Abstract: A conformable orthopaedic casting tape made with a combination of silicone elastic fiber and a non-elastic fiber is disclosed. The casting tape is capable of stretching 40% to 200% in the length direction and has a power of between 40 and 175 grams per inch width at 30% elongation.

Abstract: The present invention provides an article, comprising: a fabric sheet which has been microcreped; and a curable resin coated onto the fabric sheet. The present invention involves microcreping or compacting a fabric sheet to impart stretchability and conformability to the fabric while minimizing undesirable recovery forces. Suitable fabrics for microcreping are fabrics which comprise fibers which are capable of first being mechanically compacted or "crimped" and then being set or annealed in the crimped, i.e., distorted, state. The article may be in the form of an orthopedic bandage and may optionally contain a plurality of microfiber fillers dispersed into the resin. The incorporation of microfiber fillers into the casting materials of the present invention adds substantially to the strength of the cured casting material, particularly when the fabric used therein is a non-fiberglass fabric, while not detracting from the handling properties of the uncured casting tape.

Abstract: An apparatus for forming a brace for a scoliosis patient includes a casting board for receiving a patient in a laying-down position and a plurality of pressure pads which are releaseably securable on the casting board for applying lateral pressure to the torso portion of the patient. The apparatus is operative in a method for forming a brace by first positioning the patient in a treatment position on the casting board in which the pressure pads are assembled with the patient to apply predetermined amounts of lateral pressure to precisely defined areas of the torso portion of the patient. The patient is then removed from the casting board, an uncured cast is assembled on the torso portion of the patient and the patient is repositioned in the same treatment position on the casting board while the cast is allowed to cure. The cast can then be used to form a scoliosis brace for the patient by conventional techniques.

Abstract: A conformable orthopaedic casting tape made with a combination of an elastic fiber and a non-elastic fiber is disclosed. The casting tape is capable of stretching 40% to 200% in the length direction and has a power of between 40 and 175 grams per inch width at 30% elongation. The elastic fiber is a blend of a cured or partially cured polyolefin rubber and a polyolefin resin.

Abstract: A protective pad assembly for being custom-fitted to a body part to be protected. The assembly includes first and second protective pads, each of the first and second pads having an initially flexible 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 body part-defined shape into which it is molded during curing. First and second inner storage pouches are provided. Each of the first or second protective pads are sealed in respective ones of the first and second storage pouches. The first and second storage pouches having moisture-transmission retarding properties. A single, outer moisture-proof protective pouch is provided within which the pads and the inner pouches are sealed in the absence of moisture until the pad is to be molded to the body part to be protected.

Abstract: The bandage has a substrate, a tacky liquid-curable prepolymer resin in contact with the substrate and a permeable core on which said substrate is wrapped for storage. The core of the bandage has a lubricant adapted to be released from the core such that the lubricant renders the surface portion of the substrate substantially non-tacky to facilitate molding, laminating and smoothing of a cast to be formed from the bandage. The cores have a liquid-permeable base and a lubricant in accordance with the lubricant provided to the core of the bandage. The method includes unwinding the bandage from the core, applying the bandage to a limb to form a cast, contacting the core with liquid, applying force to the core to release lubricant from the core onto the applier's hands and molding, laminating and smoothing a surface portion of the cast rendered substantially non-tacky by the lubricant on the applier's hands.

Abstract: The present invention provides an article, comprising: a fabric sheet; a curable resin coated onto the fabric sheet; and a plurality of microfiber fillers dispersed into the resin. The incorporation of microfiber fillers into the casting materials of the present invention adds substantially to the strength of the cured casting material, particularly when the fabric used therein is a non-fiberglass fabric, while not detracting from the handling properties of the uncured casting tape or bandage.The microfiber fillers useful in this invention are generally characterized as being short fibers having an aspect ratio greater than five to one. Blends of microfibers having different aspect ratios may be utilized in the casting tapes of the present invention. Preferred microfiber fillers or blends have an aspect ratio between 5:1 and 200:1, more preferably, the aspect ratio of the microfiber is between 5:1 and 50:1, and most preferably, the aspect ratio of the microfiber is between 10:1 and 30:1.

Abstract: A medical bandaging article sealed in moisture-free condition, serially connected with other such sealed articles in roll form. The medical bandaging article comprises an open cell foam layer and a woven fabric layer with several layers of resin impregnated substrates arranged therebetween. The substrate layers are preferably smaller than the fabric and foam layers. A heat fusing web is interposed between the fabric layer and the immediately adjacent substrate layer, and extends beyond the substrates so that upon application of sufficient heat and pressure, the fabric layer and the foam layer are fused together around the periphery of the substrates encasing them between the fabric layer and foam layer. A roll of individually sealed pouches containing bandaging articles are connected together, and between adjoining sealed pouches special perforations are provided for separating the pouches without damaging the seals of the adjacent pouches.

Abstract: A porous fiberglass cast system for the setting of broken appendages is herein provided. The present invention uses a simplified technique involving a standard fiberglass bandage typical in most cast Systems. Fastening strips impregnated with a curable resin are sewn or woven in rows along the width of one side and down the length of the other side of the unimpregnated fiberglass bandage. Upon wrapping the bandage to an injured member, the fastening strips overlap and produce a cross-mesh. The nature of the fastening strips allows this cross mesh to initially stabilize the structure during cementing. After curing is complete, the intersecting points of the fastening strips in the cross mesh provide a rigidified cross-mesh structure strong enough to completely immobilize the injured member. The areas contained in the cross-meshing between the fastening strips, not being impregnated with any kind of resin, retain their porosity once the cast is cured.

Abstract: An improved substrate for retaining a hardenable composition, which substrate utilizes a double face knit having knitting fabrics of multiple bundles formed on both its face and back surfaces, the knitting fabrics being impregnatable with hardenable resin by capillary action and retaining the resin to enable curing thereof into a hard composition, the improved substrate providing the advantages of substrates composed of glass fibers such as strength and good air permeability, while also providing advantages of substrates composed of natural and synthetic fibers such as comfort and non-irritability.

Abstract: A method for obtaining a traumatologic plastering with damp-proof and hard-wearing properties consisting of adding to a volume of one liter of containing product 96 through 99% of warm water having a value of 7.65 pH, the following components being added to obtain 1 liter of this product: 43 mg of Sodium, 7.30 mg of Potassium, 8.02 mg of Calcium, 1.20 mg of Magnesium, 0.40 mg of Americium, 580 mg of Nitrate, 0.53 mg of Nitrite, 25.6 mg of Sulfate, <0.004 mg of Cyanide, <0.05 mg of Phosphorus, <0.05 mg of Iron, <0.06 mg of Manganese, <0.05 mg of Copper, and <0.10 mg of Aluminum, the inorganic elements constituting a fluid or powdered mixture if not dissolved in water.

Abstract: A body part protector assembly for being custom-fitted to a body part, and including a body part protector having at least two connected-together pad segments. Each of the pad segments having an initially flexible protective layer comprised of a fabric 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. Respective removable covers separately cover and enclose each of the at least two connected pad segments, and are individually removable from their respective pad segments to expose the initially flexible protective layer of that pad segment when the body part protector is to be wetted and fitted to the body part for curing into the proper molded shape.

Abstract: A multi-layer protective pad for being custom-fitted to a body member to be protected which includes a flexible inner cushion layer for being placed closest to the body member and an initially flexible intermediate layer bonded to the inner layer. The intermediate layer includes a fabric impregnated with a moisture-curable resin which hardens upon curing to form a rigid structure of the fabric which retains a body part-defined shape into which it is molded during curing, thereby also holding the flexible inner cushion layer in the same body-part defined shape. The fabric has a variable thickness with a relatively thick predetermined area where increased rigidity is desirable and a relatively thin area where increased flexibility is desirable. A flexible outer layer is bonded to the intermediate layer for being held by the intermediate layer in the same body-part defined shape as the intermediate layer.

Abstract: The present invention concerns a new, unconventional, mold-binding, water solidified polyurethane cast to be used in orthopedic departments for the correction of deformities, fixation of fractured limbs and joints, and mollification of affected parts, as well as the method of its preparation. The chief constituent, a polyurethane prepolymer, contains a stabilizer that can prolong appreciably the storage period of the cast material, maleic anhydride, and a mixed catalyst for control of hardening time, bis(2-morpholinoethoxy)ethane and anhydrous potassium carbonate.

Abstract: The present invention provides an article, comprising: a fabric sheet which has been mechanically compacted; and a curable item coated onto the fabric sheet. The present invention involves compacting a fabric sheet to impart stretchability and conformability to the fabric while minimizing undesirable recovery forces. Suitable fabrics for mechanical compacting are fabrics which comprise fiberglass fibers which are capable of first being mechanically compacted and then being set or annealed in the distorted, state. The article may be in the form of an orthopedic bandage and may optionally contain a microfiber filler associated with the resin.

Abstract: The invention is a method of applying a material usable as an orthopaedic bandage which material is an open weave substrate having thereon a curable resin. The resin is curable, for example, by polymerization which polymerization is initiated by immersion of the resin coated substrate in a bath. Gloves are worn during the performance of the method which gloves are provided with a coating which in use is lubricous relative to the resin coated substrate. Thus the interference in application of the substrate due to the substrate sticking to the gloves is substantially reduced or eliminated by the lubricousness of the gloves.

Abstract: A soft-goods type, custom "in situ" formable back brace for supporting a weakened or injured back and/or neck is disclosed having hardenable components which conform to the unique configuration of a patient's torso. An initially flexible rear torso component, generally extending circumferentially around the patient's back, is releasably coupled to the torso using a plurality of Velcro-type securing straps. Alternatively, an initially flexible front torso component in combination with a rear component may be releasably coupled to a patient's torso. Once properly secured, liquid, preferably water, may be introduced into each component to activate the activatable, hardenable material encapsulated therein. Each component may be further comprised of a plurality of panels or pads with elasticized, resilient material interposing adjacent panels. The panels or pads may be permanently or removably integrated into each torso component.

Abstract: The present invention provides a water-curable resin composition for use in an orthopedic cast composed of a water-reactive alkoxysilane terminated resin, having at least one hydrolyzable group per molecule. The resin composition has a viscosity of no greater than about 500 Pa-s under ambient conditions and conditions less than about 1 wt-% of a solvent, based on the total weight of the resin composition.

Abstract: A tubular cast product having an outer container formed of moisture-impervious material. A cast tube that is placed on and surrounds a body part. The cast tube includes a reactive system impregnated into or coated onto the tube. The cast tube also includes a narrow weakness zone along it length.

Abstract: A tubular cast assembly for immobilizing a body part includes an undercast protective sleeve for being placed on the body part and a cast tube for being placed on and surrounding the body part over the undercast protective sleeve. The undercast protective sleeve protects the body part against contact with the skin by the cast tube. The cast tube comprises a fabric tube knitted of fiberglass and a size suitable for the body part to be immobilized and a reactive system impregnated into or coated onto the fabric tube. The system remains stable when maintained in substantially moisture-free conditions and hardens upon exposure to sufficient moisture to form a rigid, light-weight self supporting tubular structure. Adjacent edges of the fabric tube along the length of the tube define a narrow weakness zone or zones therebetween to serve as a line along which the tube is severed along the length thereof in preparation for removal.

Abstract: The present invention provides an article, comprising: a fabric sheet which has been microcreped; and a curable resin coated onto the fabric sheet. The present invention involves microcreping or compacting a fabric sheet to impart stretchability and conformability to the fabric while minimizing undesirable recovery forces. Suitable fabrics for microcreping are fabrics which comprise fibers which are capable of first being mechanically compacted or "crimped" and then being set or annealed in the crimped, i.e., distorted, state. The article may be in the form of an orthopedic bandage and may optionally contain a plurality of microfiber fillers dispersed into the resin. The incorporation of microfiber fillers into the casting materials of the present invention adds substantially to the strength of the cured casting material, particularly when the fabric used therein is a non-fiberglass fabric, while not detracting from the handling properties of the uncured casting tape.

Abstract: The present invention is directed to a water-hardenable orthopedic splinting bandage. The substrate comprises inelastic fibers being incorporated in the substrate in the lengthwise direction. In a preferred substrate, the low modulus fiber is a multifilament polypropylene and the elastic fiber is a polyurethane yarn. Comformable orthopedic bandages employing the substrate are also described.

Abstract: The present invention provides an article, comprising: a fabric sheet which has been mechanically compacted; and a curable resin coated onto the fabric sheet. The present invention involves compacting a fabric sheet to impart stretchability and conformability to the fabric while minimizing undesirable recovery forces. Suitable fabrics for mechanical compacting are fabrics which comprise fiberglass fibers which are capable of first being mechanically compacted and then being set or annealed in the distorted, state. The article may be in the form of an orthopedic bandage and may optionally contain a microfiber filler associated with the resin.

Abstract: The knee orthesis appliance is made of carbon-fiber composite material with an integral Menshik linkover four bar chain (21) made of titanium. It provides the knee joint with secure and reliable support. Owing to its low weight, it is extremely comfortable to wear. The angle of bend (22) can be adjusted to suit the individual as prescribed by the doctor. The shells of the appliance are made from a positive plaster cast (1), using vacuum composite production techniques. This simple process enables the appliance to be manufactured to a high standard of quality in orthopaedic workshops. The joint plates (5,6) are inserted between the individual layers of the composite. Following filling and curing, the sidepieces (16,17) only have to be riveted to the joint plates to complete the four bar chains and hence the finished appliance.

Abstract: An apparatus for forming a brace for a scoliosis patient includes a casting board for receiving a patient in a laying-down position and a plurality of pressure pads which are releaseably securable on the casting board for applying lateral pressure to the torso portion of the patient. The apparatus is operative in a method for forming a brace by first positioning the patient in a treatment position on the casting board in which the pressure pads are assembled with the patient to apply predetermined amounts of lateral pressure to precisely defined areas of the torso portion of the patient. The patient is then removed from the casting board, an uncured cast is assembled on the torso portion of the patient and the patient is repositioned in the same treatment position on the casting board while the cast is allowed to cure. The cast can then be used to form a scoliosis brace for the patient by conventional techniques.

Abstract: The present invention provides an article, comprising: a fabric sheet; a curable resin coated onto the fabric sheet; and a plurality of microfiber fillers dispersed into the resin. The incorporation of microfiber fillers into the casting materials of the present invention adds substantially to the strength of the cured casting material, particularly when the fabric used therein is a non-fiberglass fabric, while not detracting from the handling properties of the uncured casting tape or bandage.The microfiber fillers useful in this invention are generally characterized as being short fibers having an aspect ratio greater than five to one. Blends of microfibers having different aspect ratios may be utilized in the casting tapes of the present invention. Preferred microfiber fillers or blends have an aspect ratio between 5:1 and 200:1, more preferably, the aspect ratio of the microfiber is between 5:1 and 50: 1, and most preferably, the aspect ratio of the microfiber is between 10:1 and 30:1.

Abstract: The present invention provides a narrow orthopedic casting tape which can be handled in longer lengths suitable for economical production of coated fabric products. The narrow casting tape of the present invention is knitted as a wide fiberglass fabric with at least one removable connecting yarn in the length (i.e., warp) direction of the fabric which acts to connect two narrower strips of fiberglass fabric. The removable connecting yarn is subsequently removed from the fabric by a heat treatment process which separates the wider fabric into two narrower fabrics and also heat sets the fabric. Alternatively, the removable connecting yarn may be removed from the fabric by a dissolution process. Narrow fabrics of the present invention can also be constructed of organic yarns.The present invention also provides a tearable orthopedic casting tape which has a high degree of extensibility.

Abstract: A casting tape comprising a fabric substrate with pigment bound thereto is provided. The preferred fabric substrate comprises inorganic material such as fiberglass. The preferred pigments are selected such that they will not interfere with shelf stability of the orthopedic casting tape. The preferred pigments are those selected from the group consisting of Colour Index Pigments Blue 15.3; Red 202; Green 7; Red 166; Red 178; Yellow 109; Violet 23; Red 242; Red 122; Red 124; Black 7; White 6; Violet 19; Violet 42; and, mixtures thereof. Methods for preparing preferred orthopedic casting tapes are also provided.

Abstract: The present invention relates to a method of dressing a wound using an open-celled foam pad prepared from a foam sheet impregnated with a water curable, isocyanate functional, polyurethane prepolymer resin. The pad can concurrently function as an orthotic pad. The pad exhibits the ability to wick wound exudate from the site of the wound, and also exhibits desirable conformability and comfort in use.

Abstract: A unitary cast or splint forming device which has a layer of cast forming material contained within a water retaining pouch so that water added to the pouch does not wet the exterior. Padded and patient contact layers may be applied to the outside of the pouch.

Abstract: An ecologically harmless process for the production of stiffening materials containing hydraulic binders, for example plaster bandages, is characterized in that a hydraulic binder is mixed in pulverulent form with a reactive binder, this mixture is applied to a sheet-like material, the sheet-like material thus coated is rolled up and the setting reaction of the reactive binder is allowed to proceed before, during and/or after the rolling-up.

Abstract: A polyvinyl acetal sponge formed from a high molecular weight polyvinyl alcohol is used for forming a splint for a portion of body, such as during healing of a bone fracture or other injury. The sponge is maintained in a softened condition in the presence of vapors of a softening agent such as ethyl alcohol within a sealed pouch. Upon removal from the pouch, the sponge is applied to the body portion and it hardens to form the splint as the softening agent vapors dissipate.

Abstract: The present invention relates to novel orthopedic casting materials having superior layer to layer lamination, and methods for preparing the same. The orthopedic casting materials comprise a resin-coated scrim having a plurality of projections along at least one surface thereof. Preferably, each projection comprises a bundle of at least about 8 filaments, and the scrim has from about 75 to about 1500 projections per gram of scrim. The projections serve to mechanically interact with adjacent layers of the material, thereby significantly enhancing the lamination properties of the resultant material and resisting delamination once the material has cured.

Abstract: A medical technique comprises the steps of attaching a hammock to the head rail and foot rail of a crib, and placing a child in the hammock. A hip spica cast is applied around the legs and a portion of the torso of the patient, as well as a portion of the hammock. The cast is dried while maintaining the patient in the hammock. Subsequently, an end portion of the hammock is pulled through the cast to separate the hammock from the cast and the patient upon completion of the drying.

Abstract: A warp knitted fabric is described in which each individual wale contains stitches formed from both elastic and inelastic yarn. The fabric is extensible in the direction of the wales and may be used as a substrate in an orthopaedic splinting bandage. Orthopaedic splinting bandages are also described which comprise the warp knitted fabric coated with a hardenable resin such as an isocyanate terminated propolymer. The lengthwise extensibility of the substrate makes the uncured bandage conformable during application to the body.

Abstract: A slippery orthopedic cast tape produced by depositing onto a substrate a layer of microencapsulated lubricating or friction-reducing material. The substrate is impregnated with a material which is hardenable upon exposure to an activating agent. The coating of each one of the microgranules is formed of a material which is removable upon the application thereto of a removing stimulus. The microencapsulated lubricious material is applied to the inner end of a rolled cast tape so that it will be adjacent the outer layers of a formed cast. In one embodiment, the microgranules are formed of a water-insoluble polymeric coating over a polyethoxylated surfactant which serves as the lubricious material, the polymeric coating being rupturable upon the application of pressure in order to release the lubricious material.

Abstract: The present invention relates to a method of dressing a wound using an open-celled foam pad prepared from a foam sheet impregnated with a water curable, isocyanate functional, polyurethane prepolymer resin. The pad can concurrently function as an orthotic pad. The pad exhibits the ability to wick wound exudate from the site of the wound, and also exhibits desirable conformability and comfort in use.

Abstract: The present invention relates to an orthotic blank comprising an open-celled foam sheet impregnated with a water curable, isocyanate functional, polyurethane prepolymer resin. The orthotic blank can be used according to the method of this invention to prepare an orthotic pad bearing the impression of a body part to be supported and/or cushioned. The resultant orthotic pad exhibits both proper weight-bearing strength and cushioning properties for effective and comfortable use.

Abstract: The invention is directed to a stable catalytic and aqua-activated polyurethane bandage used for orthopedic casting. The bandage has a substrate and an aqua-activated polyurethane prepolymer. The catalyst used to make the prepolymer is .alpha.-(morpholinopolyethoxy)-.beta.-morpholinoethane or the mixture of .alpha.-(morpholinopolyethoxy)-.beta.-morpholinoethane and cocatalyst bis-(2-dimethylaminoethyl) ether. The catalyst in this bandage can be optionally combined with a stabilizing agent, such as ethane-sulfonic acid to form a structurally stable complex. The catalyst of this invention provides an excellent solidification time and significantly prolongs the storage period of the bandage.

Abstract: A casting blank for forming orthopedic casts is provided with two layers of plaster splints having different setting rates or times. The plaster splint layer disposed on a lower sheet of the casting blank sets more slowly than the layer disposed on an upper sheet of the blank. The quicker setting upper plaster splint layer rapidly immobilizes the injured body part, while the slower setting lower splint layer results in greater final cure strength and insulates the body part from the heat generated by the upper layer to prevent burning of the skin surface. The slower setting lower splint layer adapts more completely to the contours of the body portion to increase patient comfort.

Abstract: A method of applying an orthopedic cast to an injured body portion consisting of braiding a tubular cast, in situ, around the injured body portion. A somewhat modified conventional braiding machine is operative for applying the tubular braid of fibrous casting yarns around the injured body portion, to form a braided cast which conforms to the shape of the injured body portion. The braided cast is then coated with a matrix material, which provides the necessary rigidity to the cast, yet allows the cast to breathe.

Abstract: In a construction material comprising a flexible carrier substrate impregnated or coated with a water-hardening resin, the resin contains as an additive polyether polysiloxane polyurethanes of the formula ##STR1## in which R.sup.1 is lower alkyl,m is the average number of siloxane groups in the range from 5 to 25,R is ##STR2## in which X is lower alkylene,Y is an aliphatic, cycloaliphatic, aromatic or araliphatic moiety, which is unsubstituted or substituted by further ##STR3## Z is a polyether moiety based on ethylene oxide units propylene oxide units, or both with the average number of ethylene oxide and propylene oxide units being in the range fro 10 to 100 andR.sup.2 is lower alkyl.

Abstract: The invention provides improved orthopedic cast bandages and improved orthopedic casts which include one or more colors. The orthopedic cast bandages of the invention comprise an open mesh fabric tape and a hardenable liquid resin coated onto the fibrous tape. At least one coloring agent is visibly disposed on at least a portion of the fibrous tape. The coloring agent is stably retained by the fibrous tape in the presence of the hardenable liquid resin. Because the coloring agent is stably retained by the fibrous tape, the invention provides for colored orthopedic casting tapes which do not require the use of colored liquid resins. In addition, multiple colored, patterned orthopedic casts, not heretofore available, are provided by the invention.