into a sheet.

Abstract: A multi-layered composite material suitable for use in orthopedics includes a foam core layer bonded between two layers of thermoformable polymer material. The thermoformable material is heat formable within a target temperature range allowing for rapid heating and application to a patient such as in the form of a splint. While within the target temperature range, the composite material includes a dwell time sufficiently long to enable proper fitment and adjustment, yet not overly long requiring extended periods of holding the composite material in place. The composite material is very light yet extremely rigid and easily conformable to patients.

Abstract: Orthopedic braces and splints for use on a limb of an animal, that provide stability for unstable joints and limbs for short or long term support and function. These orthoses are designed to prevent the occurrence of, or reduce the severity of, a joint injury. These braces and splints can also be fitted immediately after corrective surgery, and can support and stabilize the joint while assisting or restricting the range of motion. Various embodiments of the orthoses are modular, thermoformable and may include an adjustable tensioning system, which in combination provide a custom fit for a wide variety of animals and injuries.

Abstract: The present disclosure relates, according to some embodiments, to a device and/or system (e.g., redistributing weight away from a subject's foot), which may comprise (a) a platform, (b) at least one vertical support fixed to the platform and extending upwardly from the platform, and (c) at least one cuff (i) configured to surround and releasably grip at least a portion of a subject's leg other than the foot and (ii) mounted (e.g., adjustably) to the at least one vertical support at a vertical position along the at least one vertical support sufficient to suspend a subject's foot in a non-weight-bearing position above the platform during ambulation, wherein the platform, the at least one vertical support, and the at least one cuff together are configured to bear at least the subject's full weight.

Abstract: A moldable decorative splint material includes a heat-moldable sheet of splint material adapted to become sufficiently pliable when heated to a first temperature to allow the sheet to be molded into a splint configuration that conforms to an anatomical body part and to become hard when cooled to a second temperature to retain the splint configuration. The splint material includes a plurality of decorative elements integrated with the sheet of splint material. The decorative elements are to be retained by the sheet of splint material when the sheet is heated to the first temperature, molded into a splint configuration, and cooled to the second temperature.

Abstract: A bandaging material in the form of a linear structure. The material comprises a first layer formed by a composite containing a thermoplastic polymer selected from the group of polymers and mixtures thereof, and a woody material derived from platy or granular wood particles having a minimum average size in one dimension of 0.1 mm. The material further comprises a second layer of a textile material having a first and a second surface. The first layer is superposed on said second layer in such a way that said first layer is essentially attached only to the first surface of said second layer. In this way, a bandaging material is obtained which has a suitably small self-adhesion which allows for it being coiled to a roll without force during manufacturing process. The bandaging material can further be uncoiled smoothly by hand followed by subsequent applying of it around limb at application temperature without delamination.

Abstract: A unitized cast system for immobilizing and supporting a body part. The unitized casting system includes a first inner layer for padding and dissipating heat against the patient's skin. A second layer is formed from a thermoformable structural material such as perforated plastic. A protective third outer layer is provided to provide insulation for the second layer. These three layers are formed together to form a unitized cast system that is easily formed and applied to the patient.

Abstract: The present invention relates to an immobilization device for immobilizing a body part, the immobilization device comprising a sheet of a thermoplastic material which has been shaped to conform to the body part to be immobilized. The thermoplastic material contains at least one nano filler material which is exfoliated.

Abstract: A conformable material for an orthotic device including a plurality of fibers each including a plurality of filaments encapsulated by a first thermoplastic material. A second thermoplastic material is configured to bind the plurality of fibers and form the conformable material.

Abstract: A moldable decorative splint material includes a heat-moldable sheet of splint material adapted to become sufficiently pliable when heated to a first temperature to allow the sheet to be molded into a splint configuration that conforms to an anatomical body part and to become hard when cooled to a second temperature to retain the splint configuration. The splint material includes a plurality of decorative elements integrated with the sheet of splint material. The decorative elements are to be retained by the sheet of splint material when the sheet is heated to the first temperature, molded into a splint configuration, and cooled to the second temperature.

Abstract: A chemically-activated conformable thermal device that generates heat upon activation is provided. The thermal device typically contains an oxidizable metal that is capable of undergoing an exothermic reaction in the presence of moisture and air to generate heat. Although such metals, as well as other components of the composition (e.g., carbon), are relatively inflexible and stiff, the present inventors have nevertheless discovered that one or more conformable segments may be employed to impart flexibility and conformability to the thermal device. The conformable segments are malleable so that they yield under shear stress and acquire the shape of a surface (e.g., body part) without rupturing. The conformable segments are likewise stiff or hard enough to substantially retain the desired shape during use.

Abstract: The disclosure relates to a system for producing an orthopedic splint made of a cast material, wherein the system includes at least one thermoplastic cast material present as a flat material web and a template having a flat template body, wherein the cast material can be wound around the template body in a prescribed direction for generating a splint blank, and the splint blank can be activated in order to achieve deformability, particularly after cutting the cast material to length, and to a method for producing an orthopedic splint.

Abstract: A medical cast and methods of using the same are disclosed. The method of making includes providing a shape memory polymer (SMP) in a permanent shape which corresponds to a limb's general shape but has a diameter smaller than the limb's diameter. The SMP is converted from the permanent shape into a primary temporary shape, which has a diameter larger than both a diameter of the permanent shape and a diameter of the limb. The limb is at least partially surrounded with the SMP in its primary temporary shape. The SMP is then heated, which causes the primary temporary shape to i) attempt to revert to the permanent shape, and ii) conform to a secondary temporary shape having a diameter smaller than that of the primary temporary shape and larger than that of the permanent shape. The SMP in the secondary temporary shape conforms to the limb.

Abstract: The disclosure relates to a system for producing an orthopedic splint made of a cast material, wherein the system includes at least one thermoplastic cast material present as a flat material web and a template having a flat template body, wherein the cast material can be wound around the template body in a prescribed direction for generating a splint blank, and the splint blank can be activated in order to achieve deformability, particularly after cutting the cast material to length, and to a method for producing an orthopedic splint.

Abstract: A protective and/or splint device, for example a distal radial splint device (200), comprises a protective and/or splint member (201) and a spacer member (13). The protective and/or splint member (201) comprises a composite protective and/or splint material and is formable at a forming temperature and is substantially rigid at ambient temperature. The material comprises a polycaprolactone and a ligno-cellulose additive material. The protective and/or splint member (201) comprises a mesh of elements (202), with a plurality of openings (203) through the protective and/or splint member (201). Away from the periphery of the splint member (201), the openings (203) are diamond-shaped. Two border elements (204) extend along the two sides of the periphery of the splint member (201). The three point bending strength to openness ratio of the member is greater than 0.1 and the unidirectional bending strength to openness ratio of the member is greater than 4.

Abstract: A composite moldable splint having at least a first splinting member with an inner foam layer, an intermediate thermoplastic layer, and an external securing layer. The inner foam layer provides a soft, moisture transmitting, non-latex padding. The intermediate thermoplastic layer provides remoldable shape, and rigidity and strength after heat forming and cooling. The outer securing layer, preferably covered with continuous loop fabric suitable for hook and loop fastening, provides an essentially infinite plurality of attachment points for retaining straps including at least a section of hook fastening material for holding the splint in place. The layers of the composite moldable splint are preferably heat welded to form a strong unitary structure that is resistant to delamination. Composite moldable splints utilizing multiple splinting members are described.

Abstract: A hybrid immobilisation device which is provided to cover at least a part of a patients' body that needs to be supported and/or immobilised, the immobilisation device being at least partly made of a plastic material.

Abstract: An ankle support that is adapted to securely hold the lower leg, ankle and foot of a wearer so as to provide reparative support thereof and an associated method of fabrication thereof. The ankle support includes an outer shell formed of a rigid material that conforms substantially to the configuration of the wearer and including an upper portion for at least partially surrounding the lower leg, an intermediate portion about the ankle and a lower portion that at least partially supports the foot; an inner liner formed of a flexible and conformable material and including an upper portion for at least partially surrounding the lower leg, an intermediate portion about the ankle and a lower portion that at least partially supports the foot and an interlocking mechanism including cooperating and interlocking members of the respective outer shell and inner liner that assist in retaining the inner liner within the outer shell.

Abstract: Safety cast compositions for the prevention of thermal injury are provided basically comprising a curable casting material, a flexible substrate coated or impregnated with the casting material and a thermochromic material. Methods for using the safety cast to prevent cast burns in patients in need of immobilizing a body member are also provided.

Abstract: The present invention generally relates to a shrinkable covering that can be used to enclose a cast, splint, bandage, injury, or other affected part of the body in order to protect it from water or other external elements.

Abstract: A medical cast and methods of using the same are disclosed. The method of making includes providing a shape memory polymer (SMP) in a permanent shape which corresponds to a limb's general shape but has a diameter smaller than the limb's diameter. The SMP is converted from the permanent shape into a primary temporary shape, which has a diameter larger than both a diameter of the permanent shape and a diameter of the limb. The limb is at least partially surrounded with the SMP in its primary temporary shape. The SMP is then heated, which causes the primary temporary shape to i) attempt to revert to the permanent shape, and ii) conform to a secondary temporary shape having a diameter smaller than that of the primary temporary shape and larger than that of the permanent shape. The SMP in the secondary temporary shape conforms to the limb.