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Dynamic response ankle-foot orthosis

  • US 6,334,854 B1
  • Filed: 09/27/1999
  • Issued: 01/01/2002
  • Est. Priority Date: 09/27/1999
  • Status: Expired due to Term
First Claim
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1. A method of controlling the movement of a defective lower limb of a patient, comprising the steps of:

  • a) having a person with specific corrective needs in the movement of a lower limb;

    b) evaluating and determining by an orthotic examination design characteristics needed to improve movement of the defective lower limb;

    c) constructing a specifically designed plaster mold that is a duplicate of the defective lower limb;

    d) coating the mold with an elastomeric resin for constructing over the mold a laminated set-up for lower limb motion control;

    e) applying at least two layers of nylon stockinette over the mold;

    f) attaching aramid fiber strips, being of selected width, in specific patterns onto the layers of nylon stockinette, and strategically placed on the layers of nylon stockinette to coincide with the lower limb movement needs previously determined by the orthotic evaluation;

    g) applying at least two additional layers of nylon stockinette over the aramid fiber strips forming the laminated set-up;

    h) inverting the laminated set-up onto a vacuum stand;

    i) covering the laminated set-up with a dampened poly vinyl alcohol sleeve, having an upper end closed and sealing a lower end to the vacuum stand, thus allowing a sufficient vacuum to occur between the surface of the mold and the poly vinyl alcohol sleeve, for drying purposes;

    j) opening the upper end of the poly vinyl alcohol sleeve and applying uniformly to the laminated set-up, an elastomeric resin that produces a coating;

    k) re-closing the upper end of the poly vinyl alcohol sleeve and allowing the laminated set-up time for drying under vacuum, l) heat-curing the laminated set-up for a sufficient time under sufficient heat;

    m) cooling the laminated set-up to room temperature and removing any excess elastomeric resin from a toe section of the laminated set-up;

    n) soaking the laminated set-up in hot water and washing the poly vinyl alcohol from the laminated set-up;

    o) drying the laminated set-up and sanding a plantar surface of a foot section of the laminated set-up until fibers of the nylon stockinette layers are exposed;

    p) positioning the laminated set-up in an inverted position with the foot section horizontal in the sagittal and frontal plane;

    q) building a dam of selected height around a border of the foot section with masking tape;

    r) filling the plantar surface with elastomeric resin and allowing it sufficient time to cure;

    s) heating the laminated set-up for a sufficient time, for curing purposes;

    t) removing the masking tape and, sanding away excess material, u) cutting a center dividing line down the front of the laminated set-up and trimming away the lamination exposing a toe area section;

    v) constructing closing means;

    w) removing the laminated set-up from the mold to provide a pliable orthosis for controlling the motion of the defective lower limb; and

    x) placing the defective lower limb of the patient inside the orthosis with the closing means whereby the specifically placed strips of the orthosis control the defective lower limb movement in accordance with the previously determined orthotic design characteristics.

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