Orthopedic supports and material for making same

• US 4,832,010 A
• Filed: 11/12/1987
• Issued: 05/23/1989
• Est. Priority Date: 06/11/1985
• Status: Expired due to Term

• Current Assignee: Max Lerman
• Original Assignee: Max Lerman
• Inventors: Lerman, Max
• Primary Examiner(s): Apley, Richard J.
• Assistant Examiner(s): PREBILIC, PAUL B
• Application Number:
  US07/122,553
• Time in Patent Office: 558 Days
• Field of Search: 128/80 C, 128/80 B, 128/80 H, 128/155, 128/157, 128/165, 128/166, 128/80, 2/2, 2/DIG. 1, 2/DIG. 7, 2/24
• US Class Current: 602/63
• CPC Class Codes: A61F 13/061 for knees incorporating non-textile reinforcing elements, e.g. springs or stays, A61F5/0111; Patella supports
• CPC Class Codes: A61F 13/101 for the elbow, e.g. decubitus ulcer bandages A61F13/107 takes precedence
• CPC Class Codes: A61F 2/7812 Interface cushioning members placed between the limb stump and the socket, e.g. bandages or stockings for the limb stump
• CPC Class Codes: A61F 2002/30014 differing in elasticity, stiffness or compressibility
• CPC Class Codes: A61F 2002/30235 tubular, e.g. sleeves
• CPC Class Codes: A61F 2002/5007 having elastic means different from springs, e.g. including an elastomeric insert
• CPC Class Codes: A61F 2002/7818 Stockings or socks for the limb stump
• CPC Class Codes: A61F 2230/0069 cylindrical
• CPC Class Codes: A61F 2250/0018 differing in elasticity, stiffness or compressibility
• CPC Class Codes: B32B 2305/026 Porous
• CPC Class Codes: B32B 2307/51 Elastic
• CPC Class Codes: B32B 25/10 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 25/16 comprising polydienes homopolymers or poly-halodienes homopolymers B32B25/12 takes precedence
• CPC Class Codes: B32B 2535/00 Medical equipment, e.g. bandage, prostheses or catheter

Abstract

Orthopedic supports are made from a flexible, resilient composite material which includes a base layer of a flexible, closed cell elastomeric material such as neoprene rubber in thin sheet form, with a multiplicity of relatively large air holes extending through the depth of the sheet and dispersed across the surface of the sheet. A skin-protecting first layer of a soft, flexible stretchable porous knitted fabric is adhered to a first face of the base layer. A protective second layer of a flexible, stretchable porous knitted fabric is adhered to the second face of the base layer. The composite material is porous to air and water passing through the depth of the composite layer. Orthopedic supports made from the material are sufficiently elastic to provide compression around a body part supported by the composite material in its stretched condition. The composite material is sufficiently porous to ventilate the supported body part during use such that elasticity and support is provided while heat discomfort and perspiration are prevented.

Claims

1. A flexible, resilient composite material for use in making elastic orthopedic compression supports for surrounding and supporting a body part by compression, the composite material comprising:

a porous base layer of a flexible, closed cell elastomeric foam material in thin sheet form and having a multiplicity of holes extending through the entire depth of the sheet and distributed across the surface area of the sheet, the closed cell elastomeric material having sufficient elasticity and a density of at least about ten pounds per cubic foot to provide orthopedic compression support;

a skin-protecting first layer of a flexible, resiliently elastic porous fabric adhered to a first face of the base layer; and

a protective second layer of a flexible, resiliently elastic porous fabric adhered to an opposite second face of the base layer, the first and second layers providing a means for reinforcing the elasticity of the porous base layer so that the composite material consisting of the combination of said base layer, first layer, and second layer maintains sufficient elasticity and density to provide a useful level of orthopedic compression support, and in which said composite material is porous to air and water passing through the depth of said composite material to provide a means of heat and moisture dissipation for the surrounded body part during use of such an orthopedic compression support.

2. The article according to claim 1 in which the first and second layers are knitted fabrics having pores naturally formed in the fabric, and the individual holes in the base layer have a substantially larger area than the area of the individual pores formed in the knitted fabric.

3. The article according to claim 1 in which the base layer is made of polychloroprene rubber.

4. The article according to claim 1 in which the holes occupy about three percent to about ten percent of the surface area of the base layer.

5. The article according to claim 4 in which the thickness of the polychloroprene rubber layer is about 1/16 to about 1/4 inch.

6. An orthopedic support for supporting the knee, elbow, wrist, or the like, made from the composite material of claim 1 wherein the composite layer is overlayed and seamed to form a tubular support open at both ends.

7. An ankle support made from the composite material of claim 1 wherein the composite material is overlayed and seamed to form a generally L-shaped tubular support open at opposite ends.

8. The process according to claim 1 in which the first and second layers are adhered to opposite faces of the perforated base layer by surface adhesion over substantially the entire contacting surface areas.

9. A flexible, resilient composite material for use in making elastic orthopedic compression supports for surrounding and supporting a body part by compression, the composite material comprising:

a porous base layer of a flexible, resilient polychloroprene rubber closed cell elastomeric foam material in thin sheet form having a multiplicity of holes extending through the entire depth of the sheet and distributed across the surface area of the sheet, in which the closed cell elastomeric material has sufficient elasticity and a density from about ten to about thirty pounds per cubic foot to provide orthopedic compression support;

a skin-protecting first layer of a flexible, resiliently elastic porous fabric adhered to a first face of the base layer; and

a protective second layer of a flexible, resiliently elastic porous fabric adhered to an opposite second face of the base layer, in which the resilient first and second layers provide a means for reinforcing the elasticity of the porous base layer so that the composite material consisting of the combination of said base layer, first layer, and second layer maintains sufficient elasticity and density to provide a useful level of orthopedic compression support, and in which the composite material is porous to air and water passing through the depth of said composite material, to thereby provide heat and moisture dissipation for the surrounded body part during use of such an orthopedic support.

10. The article according to claim 9 in which the holes occupy about three percent to about ten percent of the surface layer of the base layer.

11. The article according to claim 10 in which the holes are substantially uniform in size and are spaced apart substantially uniformly across the surface of the base layer.

12. The article according to claim 9 in which the thickness of the polychloroprene layer is about 1/16 to about 1/4 inch thick.

13. The article according to claim 9 in which the first and second layers are adhered to opposite faces of the perforated base layer by surface adhesion over substantially the entire contacting surface areas.

14. A tubular orthopedic compression support for applying compression-type support to a surrounded body part, in which the tubular support is made from a composite material comprising:

a porous base layer of a flexible, resilient elastomeric closed cell elastomeric foam material in thin sheet form and having a multiplicity of holes extending through the entire depth of the sheet and distributed across the surface area of the sheet, the closed cell elastomeric material having sufficient elasticity and a density of at least about ten pounds per cubic foot to provide orthopedic compression support;

a skin-protecting first layer of a flexible, resiliently elastic porous fabric adhered to an inner face of the base layer; and

a protective second layer of a flexible, resiliently elastic porous fabric adhered to an outer face of the base layer, in which the resilient first and second layers reinforce the elasticity of the porous base layer so that the composite material consisting of the combination of said base layer, first layer, and second layer maintains sufficient elasticity and density to provide a useful level of orthopedic compression support, and in which the composite material is porous to air and water passing through the depth of said composite material, to thereby provide a means of heat and moisture dissipation for the surrounded body part during use of such an orthopedic compression support.

15. The article according to claim 14 in which the holes occupy about 3 percent to about 10 percent of the surface area of the base layer.

16. The article according to claim 15 in which the density of the base layer is about 10 to about 30 pounds per cubic foot.

17. The article according to claim 16 in which the elastomeric closed cell base layer comprises polychloroprene rubber.

18. The article according to claim 14 in which the resulting orthopedic support has mutually orthogonal lateral and longitudinal dimensions, and in which the support has greater stretchability laterally than longitudinally.

19. The article according to claim 14 in which the first and second layers are adhered to opposite faces of the perforated base layer by surface adhesion over substantially the entire contacting surface areas.

20. A flexible, resilient composite material for use in making elastic orthopedic compression supports for surrounding and supporting a body part by compression, the composite material comprising:

a porous base layer of a flexible, closed cell elastomeric foam material in thin sheet form and having a multiplicity of holes extending through the entire depth of the sheet and distributed across the surface area of the sheet, the closed cell elastomeric material having sufficient elasticity and density to provide orthopedic compression support;

a skin-protecting first layer of a flexible, resiliently elastic porous fabric adhered to a first face of the base layer; and

a protective second layer of a flexible, resiliently-elastic porous fabric adhered to an opposite second face of the base layer, the first and second layers providing a means for reinforcing the elasticity of the porous base layer, the first and second fabric layers each having an elasticity greater than the elasticity of the perforated closed cell elastomeric base layer, the composite material consisting of the combination of said base layer, first layer, and second layer maintaining a sufficient level of elasticity and density to provide a useful level of orthopedic compression support, and in which the composite material is porous to air and water passing through the depth of said composite material to provide a means of heat and moisture dissipation for the surrounding body part during use of such an orthopedic compression support.

21. The article according to claim 20 in which the base layer material has a density of at least about ten pounds per cubic foot.

22. The article according to claim 20 in which the holes occupy about three percent to about ten percent of the surface area of the base layer.

23. The article according to claim 20 in which the first and second layers are knitted fabrics having pores naturally formed in the fabric, and the individual holes in the base layer have a substantially larger area than the area of the individual pores formed in the knitted fabric.

24. The article according to claim 20 in which the first and second layers are adhered to opposite faces of the perforated base layer by surface adhesion over substantially the entire contacting surface areas.

25. A tubular orthopedic compression support for applying compression-type support to a surrounded body part, in which the tubular support is made from a composite material comprising:

a porous base layer of a flexible, resilient elastomeric closed cell elastomeric foam material in thin sheet form and having a multiplicity of holes extending through the entire depth of the sheet and distributed across the surface area of the sheet, the closed cell elastomeric material having sufficient elasticity and density to provide a level of orthopedic compression support;

a skin-protecting first layer of a flexible resiliently elastic porous fabric adhered to an inner face of the base layer; and

a protective second layer of a flexible, resiliently elastic porous fabric adhered to an outer face of the base layer, in which the first and second fabric layers reinforce the elasticity of the porous base layer, and in which the first and second fabric layers each have an elasticity greater than the elasticity of the perforated closed cell elastomeric base layer, so that the composite material consisting of the combination of said base layer, first layer, and second layer maintains sufficient elasticity and density to provide a useful level of orthopedic compression support, and in which the porosity of the base layer provides heat and moisture dissipation during use of such an orthopedic compression support.

26. The article according to claim 25 in which the elastomeric base layer material has a density of at least about ten pounds per cubic foot.

27. The article according to claim 25 in which the holes occupy about three percent to about ten percent of the surface area of the base layer.

28. The article according to claim 25 in which the first and second layers are knitted fabrics having pores naturally formed in the fabric, and the individual holes in the base layer have a substantially larger area than the area of the individual pores formed in the knitted fabric.

29. The article according to claim 25 in which the first and second layers are adhered to opposite faces of the perforated base layer by surface adhesion over substantially the entire contacting surface areas.