Abstract: A medical bandage is disclosed including a knitted spacer fabric cover or padding positioned in surrounding relation on a moisture-hardenable substrate. A reactive system is applied to and into the thickness of the substrate. The reactive system having a first state wherein the substrate remains in a flexible, conformable condition and a second state wherein the reactive system hardens, simultaneously hardening the substrate into a desired conformation.

Abstract: A splint includes a first container capable of being wrapped about an item to be supported and a second container capable of containing a multiple part mixture during a mixing operation. The second container being capable of delivering the mixture into the first container, wherein the mixture hardens to form a support structure. A method for using the splint is also disclosed.

Abstract: The present invention relates to a transparent immobilization device which is able to be molded direct on a patient and which is provided to cover at least a part of a patients' body that needs to be fixed, supported and/or immobilized, which immobilization device is at least partly made of a plastic material. The immobilization device is at least partly made of a sheet of a material comprising at least one thermoplastic elastomer which is a copolymer of ethylene with at least one ?-olefin having 3-10 carbon atoms, or a blend of two or more of such copolymers. The present invention also relates to a method for producing such an immobilization device, according to which the plastic material is first heated to a temperature which is 15-20° C. above the melting temperature, then cooled to a temperature which may be supported by the body and molded on the body part of the patient that needs to be immobilized.

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: A cast for use in limiting movement of the hand to promote healing of an injured body part includes a water hardenable orthopaedic blank for mounting on the forearm, preferably with a thumb hole, and an outrigger, also impregnated with water hardenable material, secured to the blank for holding the thumb or fingers against movement. This construction minimizes irritation of the web between the thumb and forefinger and reduces discomfort and trauma caused by chafing and pressure.

Abstract: Disclosed is a portable splint assembly for emergency patient capable of remarkably reducing a setup time for surgical operation on a bone-fracture patient. The portable splint assembly for emergency patient comprises a medical splint for bone-fracture patient; a first envelope of synthetic resin series for surrounding the medical splint in the shape of a seal; a hardening solution having a purified water for hardening the splint; a second envelope of synthetic resin series for surrounding the hardening solution in the shape of a seal; and a connection part for connecting the first envelope and the second envelope to each other. Here, in a state that the first envelope and the second envelope are integrally formed as one member, the connection part of a line shape is formed in a boundary line of the first and the second envelopes through a heat-fusing process.

Abstract: Embodiments of the present invention include an apparatus for encouraging compliance with a prescribed orthotic treatment, including an orthotic device applied to a limb of a user, a strap coupled to the orthotic device, the strap having two ends and configured to wrap around the orthotic device at an attachment area, where a length along the strap is smaller than a maximum circumference of the limb distal to the attachment area, and a locking mechanism to lock the strap onto itself. Other embodiments of the present invention include a system for off-weighting a user's foot, including a hardenable cast; a rigid outer boot having a footbed, a first side strut with a first strap aperture, a second side strut with a second strap aperture, and a strap extending through the first strap aperture and the second strap aperture and operable to tighten around the hardenable cast.

Abstract: A medical bandaging product, including a sleeve formed of moisture-impervious material and sealable to prevent entry of moisture, and a medical material positioned in the sleeve and sealed therein against entry of moisture until use. The medical material is a substrate having two marginal areas of relatively lower modulus yarns and/or a more open knitted structure to provide reduced abrasion against the skin. A reactive system on the substrate 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 medical bandaging product fabricated of a rib-knitted fabric constructed of synthetic yarns selected from the group of acrylic, polyester and polypropylene yarns. An elastic yarn provides elasticity to the fabric, and an effective amount of a water repelling treatment is applied to the fabric for imparting water-repellent characteristics. The fabric may be used as a cast liner or as a protective wrapping of a splint product.

Abstract: An article useful in orthopedic cast care is described as well as a method of making the article and applying it to the cast. The article is a fragranced solid or semi-solid material that is applied to an orthopedic cast by rubbing it over the outside so as to reduce or mask the unpleasant odor resulting from sweat and dirt building up inside the cast and to provide a pleasant fragrance.

Abstract: A medical bandaging product, including a sleeve formed of moisture-impervious material and sealable to prevent entry of moisture, and a medical material positioned in the sleeve and sealed therein against entry of moisture until use. The medical material is a substrate having two marginal areas of relatively lower modulus yarns and/or a more open knitted structure to provide reduced abrasion against the skin. A reactive system on the substrate 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 biomechanical custom made foot orthosis (10) and a method for making the same. The orthosis (10) has a thermoformed flexible top layer (12) made of a first moldable synthetic rubber material, and a thermoformed flexible reinforcement core layer (14) made of a. moldable core material that is molded onto the top layer, (12). The core layer (14) has a posterior end (16) aligned with a mid anterior plantar prominence (K) of a calcaneus bone (C), and an anterior end (18) aligned near metatarsal-phalangeal joints (J) of the foot. The orthosis (10) also has a thermoformed flexible bottom layer (20) made of a second moldable synthetic rubber material that is molded onto the top layer (12) and the core layer (14). The core layer (14) is more rigid than the top and bottom layers (12, 20). The orthosis (10) corrects anatomic biomechanical deficiencies of the foot and ensuing body deficiencies.

Abstract: A corrective device to be worn on a human foot having a misalignment and positioned inside of footwear. The device having an inner shell having a first material composition and flexibility, and shaped to accommodate receiving therein and supportingly couple with the foot, and an outer shell having a second material composition and flexibility, the second material composition and flexibility being substantially the same as the first flexibility, the outer shell shaped to accommodate receiving therein the inner shell, supportingly couple with the inner shell and allow positioning into the footwear. At least a sufficient portion of a pressure is distributed by the outer shell and the inner shell over a desired area of the foot to provide an amount of correction to the misalignment while allowing the human to wear the inner shell inside of the outer shell inside of the footwear.

Abstract: This invention is directed toward a splint, where there is a layer of material, such as fabric-laminated foam neoprene, that encompasses a part of the body intended to be immobilized, supported, or protected, and permanently secured to this layer of material is a low temperature thermoplastic. This thermoplastic is rigid when cool, and malleable when heated. The temperature at which the thermoplastic is malleable is low enough so that the splint can be molded directly on the body. The thermoplastic can be heated, molded, and cooled together with the layer of material. The combined elements of the low temperature thermoplastic with the layer of material create a removable remoldable splint that can be immersed in water without degrading the integrity of the splint.

Abstract: A medical bandaging product, including a non-woven, fibrous, flexible medical material adapted for being applied and conformed to a body part to be supported, and a reactive system impregnated into or coated onto the medical material. The system remains stable when maintained in a non-activated condition in the absence of an activating agent, such as water, and hardens upon activation by exposure to the activating agent to form a rigid, self supporting structure. An enclosure is provided within which the medical material is maintained against exposure to the activating agent until use. The product may be in pre-cut shapes or in roll-form for cutting off a desired length for a given use.

Abstract: The invention relates to a fixing means which is used to temporarily fix human or animal body parts. The fixing means comprises at least one flexible carrier layer which is coated with a hardenable material, wherein the body part which is to be fixed can be surrounded either fully or partially by the fixing means and the hardenable material can then be hardened, wherein the carrier layer is stiffened. In order to provide for individual fixing of the body part while guaranteeing a partial adjustment of the desired rigidity of the fixing means, the fixing means is provided with at least two carrier layers, with at least one outer layer made of a flexible polymer film and at least one inner layer made of a flexible film in addition to at least one substantially liquid or viscous layer which is arranged between the outer and inner layer and which is made of at least one hardenable adhesive.

Abstract: A medical bandaging product, including a sleeve formed of moisture-impervious material and sealable to prevent entry of moisture, and a medical material positioned in the sleeve and sealed therein against entry of moisture until use. The medical material is a substrate having two marginal areas of relatively lower modulus yarns and/or a more open knitted structure to provide reduced abrasion against the skin. A reactive system on the substrate 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 method of making an orthoses, comprising the steps of preparing a plaster mold, upon which the layers of the orthosis will be placed and formed; and placing layers of material on the mold, then forming and removing the layers. An orthosis, comprising a footplate that is capable of receiving a human foot thereabove, a heel portion at the rear side of the footplate; a strut extending upwardly from the heel portion; a calf portion extending forwardly from the strut, the calf portion including a tibial shell; the tibial shell extends around the front of the user's tibia; a rear portion extends around the back of the user's calf a rear portion disposed rearwardly with respect to the calf portion; and sides such that the calf portion is completely circumferential without seams. Two foam layers line the orthoses for comfort and ease of use.

Abstract: A cast or support assembly includes inner double knit padding material in which the outer layer is woven or knit to have substantial size openings, while the inner layer of the double knit material to be located against the skin of the patient is more closely woven or knit. Additional casting fabric is also provided, with this casting fabric being impregnated with water hardenable material. The outer casting fabric may include openings extending through it, so that the entire cast assembly has ventilation openings allowing air circulation to accomplish rapid drying following wetting of the assembly by sweat, rain, or by swimming, for example.

Abstract: A medical bandaging product, including a package formed of a moisture-impervious material and sealable to prevent entry of moisture. A medical bandage is positioned within the package in substantially moisture-free conditions and sealed therein against moisture until use. The medical bandage is constructed of a fabric having a pair of opposed, major surfaces and a reactive system impregnated into or coated onto the fabric. The reactive system remains stable when maintained in substantially moisture-free conditions and hardens upon exposure to sufficient moisture to form a self-supporting structure having an immobilization value of less than about 43. The fabric is preferably knitted.

Abstract: An orthopedic cast system, including a hydrophilic inner layer; a hydrophobic outer layer having opposing surfaces adjacent to said hydrophilic inner layer, wherein the hydrophobic layer has an apparent surface energy less than about 60 dynes per centimeter; and a curable casting material disposed on one of the opposing surfaces is provided. Additionally, a method of immobilizing a body part is provided. An orthopedic cast kit is also provided.

Abstract: A back support apparatus intended for use during emergency transport of a patient suffering an actual or suspected spine injury is disclosed. The device provides a solid support for the arched portion of the spine that molds to the shape of the individual patient's back. The device comprises a bag or other container into which a solid curable material and a liquid activator are introduced; which is then placed beneath the patient's spine on a back board or like support. The device may be deployed quickly without the need for additional straps, belts, or the like, and may be treated as disposable due to its low cost.

Abstract: An orthopedic stockinette includes a preformed sleeve of elastic fabric material. At least a portion of the sleeve is drawn together to form secondary sleeves for receiving digits of a wearer and serving as a divider between the received digits. An orthopedic cast or splint may be formed with the stockinette by providing a layer of overlaying layer of hardenable cast material.

Abstract: An article comprising two or more layers. One or more of the layers includes of a polymeric foam tape containing one or more curable resins. One aspect of the present invention is to use the article as an orthopedic casting splint.

Abstract: An article including a polymeric foam having a thickness of less than about 3/16 inch (about 5 mm) and one or more curable resins.

Abstract: Custom footbed devices, methods of constructing the devices and kits for constructing custom footbeds are disclosed that may be particularly advantageous in the treatment of plantar ulcers. The devices offer the advantage of off-loading pressure from the plantar ulcers in a device that is easy to construct, reusable, lightweight, and custom-made to improve patient comfort. The footbeds are constructed using a curable substrate that is formed to the plantar surface of the foot except in the areas occupied by spacers designed to off-load wounds on the bottom of the foot.

Abstract: The present invention provides a stretch fabric substrate for medical use in a simple knitted structure with a good productivity having such a desired elastic recovery of elongation that no reduction of the fabric substrate in the widthwise direction takes place when elongation is applied to a necessary extent in the lengthwise direction. The fabric substrate according to the present invention is constituted by means of a warp knit substrate, the warp knit substrate is formed by means of a chain stitch using a stretch multifilament textured yarn and elastic yarns and non-stretch yarns are inserted in the lengthwise direct ion and in the widthwise direction, respectively to the chain stitch.

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: A water-curable orthopedic splint, which can be immediately applied to an affected limb includes a water-curable orthopedic casting material, which is in the form of a splint, and a gel container. The word gel is meant to apply to a viscous semi-solid which can be applied over surfaces in an adherent film and will disperse and move in response to the movement of the practitioner's hands in molding and forming the adhesive bandage around the limb or in the formation of various shapes as splints prior to application to the patient. It is to be distinguished from a free-flowing liquid which drips when applied to a limb resulting in a messy environment.

Abstract: A casting product for forming a hard structure about an object including a flexible fibrous substrate impregnated with a fluid-activated resin and a protective flexible casing surrounding the impregnated substrate. The casing includes a sealable passageway defined between the atmosphere and the interior of the casing, and is configured to permit injection of fluid, and removal of vapors and extant fluid with a vacuum from the casing.

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: An orthopedic fixture has a support member adapted to be positioned around a diseased or injured part of a patient's body and conformed to the shape of the diseased or injured part, and at least one buffer member comprised of a mixture containing a predetermined amount of elastic granules and a predetermined amount of a water-curable resin having an elasticity after curing sufficient for bonding the elastic granules after curing of the water-curable resin. The mixture of the buffer member forms a mass before curing of the water-curable resin so that when the support member is positioned around the diseased or injured part and pressure is applied to the mass, the elastic granules move one another to shape the mass into a configuration corresponding to the shape of the diseased or injured part.

Abstract: An orthopedic casting article comprising a polymeric foam tape containing one or more curable resins. The polymeric foam tape can be a foam having a substantially open cell structure, substantially closed cell structure, or a substantially reticulated cell structure. The curable resin can be a water-curable resin. The casting article can be multi-layered to obtain an article suitable for splinting applications.

Abstract: A cast tape or medical bandaging product formed from a resin-coated or impregnated fabric material that includes a knitted substrate having a combination of non-fiberglass high and low tenacity yarns such as polypropylene, polyester and elastomer. The polypropylene and polyester yarns have a high number of filaments, typically 48 to 90 filaments. This significantly improves the surface area of the fabric, that helps help to hold the curable resin onto the fabric and avoids pooling. This in turn improves lamination layer-to-layer and gives the substrate high strength.

Abstract: An improved apparatus and method for applying a total contact cast to a patient utilizes a kit of pre-packaged materials containing all of the items necessary. A uniquely designed padding strip pads the bony prominence on either side of the ankle, the top metatarsal area, and the crest of the shinbone in one unitary piece. Special cuts in the padding strip allow it to conform tightly to the bend between the foot and lower leg. The special cuts also allow the connected circular or elliptical flaps to also conform easily to the bony prominence of the ankle. Positioning the padding strip is simpler, easier, faster, and provides greater structural integrity to the overall cast. The unitary design helps prevent the padding strip from shifting when the cast is complete. An enlarged base portion of the walking heel eliminates the need for a separate wood platform for support.

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: 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: One aspect of the present invention is a casting article comprised of a water-curable Plaster of Paris (PP) article having a first side and a second side and having a substrate and PP material and a polyisocyanate material being applied to at least one of the first and second sides of the water-curable PP to obtain a water-curable hybrid plaster-polyisocyanate (HPP) casting article.

Abstract: It is an object to obtain a water-curable supporting bandage which can be applied to even an affected part of complicated shape with sufficient time, when it is applied by winding it around an affected part such as bone fracture for fixing. A supporting bandage comprising a water-curable polyurethane pre-polymer composition held on the fabric material is applied to an affected part without water supply. Sufficient time can be taken for application of the supporting bandage to the affected part. After completion of the application, the polyurethane prepolymer is rapidly cured by supplying water from outside of the supporting bandage to obtain a sufficient strength.

Abstract: An orthopedic casting article comprising a polymeric foam tape containing one or more curable resins. The polymeric foam tape can be a foam having a substantially open cell structure, substantially closed cell structure, or a substantially reticulated cell structure. The curable resin can be a water-curable resin. The casting article can be multi-layered to obtain an article suitable for splinting applications.

Abstract: An orthopaedic support assembly is formed of a flexible material impregnated with a hardenable material, e.g. a water-hardenable urethane. The orthopaedic support may include an outer layer of napped material, e.g., an unbroken loop material, that reduces migration of the hardenable material. The orthopaedic support may also include an inner layer of foam padding to increase the comfort of the patient.

Abstract: An improved apparatus and method for applying a total contact cast to a patient utilizes a kit of pre-packaged materials containing all of the items necessary. A uniquely designed padding strip pads the bony prominence on either side of the ankle, the top metatarsal area, and the crest of the shinbone in one unitary piece. Special cuts in the padding strip allow it to conform tightly to the bend between the foot and lower leg. The special cuts also allow the connected circular or elliptical flaps to also conform easily to the bony prominence of the ankle. Positioning the padding strip is simpler, easier, faster, and provides greater structural integrity to the overall cast. The unitary design helps prevent the padding strip from shifting when the cast is complete. An enlarged base portion of the walking heel eliminates the need for a separate wood platform for support.

Abstract: A cast or support for use in limiting movement of the anatomy to promote healing of an injured body part includes initially flexible and subsequently rigid double-knit material, or other casting blanks. There is a water-hardenable material impregnated into the casting blank. Certain areas of the blank have significantly reduced or no hardenable material. This construction may provide at least one hinge line which extends substantially across the double-knit material or other casting blank where said upper and lower layers are held in engagement with each other. The cast or support may be folded open along the hinge line to permit washing, inspection, or treatment of the portion of the anatomy to which said cast or support is applied or as one step in the preparation of a mold of a portion of the anatomy. More than one hinge line may be provided.

Abstract: A medical bandaging product having a predetermined length suitable for a given medical use, including an enclosure formed of a moisture-impervious material sealable to prevent entry of moisture and a medical bandage material positioned therein and sealed against entry of moisture until use. The medical bandage material includes a substrate formed from a single integrated knitted fabric layer having a plurality of interconnected knitted fabric yarns forming a three-dimensional structure. A reactive system is 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 cooperate with the three-dimensional structure to form a rigid, self supporting structure. A soft, flexible protective wrapping encloses the substrate along its length for providing a cushioning barrier interposed between the substrate and a patient when the medical bandage material is in use.

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: A resin system including a water curable isocyanate functionalized prepolymer, a first catalyst chemically bound-in to the prepolymer, and a second catalyst soluble in water and insoluble in the prepolymer.

Abstract: An orthotic device is developed and customized to control the desired movement of a 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.

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: Curable adhesive splints, methods of manufacturing the splints and methods of using the splints are disclosed. The splints include a curable splinting layer and an exposed pressure sensitive adhesive proximate a first major side of the splinting layer. The pressure sensitive adhesive is used to secure the curable layer in position to provide the desired immobilization. The curable splinting layer may be of any material that can be shaped and cured to provide the desired level of stiffness required for immobilization, such as, e.g., moisture-curable splinting material, etc. The curable adhesive splints may be molded or formed to a desired shape while still providing the stiffness required for immobilization after curing.

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.