Formed resilient orthopaedic device

An orthopaedic support comprising:

• means for supporting a portion of the anatomy;
• resilient foam material in sheet form comprising at least a part of said support, said foam material having a surface, a predetermined thickness and density in major areas of said support, and at least one compression molded area extending inwardly from said surface, the thickness of said foam material in one portion of said compression molded area being substantially less than said predetermined thickness and the density of said foam material at said portion of said compression molded area being greater than said predetermined density;
• and
• means for holding said orthopaedic support on a joint of the user's anatomy:
• wherein said compression molded area has been subjected to a compression molded process comprising heat and pressure prior to any contact with the portion of the anatomy, said compression molded area retaining a compression molded shape from the pressure and heat of the compression molding process alone.

An orthopaedic support comprising:

• a support body for supporting a portion of the anatomy, said support body constituting at least in part resilient material in sheet form;
• said resilient material being compression molded prior to contact with the portion of the anatomy by heat and pressure in specific areas to vary the thickness and density of the material to improve the function of said support;
• said support including areas subject to greater flexing in a first area and lesser flexing in other areas, said foam material being varied in thickness and density to give different resiliency in said first area than in said other areas;
• and
• said resilient sheet having a surface, a predetermined thickness in major areas of said support, and at least on compression molded area extending inwardly from said surface, the thickness of said support in one portion of said compression molded area being substantially less than said predetermined thickness.

A fail-safe orthopaedic support comprising:

• a first sheet of resilient closed cell foam;
• a second sheet of gas impermeable material, stacked together with said first sheet;
• said first and second sheets being bonded together by a heat and pressure compression molding process to form a bladder having edges, said bladder being compression molded with heat and pressure about edges of the bladder to substantially seal the bladder;
• and
• means for securing said bladder to the anatomy of a user,
• whereby in the event the bladder becomes deflated, the resilient foam will still provide cushioning support.

A compression molded orthopaedic back brace comprising:

• a belt member having a central portion, a plurality of lateral support straps connected to said central portion, and a surface adapted to be placed against the back of a user;
• at least one sheet of resilient foam material having a predetermined thickness and density, said sheet of resilient foam material being compression molded by a heat and pressure process in certain areas to reduce the thickness and increase the density of said foam material in the compression molded areas, thereby creating a foam body having areas of less dense material which serve as padding and areas of more dense material which serve to facilitate the function of the back brace;
• said compression molded areas retaining a compression molded thickness and density from the pressure and heat of the compression molding process alone;
• and
• said belt member further comprising a fastening element that is adapted to secure said belt member in a desired position and with a desired fit around a user.

A compression molded orthopaedic back support comprising:

• a belt member;
• at least one sheet of resilient foam material having a predetermined thickness and density, said sheet of resilient foam material being compression molded by a heat and pressure process in certain areas to reduce the thickness and increase the density of said foam material in the compression molded areas, thereby creating a foam body having areas of less dense material which serve as padding and areas of more dense material which serve to facilitate the function of the back brace;
• said compression molded areas retaining a compression molded thickness and density from the pressure and heat of the compression molding process alone;
• said central portion having an interior, said central portion comprising a compression molded bladder in said interior;
• and
• said central portion being secured to said belt member.