Composite material for custom fitted products

A method of manufacturing an orthopedic product for supporting a body part of a patient, the orthopedic product including a composite material comprising an inner layer, an outer layer and a polymer middle layer substantially coextensive with the inner layer and outer layer, the middle layer thermoformable within a target temperature range and substantially rigid at temperatures below a minimum formable temperature of 130 degrees Fahrenheit, the method comprising:

• heating the composite material such that the middle layer is above the minimum formable temperature;
• directly joining a first edge of the composite material to a second edge of the composite material while the middle layer is above the minimum formable temperature so as to form a three dimensional structure that conforms with a corresponding portion of the body part, wherein said three dimensional structure includes at least two separate components each formed of said composite material, and wherein each component has an edge that forms a distinct one of said first and second edges;
• and
• joining the separate components to form the three dimensional structure.

A method, comprising:

• causing a composite material to be manufactured and made available to a user, the composite material including:
• an inner layer configured to face toward the body part and having a perimeter;
• an outer layer configured to face away from the body part and having a perimeter, said perimeter of said outer layer being similar to said perimeter of said inner layer;
• and a middle layer having a perimeter that is substantially coextensive with said perimeters of said inner layer and said outer layer, and sandwiched between said inner layer and said outer layer, said middle layer comprising a polymer layer that is thermoformable within a target temperature range and substantially rigid at temperatures below a minimum formable temperature of 130 degrees Fahrenheit, wherein the composite material includes at least two closable edges;
• causing a closure means to be manufactured and made available to the user;
• providing instructions to the user for creating an orthopedic product, including:
• heating the composite material such that the middle layer is above said minimum formable temperature;
• creating an aperture within and through said composite material that defines a first contoured edge and a second contoured edge, the contoured edges adapted to be positioned substantially adjacent one another;
• directly joining the first contoured edge to the second contoured edge while the middle layer is above said minimum formable temperature so as to form a three dimensional structure that conforms with a corresponding portion of the body part;
• forming the composite material about the body part while the middle layer is above said minimum formable temperature;
• and
• selectively closing the at least two closable edges with the closure means, without directly joining the closable edges.

An orthopedic product for supporting a body part, comprising:

• a closure system including:
• a first attachment member having a plurality of hook elements;
• a fastening mechanism affixed to the first attachment member;
• a second attachment member having a plurality of hook elements;
• a guide element affixed to each of said first and second attachment members;
• and
• an elongated flexible member inserted through each of said guide elements and engaging said fastening mechanism;
• and
• a composite material including:
• an inner layer configured to face toward the body part and having a perimeter;
• an outer layer configured to face away from the body part and having a perimeter, said perimeter of said outer layer being similar to said perimeter of said inner layer and the outer layer including at least one section configured to interface with a hook material as part of a hook-and-loop fastening system;
• and
• an intermediate layer having a perimeter that is substantially coextensive with said perimeters of said inner layer and said outer layer, and sandwiched between said inner layer and said outer layer, said intermediate layer comprising a polymer layer that is thermoformable within a target temperature range and substantially rigid at temperatures below a minimum formable temperature of 130 degrees Fahrenheit, wherein the first attachment member and second attachment member are releasably coupleable to the at least one section of the outer layer of the composite material via the plurality of hook elements of the first and second attachment members so as to create an adjustable and repositionable orthopedic product.

An orthopedic product for supporting a body part, comprising:

• a composite material including:
• an inner layer defining an area configured to face toward the body part;
• an outer layer defining an area configured to face away from the body part, said area of said outer layer being similar to said area of said inner layer;
• and
• a middle layer substantially coextensive with said areas of said inner layer and said outer layer, and sandwiched between said inner layer and said outer layer, said middle layer comprising a polymer layer that is thermo formable within a target temperature range and substantially rigid at temperatures below a minimum formable temperature of 130 degrees Fahrenheit;
• at least two contoured edges of said composite material adapted to be positioned substantially adjacent one another;
• means for directly joining said at least two contoured edges of said composite material while said middle layer is above said minimum formable temperature to form a three dimensional structure that conforms with a corresponding portion of the body part;
• at least two closable edges of said three dimensional structure adapted to be positioned substantially adjacent one another when the orthopedic product is placed upon the body part, said closable edges being distinct from said contoured edges;
• and
• means for selectively closing said at least two closable edges without directly joining said closable edges.