CUSTOM ANKLE BRACE SYSTEM

• US 20110196276A1
• Filed: 02/10/2010
• Published: 08/11/2011
• Est. Priority Date: 02/10/2010
• Status: Active Grant

• Current Assignee: Jeffrey Andrew Kuhn
• Original Assignee: Jeffrey Andrew Kuhn
• Inventors: Kuhn, Jeffrey Andrew
• Granted Patent: US 8,708,942 B2
• Time in Patent Office: Days
• US Class Current: 602/27
• CPC Class Codes: A61F 5/0111 for the feet or ankles
• CPC Class Codes: A61F 5/0127 for the feet A61F5/0111 takes precedence

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.

Claims

1. An ankle brace comprising:

a. a non-olefinic elastomeric blend thermoplastic polymer support having;

i. a back portion extending substantially circumferentially around a posterior section of the user'"'"'s lower leg; and

ii. a sole portion extending outwardly from and integrally formed with said back portion, said sole portion formed to be mounted adjacent to and supporting substantially all of the sole and heel of a user'"'"'s foot.

2. The ankle brace of claim 1 further comprising an inner liner, foam pads and a flexible outer layer.

3. The ankle brace of claim 2 wherein said inner liner and said flexible outer layer further comprise a closure apparatus.

4. The ankle brace of claim 3 wherein said closure apparatus comprises eyelets and laces.

5. The ankle brace of claim 1 further comprising a tongue.

6. The ankle brace of claim 1 further comprising a heel cut-out portion.

7. The ankle brace of claim 1 further comprising a toeless portion.

8. The ankle brace of claim 1 further comprising a moveable ankle joint.

9. A method of making an ankle brace system comprising:

a. covering a replica mold of the relevant appendage provided with an inner lining;

b. heating a non-olefinic elastomeric blend polymer material support device to a moldable temperature, creating a support and;

c. molding and securing said non-olefinic elastomeric blend polymer support to said inner lining and said foam pads to create a thermoplastic support device, said thermoplastic support device comprising

i. a back portion extending substantially circumferentially around the posterior section of the user'"'"'s lower leg; and

ii. a sole portion extending outwardly from and integrally formed with said back portion, said sole portion formed to be mounted adjacent to and supporting substantially all of the sole and heel of a user'"'"'s foot.

10. The method of claim 9, further comprising securing foam pads to said inner lining;

11. The method of claim 9, further comprising securing a flexible outer layer to said thermoplastic support device.

12. The method of claim 9 further comprising securing a closure apparatus to said inner liner and said flexible outer layer.

13. The method of claim 12 wherein said closure apparatus comprises eyelets and laces.

14. The method claim 9 further comprising securing a tongue to said ankle brace.

15. The method of claim 9 further comprising creating a heel cut-out portion in said thermoplastic support.

16. The method of claim 9 further comprising creating a toeless portion in said thermoplastic support.

17. The method of claim 9 further comprising creating a moveable ankle joint in said thermoplastic support.

18. The method of claim 9 further comprising securing a securing mechanism in said thermoplastic support.

19. The method of claim 9, further comprising selecting a non-olefinic elastomeric blend thermoplastic polymer material which is moldable at a temperature appropriate for affixing said ankle brace system to the user while molding.

20. A method of fitting an ankle brace system, comprising

a. preparing an ankle brace comprising a thermoplastic support constructed of a material of sufficient rigidity to support said ankle comprising:

i. a back portion extending substantially circumferentially around the posterior section of the user'"'"'s lower leg; and

ii. a sole portion extending outwardly from and integrally formed with said back portion, said sole portion formed to be mounted adjacent to and supporting substantially all of the sole and heel of a user'"'"'s foot;

b. heating said ankle brace to a temperature appropriate for molding;

c. placing the foot and ankle of the user in a clinically desirable position; and

d. compressing and fitting said heated ankle brace on the limb of the user until said ankle brace has cooled to room temperature.