Hardenable orthopaedic support with improved configuration

A hardenable orthopaedic support assembly comprising a double layer fabric having a first interwoven layer and a second interwoven layer spaced apart from said first layer, and an open-work matrix of filaments interconnecting said layers;

• said fabric being formed in a manufacturing step with said filaments being woven or knitted into both of said two spaced layers;
• said double layer fabric being impregnated with water-hardenable material leaving some space within said matrix to receive water;
• a water resistant padding layer on one side of said double layer fabric;
• a flexible porous layer on the other side of said double layer fabric;
• said support assembly being fundamentally knit into a three-dimensional configuration generally conforming to a portion of the anatomy to be supported;
• said fabric being knit into a closed knit configuration without severed fabric edges which might otherwise be subject to fraying;
• and
• said fabric being variable in thickness to provide an increased level of support in at least one area of said assembly.

A hardenable orthopaedic support assembly comprising:

• a double layer fabric having spaced interwoven layers and an open-work matrix of fibers interconnecting said layers;
• said fabric being formed in a single manufacturing step with said filaments being woven or knitted into both of said two spaced layers;
• said double layer fabric being impregnated with water-hardenable resin leaving some space within said matrix to receive water;
• a water resistant fabric padding layer on one side of said double layer fabric;
• and
• a flexible porous layer on the other side of said double layer fabric;
• whereby the open-work matrix of said double layer fabric and said porous layer facilitate rapid and uniform impregnation by the water-hardenable material, and rapid and uniform penetration of the water, and also provides firm support resulting from the hardening of the water-hardenable material in the open-work matrix.

A hardenable orthopaedic support assembly comprising:

• a double layer fabric having spaced interwoven layers and an open-work matrix of filaments interconnecting said layers, said fabric being a double-knit type fabric having between 10 and 30 picks per inch and between 5 and 25 wales per inch;
• said fabric being formed in a single manufacturing step with said filaments being woven or knitted into both of said two spaced layers;
• said double layer fabric being impregnated with water-hardenable resin leaving some space within said matrix to receive water;
• a water resistant fabric padding layer on one side of said double layer fabric;
• and
• a flexible porous layer on the other side of said double layer fabric;
• whereby the open-work matrix of said double layer fabric and said porous layer facilitate rapid and uniform impregnation by the water-hardenable material, and rapid and uniform penetration of the water, and also provides firm support resulting from the hardening of the water-hardenable material in the open-work matrix.

A hardenable orthopaedic support assembly comprising:

• an active double layer fabric having spaced interwoven layers and an open-work matrix of filaments or fibers interconnecting said layers;
• said fabric being formed in a single manufacturing step with said filaments being woven or knitted into both of said two spaced layers;
• at least ten percent (10%) of said fabric being formed of fibers having a tensile strength greater than 500 Mpa;
• and
• said active layer being impregnated with the water-hardenable material;
• whereby the open-work matrix of said double layer fabric facilitates rapid and uniform impregnation by the water-hardenable material, and rapid and uniform penetration of the water, and also provides firm support resulting from the hardening of the water-hardenable material in the open-work matrix.

A hardenable orthopaedic support assembly comprising:

• an active layer formed of a double layer fabric having spaced interwoven layers and an open-work matrix of filaments inter-connecting said layers;
• said fabric being formed in a single manufacturing step with said filaments being woven or knitted into both of said two spaced layers;
• said active layer being impregnated with water-hardenable material;
• said spaced layers being independently movable with respect to each other, within the limits of said inter-connecting fibers, for case in three-dimensional draping around the anatomy;
• a padding layer including water resistant material on one side of said double layer fabric;
• a flexible porous layer on the other side of said double layer fabric;
• and
• a water vapor impermeable packaging enclosing said impregnated double layer fabric;
• whereby the open-work matrix of said active double layer fabric facilitates rapid and uniform impregnation by the water-hardenable material, and subsequent uniform penetration of water, and also provides firm support resulting from the hardening of the water-hardenable material in the open-work matrix.

A hardenable orthopaedic support assembly comprising:

• an active layer formed of a double layer fabric having spaced interwoven layers and an open-work matrix of filaments interconnecting said layers, at least 10 percent by weight of said fabric being formed of high strength, stiff filaments of a material selected from the group consisting of fiberglass, aramids and carbon;
• said fabric being formed in a single manufacturing step with said filaments being woven or knitted into both of said two spaced layers;
• said active layer being impregnated with water hardenable material;
• said spaced layers being independently movable with respect to each other, within the limits of said interconnecting filaments for ease in three dimensional draping around the anatomy;
• and
• a water vapor impermeable packaging enclosing said impregnated double layer fabric,
• whereby the open work matrix of said active double layer fabric facilitates rapid and uniform impregnation by the water hardenable material, and subsequent uniform penetration of water, and also provides firm support resulting from the hardening of the water hardenable material in the open work matrix.

A hardenable orthopaedic support or cast assembly comprising:

• a high strength fabric core layer;
• said fabric core layer being impregnated with water hardenable resin;
• a water resistant fabric padding layer on one side of said fabric core layer for comfortable engagement with the skin of a patient;
• and
• the only material on the other side of said core layer consistency essentially of a thin flexible porous plastic layer for permitting wetting of said water hardenable material;
• whereby the water resistant padding layer inhibits the flow of fluid from said fabric core layer to the patient, and said porous layer facilitates water flow to activate hardening of said core.

A hardenable orthopaedic support assembly comprising:

• a double layer fabric having spaced interwoven layers and an open-work matrix of filaments interconnecting said layers;
• said fabric being formed in a single manufacturing step with said filaments being woven or knitted into both of said two spaced layers;
• said double layer fabric being impregnated with water-hardenable material leaving some space within said matrix to receive water;
• said support assembly being fundamentally knit into a three-dimensional configuration generally conforming to a portion of the anatomy to be supported;
• said fabric being knit into a closed knit configuration without severed fabric edges which might otherwise be subject to fraying;
• and
• said fabric being variable in thickness to provide an increased level of support in at least one area of said assembly.

A hardenable orthopaedic support assembly comprising:

• a high strength fabric core layer;
• said fabric core layer being impregnated with water-hardenable material;
• said support assembly being fundamentally knit into a three-dimensional configuration generally conforming to a portion of the anatomy to be supported;
• and
• said fabric being knit into a closed knit configuration without severed fabric edges which might otherwise be subject to fraying.

A hardenable orthopaedic support assembly comprising:

• a double layer fabric having first and second spaced interwoven layers and an open-work matrix of filaments interconnecting said layers;
• said fabric being formed in a single manufacturing step with said filaments being woven or knitted into both of said two spaced layers;
• said double layer fabric being impregnated with water hardenable resin leaving some space within said matrix to receive water;
• said first layer being relatively open for the transmission of water through said first layer;
• and
• said second layer being relatively closed as compared to said first layer, to restrict flow through said second layer;
• whereby the open work matrix of said double layer fabric and the porous first layer facilitate rapid and uniform impregnation by the water hardenable material, and rapid and uniform penetration of the water, and the closed configuration of said second layer protects the patient from the effects of the exothermic hardening reaction.

A hardenable orthopaedic support assembly comprising:

• a double layer fabric having spaced interwoven layers and an open-work matrix of filaments interconnecting said layers;
• said fabric being formed in a single manufacturing step with said filaments being woven or knitted into both of said two spaced layers;
• said double layer fabric being impregnated with water hardenable resin leaving some space within said matrix to receive water;
• said fabric being wound into a roll having a central core or mandrel upon which the fabric is wound;
• and
• water vapor impermeable packaging for enclosing said assembly, for preventing premature activation and hardening of said water hardenable material during storage prior to intentional activation.

A hardenable orthopaedic support assembly comprising:

• a high strength double-knit type fabric core layer;
• said double knit type fabric core layer being formed with an upper layers a spaced lower layer, and intermediate filaments extending between and spacing said layers and woven or knitted into both of said layers;
• said fabric core layer being impregnated with water-hardenable material;
• and
• said fabric being knit into a closed knit configuration without severed fabric edges which might otherwise be subject to fraying.

A method for forming a support or splint comprising the steps of:

• forming a support assembly including a double-knit type fabric of a predetermined thickness, impregnated with a water hardenable resin;
• said double knit type fabric core layer being formed with an upper layer, a spaced lower layer, and intermediate filaments extending between and spacing said layers and woven or knitted into both of said layers;
• packaging said assembly in a water vapor impermeable package;
• opening said package;
• applying water to said assembly to activate the exothermic hardening process;
• molding said assembly to a portion of the anatomy requiring support while the assembly is still in the exothermic phase;
• and
• compressing some of the double-knit fabric so that it has different thicknesses in different areas, in the course of providing full support to the injured portion of the anatomy.

A hardenable orthopaedic support assembly comprising:

• a double layer fabric having spaced interwoven layers and an open work matrix of filaments interconnecting said layers;
• said fabric being formed in a single manufacturing step with said filaments being woven or knitted into both of said two spaced layers;
• said double layer fabric being impregnated with water hardenable resin leaving some space within said matrix to receive water;
• a water resistant cloth padding layer on one side of said double layer fabric;
• and
• a layer of hydrophilic material between said double layer fabric and said water resistant layer to facilitate flow of water through said double layer material to activate said water hardenable resin.

A hardenable orthopaedic support assembly comprising:

• a double layer fabric having spaced interwoven layers and an open-work matrix of filaments interconnecting said layers;
• said fabric being formed in a single manufacturing step with said filaments being woven or knitted into both of said two spaced layers;
• said fabric being a double-knit type fabric having between 10 and 30 picks per inch and between 5 and 25 wales per inch,
• at least ten percent (10%) of said fabric being formed of fibers having a tensile strength greater than 500 MPa;
• and
• said double layer fabric being impregnated with water-hardenable resin leaving some space within said matrix to receive water;
• whereby the open-work matrix of said double layer fabric facilitate rapid and uniform impregnation by the water-hardenable material, and rapid and uniform penetration of the water, and also provides firm support resulting from the hardening of the water-hardenable material in the open-work matrix.

A hardenable orthopaedic support assembly comprising:

• a double layer fabric having spaced interwoven layers and an open-work matrix of filaments interconnecting said layers;
• said fabric being formed in a single manufacturing step with said filaments being woven or knitted into both of said two spaced layers;
• said double layer fabric being impregnated with water-hardenable material leaving some space within said matrix to receive water;
• said support assembly being fundamentally knit into a three-dimensional configuration generally conforming to a portion of the anatomy to be supported;
• and
• said fabric being variable in thickness to provide an increased level of support in at least one area of said assembly.

A hardenable orthopaedic support assembly comprising:

• a double layer fabric having spaced interwoven layers and an open-work matrix of fibers interconnecting said layers, at least ten percent (10%) of said fabric being formed of fibers having a tensile strength greater than 500 MPa;
• said fabric being formed in a single manufacturing step with said filaments being woven or knitted into both of said two spaced layers;
• said assembly being a flat sheet preformed into an anatomical shape for mounting on specific portions of the anatomy;
• and
• said double layer fabric being impregnated with water-hardenable resin leaving some space within said matrix to receive water;
• whereby the open-work matrix of said double layer fabric facilitate rapid and uniform impregnation by the water-hardenable material, and rapid and uniform penetration of the water, and also provides firm support resulting from the hardening of the water-hardenable material in the open-work matrix.