U.S. patent number 3,871,367 [Application Number 05/435,460] was granted by the patent office on 1975-03-18 for pelvic brace.
Invention is credited to Marion E. Miller.
United States Patent |
3,871,367 |
Miller |
March 18, 1975 |
Pelvic brace
Abstract
A pelvic girdle comprising an outer layer of a hard
substantially rigid plastic material and an inner layer of soft
compressible plastic material bonded to the outer layer, the girdle
being shaped to engage a person's pelvis and including an anterior
and a vertically split posterior portion, the girdle having an
upper anterior portion separated laterally from the remainder of
the girdle and curving outwardly thereof, and connecting upper side
portions on the girdle connecting the anterior and posterior
portions thereof and including inwardly curved sections in both
layers of the girdle for engaging the iliac crests of the wearer
and which sections have appreciably thicker compressible inner
layers thereon.
Inventors: |
Miller; Marion E.
(Indianapolis, IN) |
Family
ID: |
23728499 |
Appl.
No.: |
05/435,460 |
Filed: |
January 22, 1974 |
Current U.S.
Class: |
602/19;
264/222 |
Current CPC
Class: |
A61F
5/024 (20130101) |
Current International
Class: |
A61F
5/02 (20060101); A61f 005/02 () |
Field of
Search: |
;128/78,89,90,87,91,157,69 ;2/44,69,243 ;264/222 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Gaudet; Richard A.
Assistant Examiner: Yasko; J.
Attorney, Agent or Firm: Oldham & Oldham Co.
Claims
What is claimed is:
1. A pelvic girdle shaped to engage a person at his pelvis and
comprising an outer layer of a hard substantially rigid layer of a
plastic material and an inner layer of a soft compressible plastic
material bonded to said outer layer, which inner layer has
localized areas of varied thickness,
the girdle including anterior and posterior portions and being
vertically split in its posterior portion and including releasable
fastening means secured to the adjacent posterior portions, the
girdle also having a center anterior upper portion adapted to
extend up to about the base of the sternum of the wearer and curved
outwardly of the girdle, which upper portion is separated at its
lateral margins from other anterior portions of the pelvic girdle
and is free to flex slightly, the girdle having upper side portions
connecting the anterior and posterior portions and including
inwardly curved sections adapted to engage the iliac crests and
having appreciably thicker compressible inner layers on such
sections.
2. A pelvic girdle as in claim 1 where one of said posterior
portions has an inner layer thereon of tapered thickness at the
upper end of its edge at said split and of maximum depth at said
edge to form a back pressure point laterally of the wearer's
spine.
3. A pelvic girdle as in claim 1 where said girdle has a continuous
upwardly and laterally extending brace member operatively
connecting at its ends to anterior and posterior portions of the
girdle to provide an upper lateral pressure area for engaging a
wearer's axilla at the level of the apex of the thoracic curvature
of the spine.
4. A pelvic girdle as in claim 3 where anterior and posterior
uprights are vertically adjustably secured to said girdle and
extend upwardly therefrom, and a pressure means is removably
secured to and extends between said uprights to provide a lateral
pressure area on a wearer substantially opposed to the lateral
pressure area of said brace member.
5. A pelvic girdle as in claim 1 where said girdle has a generally
upwardly and forwardly extending loop portion operatively
connecting to the upper lateral sections of the girdle, which loop
portion is adapted to extend over a wearer's sternum to form a
pressure area there.
6. A pelvic girdle as in claim 5 where said loop portion is formed
integrally with said girdle and has a resilient inner layer, and a
removable transverse pressure pad is secured to and is adapted to
extend between horizontally opposed parts of said loop portions at
the thoracic level of the wearer.
7. A pelvic girdle as in claim 2 where said one of said posterior
portions extends vertically further than the other of said
posterior portions.
8. A pelvic girdle as in claim 3 where said girdle has said
continuous upwardly and laterally extending brace member extending
laterally of the brace in one direction, and the posterior portion
of the girdle positioned in the girdle in the other lateral
direction from the girdle vertical center axis extends vertically
further than the posterior portion positioned in said one direction
from said center axis.
Description
BACKGROUND OF INVENTION
Heretofore there have been various types of braces proposed for use
in correcting various deformities of the spine, such as lordosis
and other improper curvatures of the spine.
One of these braces used heretofore for achieving spinal
corrections is a "Milwaukee" brace. Such braces normally are made
to individual measurements corresponding to the individual wearer
of the brace. The production of the individual braces has included
taking casts from the potential wearer's body, and then working
from these casts to form the individual rigid pelvic girdle for
engaging the person and carrying one or more uprights thereon to
position support pads on the wearer adjacent the back of his neck
and his chin, when required. Obviously these individually formed
and produced braces have been costly to make and they have been
slow to produce, as well as being rigid and uncomfortable to
wear.
The general object of the present invention is to form pelvic
girdles from a number of standard symetrical molds of varying sizes
and wherein the molds represent correct spinal positions and
uniform body structures, and wherein pelvic girdles including a
soft compressible inner layer and a relatively rigid plastic outer
layer are produced in a variety of sizes for meeting most standard
requirements of patients requiring a pelvic girdle.
Another object of the invention is to form pelvic girdles from
thermoplastic plastic materials and layers of foam material and
wherein the foam padding, being on the inside of the girdle, can be
made appreciably thicker in certain areas for aiding in producing
pressures on the patient's body or for aiding in supporting the
girdle on the person without skin breakdown.
Another object of the invention is to provide pelvic girdles with
attachments therefor, which attachments can be integrally molded
with the girdle or can be formed separately and attached thereto as
desired.
Another object of the invention is to provide a basic pelvic girdle
formed from plastic layers and wherein the girdle can readily have
attachments secured thereto for aid in correcting all common back
disorders including kyphosis and scoliosis, as well as
lordosis.
Another object of the invention is to provide pelvic girdles at
reduced costs and to provide pelvic girdles adapted to individual
measurements of the wearer rapidly and conveniently from a
plurality of standard symetrical molds corresponding to normal
spinal conditions.
A further object of the invention is to provide a novel method of
forming a pelvic girdle or other brace means made from a soft
flexible liner material and a substantially rigid plastic outer
layer.
Other objects of the invention are to provide special heating,
laminating and molding steps to combine a closed cell plastic layer
and special padding members, when desired, with a relatively rigid
plastic outer sheet to form a shaped pelvic girdle therefrom with
localized padding provided therein; to provide a low-cost,
practical method of molding pelvic girdles to standard sizes and to
facilitate the attachment of special braces or padding means
thereto; to provide a bonding action between a preheated
thermoplastic carrier sheet and a heated, soft, flexible lining
layer; and to mold the resulting laminate when the carrier sheet is
at an elevated temperature and quite soft for mold-shaping
action.
Further objects of the invention will be made apparent from the
following specification.
Reference now is made to the accompanying drawings, wherein:
FIG. 1 is a front elevation of a pelvic girdle embodying the
principles of the present invention;
FIG. 2 is a vertical section through the center of the girdle of
FIG. 1;
FIG. 3 is a vertical section of a back portion of the girdle
adjacent the opening in the back;
FIG. 4 is a fragmentary vertical section of the side upper end of
the girdle;
FIG. 5 is a front elevation of a modified girdle of the invention
having an upwardly extending side engaging section carried by the
girdle;
FIG. 6 is a plan of the pelvic girdle shown in FIG. 5 with the side
engaging section removed;
FIG. 7 is a rear elevation of a further modified type of pelvic
girdle particularly adapted for treatment of a lordosis
condition;
FIG. 8 is a fragmentary section taken on line 8--8 of FIG. 7;
FIG. 9 is a side elevation of a further modification of the pelvic
girdle of the invention;
FIG. 10 is a rear elevation of the girdle of FIG. 9;
FIG. 11 is a front elevation of a further modification of the
girdle of the invention showing further supports secured
thereto;
FIG. 12 is a right side elevation of the girdle of FIG. 11;
FIG. 13 is an elevation showing a step in the method of making the
pelvic girdles of the invention prior to the molding thereof;
FIG. 14 is a fragmentary section taken on line 14--14 of FIG.
13;
FIG. 15 is a plan of the laminated material of FIG. 13 as applied
to a mold and prior to complete engagement of the laminate with the
mold surface;
FIG. 16 is a vertical section through the mold with the laminate
material engaged therewith;
FIG. 17 A and B are fragmentary edge sections of the girdle
produced by the molding action; and
FIG. 18 is a block diagram of the method of the invention.
When referring to corresponding members shown in the drawings and
described in the specification, corresponding numerals are used to
identify the parts to facilitate comparison therebetween.
Reference now is made to the details of the structure shown in the
accompanying drawings, and a pelvic girdle is indicated as a whole
by the numeral 10. This pelvic girdle is shaped to engage with a
person's pelvic area for applying pressures thereto for aid in
correcting deformities of the spine. The girdle is formed from a
substantially rigid outer layer 12 of a suitable thermoplastic
plastic material, such as polypropylene. The outer layer may be
about 1/8 to 3/16 inch thick, while an inner layer 14 is bonded to
the outer layer over the entire surface thereof and such inner
layer is formed from a soft compressible plastic material, such as
closed cell foam latex rubber, polyurethane, or the like, and this
soft inner layer is about 3/16 inch to 1/4 inch thick as a uniform
layer bonded to the outer layer of the girdle. However, the inner
layer can be suitably reinforced, padded, or thickened at desired
pressure points or other portions of the girdle, as hereinafter
described.
The girdle includes a continuous anterior portion 16 and a
vertically split posterior portion 18. For engagement with a
person's pelvis, the girdle has a center anterior upper portion 20
which if formed to extend up to the base of the sternum of the
wearer and such upper portion, or in effect, the entire anterior
portion is so shaped and curved that the upper portion thereof is
curving outwardly of the wearer at an angle of about 20.degree. to
about 40.degree. to the vertical, but with the vertically
intermediate portion of the anterior of the girdle being smoothly
curved and being inwardly extending to exert a backward pressure on
the wearer. Such outward curve can be varied and usually is about
40.degree.. This upper portion 20 is separated at its lateral
margins from the other anterior portions of the pelvic girdle and
has a relatively rigid, but yet flexible construction wherey a
resilient pressure applying section or portion is formed by this
area of the girdle.
Upper side portions 22 and 24 extend between the anterior and
posterior portions of the girdle for connecting the same and
relatively sharply inwardly curved sections 26 are provided on each
of these upper side portions of the girdle and these are curved to
extend inwardly of the girdle for engaging the iliac crests at the
hips of a wearer. FIG. 4 indicates that the padding 28 on these
edges as they are pressing inwardly against the body have an
appreciably thickened, soft, compressible inner layer thereon for
aiding in good engagement with the hips of the wearer and applying
pressures thereto.
To aid in securing the pelvic girdle 10 to a wearer, a flexible
securing means, such as a strap 30 and a buckle 32, or equivalent
members, are secured to the adjacent posterior portions of the
girdle for extending therebetween in a removable manner.
FIG. 2 of the drawings shows how the pelvic girdle 10 is adapted to
provide a plurality of vertically spaced pressure points for
determining the pressure engagement of the girdle with the wearer.
Thus the anterior portion 16 has a center pressure point or area
indicated at "A" for applying rearwardly directed distortion or
compression forces to one's pelvis, whereas the posterior portions
of the girdle have vertically spaced pressure points thereon at the
areas indicated at "B" and "C" whereby the girdle is adapted to
press inwardly on the spine in the lumbar curve area thereof so as
to apply forward pressures on the lumbar area of the back at these
areas "B" and "C" of the girdle whereby forces tending to
straighten the lumbar area of the spine and to overcome a lordosis
condition existing therein are provided by the girdle of the
invention.
FIG. 5 of the drawings shows a modified pelvic girdle 40 very
similar to the girdle shown in FIG. 1 with the exception that the
girdle at its posterior upper end portions indicated at 42 and 44
of the drawings, it is seen that the end 44 terminates appreciably
below the adjacent end 42, and the rear end or corner 42 is
provided with an additional thickness of padding 43 thereon. This
padding 43 tapers inwardly in a downward direction to be of maximum
thickness at the upper end 42 of the girdle, and it also tapers
downwardly in thickness to a feather edge as it extends laterally
of the girdle.
A feature of the girdle 40 is that it is particularly adapted for
correcting a curvature of the spine out of the vertical in a
lateral direction. Such spinal curvature is called scoliosis. The
girdle 40 has a separate attachment loop 46 secured thereto and
extending upwardly therefrom. This loop or pressure strap is made
from the same laminate of a relatively rigid hard plastic material
on the outer surface and a soft plastic foam material on its inner
surface just like the primary girdle 10. The pressure strap 46 can
have a plurality of holes 48 therein whereby it can be secured to
the girdle 40 in a vertically adjustable manner as by screws or
rivets 50 or the like. The lower end of the pressure strap 46 can
be received in a positioning pocket 52 provided in the lower
portion of the anterior wall of the girdle 40. The rear end of the
pressure strap 46 would be secured in similar manner to the rear
wall 44 of the girdle adjacent the vertically extending split in
the girdle. This pressure strap 46 extends upwardly and laterally
of the wearer and then back down to the girdle so that it provides
pressure at the axilla at the level of the apex of the thoracic
curvature of the spine. Hence, the girdle of the invention, which
is in general, similar to the girdle 10 in engaging the pelvic area
of a wearer, would have vertically and laterally spaced pressure
points provided on the wearer. The upper end of the pressure strap
46 as indicated at "D" would be a pressure point as would the
lateral lower area of the girdle on the same side as the section
"D" of the strap, and indicated at "E", would provide two
vertically spaced pressure points and then the opposite pressure
point, indicated at "F," would be provided by the girdle at the
opposite lateral margin of the girdle normally that engages the
iliac crest of the wearer whereby forces would be exerted on the
spine to endeavor to correct the curvature thereof in a lateral
direction out of vertical. Further, the padding 43 presses in on
the back adjacent the spine S at the vertical margin 44 of the pad
to apply further corrective lateral pressure on the spine.
The girdle shown in FIG. 5 can have the laterally reinforcing strap
46 molded as a unit therewith, when desired. By making the strap a
separate unit, it can be adjusted vertically of the basic carrier
girdle 40 to fit individual patient requirements.
FIG. 6 shows the girdle 40 with the brace 46 removed. The relation
of the pressure pad 43 to the wearer's spine S is indicated so that
a laterally directed pressure can be applied to the spine.
FIGS. 7 and 8 of the drawings show another modification of the
girdle 10 of the invention. In general, a girdle 70 is shown which
can be very similar, if not identical, to the girdle 10. However,
in this instance, a vertically upwardly extending attachment is
provided for the girdle to aid in providing corrective pressure to
the back. Thus, a pair of uprights 72 and 74 are secured to the
posterior sections of the girdle 70 and these uprights normally are
vertically adjustably engageable with back portions of the girdle
as by screws or rivets 76 engaging vertically spaced holes provided
in the uprights. A cross bar 78 or a similar pressure applying
member is suitably secured to the uprights 72 and 74 at their upper
ends and extends therebetween. This cross member may comprise a
plastic strip or bar, or it can be a canvas strip and buckle
combination supporting a pressure pad thereon. Thus, FIG. 8 shows
that a carrier bar or member 78 has a pressure pad 80 on the inner
surface thereof, which pressure pad is flexible and compressible
and normally would be made from foam material. The cross bar 78, as
well as the uprights 72 and 74, can be made from metal or
preferably are made from the laminate of a rigid plastic material
and a foam interlayer thereon as in the other components of the
girdle. One end of the cross bar 78 preferably has a keyhole shaped
slot 82 therein in which a headed rivet member or the like can be
received for detachable engagement of one end of the cross bar with
one of the uprights to facilitate applying the girdle to a wearer
and removal from the wearer.
By the modified girdle 70 of the invention, it will be seen that
the upper pressure point on the back, corresponding to the point
"B" shown in FIG. 2 would now be provided by the cross bar 78. This
just provides a pressure at the thoracic level to aid in reducing
the curvature of lordosis of the spine. Naturally, the thickness of
the pressure pads on the cross bars 78 can be varied to modify the
corrective action of the girdle.
FIGS. 9 and 10 show a modified girdle 10a having the same basic
lower construction as the girdle 10 but in this instance, an
upwardly and forwardly curved reinforcing strap 90 is formed
integral with the upper lateral portions of the pelvic girdle to
engage the sides and chest of the wearer. This strap 90 would be
formed from the same laminate as the remaining portion of the
girdle. The strap 90 includes anterior lateral uprights or sections
90a and 90b on opposite lateral portions of the girdle that
smoothly blend into a forwardly and upwardly extending section 90c
on the strap 90 to provide a sternal pressure area in the girdle
structure. Normally a flexible band or a belt 92 is removably
secured to and extends between the lateral uprights 90a and 90b in
a removable manner, as by the use of companion snaps 94 or the
like, provided on the band and on the strap 90 and a suitable
resilient pressure pad 96 is secured on the inner surface of this
band 92.
By the basic pelvic and iliac engaging lower portion of the girdle
10a, a wearer's pelvis is flexed to reduce lordosis, and the
pressure forces applied to the spine by the posterior pressure pad
96 at the thoracic level aids in reducing the curvatures of
kyphosis and/or lordosis of the wearer.
The pressure points on the girdle construction 10a to aid in
reducing lordosis, would be considered to be the back pressure pad
"C," the buttocks engaging posterior portion of the girdle
indicated at "A," and the front pelvic engaging area "B" of the
girdle. Pressure points for aiding in reducing kyphosis would
include the same pressure points "B" and "C" of the girdle in
combination with the upper pressure point "D" provided by the
center upper section 90c of this strap 90. Obviously, when desired,
the sternal section of the girdle can have an additional resilient
pressure pad provided on the inner surface thereof at "D" , which
pad can be bonded to the strap.
It naturally is possible to form the loop or strap 90 from a
separate molded member and to attach it in a vertically and/or
laterally adjustable manner to the basic pelvic engaging girdle to
support such strap portion of the brace of the invention.
Yet a further modified type of a girdle is shown in FIGS. 11 and 12
and the girdle is indicated by the number 100. This girdle 100 is
basically the same as the girdle 40 of FIG. 5 but with a laterally
extending reinforcing brace, loop, or strap 101 being formed as an
integral portion of the pelvic engaging section of the girdle, such
loop 101 extends upwardly and laterally from the upper anterior
portion 102 of the girdle up around the axilla area of the wearer
and back down to engage one of the posterior sections of the girdle
at its upper margin.
This girdle 100 preferably has posterior portions of different
vertical extents, like the girdle 40, and again a special tapered
pad 104 is provided on the higher posterior section of the girdle
at the vertical edge thereof to apply laterally directed pressures
to the spine as done by the girdle 40 and shown in FIGS. 5 and
6.
The girdle 100 is adapted to have any desired number of vertically
extending reinforcements or supports provided thereon, and
laterally extending flexible supports or pressure pads can also be
carried by the vertical extending supports in the girdle. In the
construction shown, an upwardly extending support bar 106 is shown
in vertical adjustable engagement with the anterior portion of the
pelvic section of the girdle and it preferably extends up to and
immediately adjacent the wearer's chin so that an enlarged chin
engaging section 108 is provided at the upper end of this bar 106
and it can be curled outwardly for comfortable engagement with the
wearer's chin to increase vertical extension of the wearer's spine.
A similar vertically upwardly extending support bar 110 is carried
by the one posterior portion of the girdle and extends up to the
occipital area of the wearer and has a suitable section at its
upper end, as indicated at 112, for comfortable engagement with the
wearer's neck and head area. The reinforcing brace bar 110 aids in
increasing vertical extension of the spine of the wearer by
encouraging the wearer to stretch upwardly and to avoid pressure
contact with the chin and neck portions 108 and 112 on the
vertically upwardly extending reinforcing bars.
FIG. 11 of the drawings indicates that a flexible strap 114 can be
removably secured to and extended between the front and rear brace
bars 106 and 110 so that any suitable pressure pads (not shown) can
be secured to the inner surface of this strap 114 to provide a
lateral pressure point on the wearer whereby a lateral pressure
force can be applied to thee spine of the wearer to aid in
correcting curvatures therein. Naturally, both the front and back
support or brace bars 106 and 110 normally would be vertically
adjustably engaged with the pelvic portion of the girdle for
individual adjustment to the wearer's spinal problems and the
corrective actions required. Such girdle 100 would have the various
pressure points as referred to hereinbefore but with at least two
additional pressure points being provided by the chin and neck
engaging portions 108 and 112 to provide for spinal extension
action.
The flexibility of the girdle 100 in corrective action can be
varied by varying the size of the corrective pad 104 provided on
the posterior portion thereof, and even by positioning it on the
opposite of the girdle, when desired. Likewise, the heights of the
posterior portions of the girdle can be altered to reverse the
relationship of the posterior portions of the girdle as shown in
the drawings. Of course, other types of flexible straps like strap
114 can be secured to and extended between the vertical support or
brace bars for laterally corrective forces at the required location
of the spine, and pads as required may be provided on the inner
surface of the loop 101.
METHOD OF BRACE MANUFACTURER
In making the various braces of the invention, a metal carrier
plate 120 is provided and a heat resistant flexible rubber or
synthetic sheet 122 is placed on the plate 120. The sheet 122 can
be made from a silicone rubber or other conventional types of
flexible, heat resistant materials. This rubber sheet has lobes or
ears 124 and 126 on opposed edges thereof and centering appertures
128 are formed therein for a purpose hereinafter to be described. A
sheet 130 of the thermoplastic material used to form the relatively
rigid outer surface of the pelvic girdle of the invention is first
processed by being cut or machined to the required size and shape,
and then the edges of such plastic sheet are further machined or
ground away to provide a smoothly curved outer edge on the sheet.
By processing the plastic sheet 130 when it is flat, the machining
and the cutting thereof is simplified, and it is shaped to a flat
layout of the brace or girdle to be made. The metal carrier sheet
120 with the rubber sheet 122 and plastic sheet 130 thereon is then
placed into a suitable oven and heated to a temperature of
approximately 400.degree. Farenheit. Usually the metal sheet 120
would have a non-stick surface, such as a teflon coat. The rubber
sheet used as a carrier medium is temperature resistant up to a
temperature of approximately 500.degree. to withstand repeated
heating actions.
After the stacked laminate has been heated to raise the sheet to
approximately 400.degree. Farenheit, then the metal carrier sheet
and laminate thereon is withdrawn from the heating oven and special
pads 132 are pressed against the exposed surface of the plastic
sheet in the area to form the hip or iliac crest engaging area in
the finished girdle. These pads 132 naturally have flat base
surfaces and crowned upper surfaces to fit smoothly against the
plastic sheet. The metal carrier sheet is next re-inserted into the
oven for just a few seconds such as from about four or five to
eight to ten seconds to aid in bonding the pads 132 to the plastic
sheet.
A closed cell polyurethane foam layer 134 is preferably separately
pre-heated to about 150.degree. Farenheit and then, while heated,
placed on the heated laminate carried by the rubber sheet 122.
Light pressure can be applied to the foam layer 134 to smooth or
press it into tight engagement with the plastic sheet 130 over the
entire upper surface thereof. The foam layer 134 is formed to the
same outline as the plastic sheet 130 but with the foam layer 134
usually being slightly larger than the plastic and extending
therebeyond a short distance at all margins thereof, as indicated
in FIG. 14.
A mold 136 which is of the size and shape of a wearer's torso is
separately formed. Such mold 136 has a plurality of holes 138
therein and the mold has ends 137 to form a closed inner chamber. A
vacuum line 140 connects to the chamber in the mold and it has a
suitable valve 142 therein whereby vacuum forces can be applied
over substantially the entire surface of the mold 136 when the
valve 142 is opened. The line 140 connects to any desired source of
vacuum supply. The mold 136 also has a pair of vertically upwardly
extending centering pins or posts 144 secured to it beyond its
operative margins. In order to apply the laminate formed of the
rubber sheet 122, plastic sheet 130, and foam layer 134 to the
mold, the rubber sheet 122 is grasped at its end and/or edge
portions, the rubber sheet is turned over, and the centering pins
144 are engaged with the appertures 128 formed in the lobes
extending from the rubber sheet whereby the laminate is centered
with relationship to the mold. The rubber sheet and the heated
plastic sheet will adhere for this action and the heated plastic
sheet, being flexible at that time, will drape over the surfaces of
the mold, and light manual pressure, if necessary, can be applied
to the dependant portions of the laminate to press them up against
the mold while the vacuum is applied thereto to obtain full
operative engagement with the mold. Thereafter, the mold 136
usually has external pressure applied thereto and it is moved into
a pressure chamber indicated at 146, or a portable pressure chamber
is moved to encircle the mold and the laminates thereon, and
pressure then is applied to the chamber 146 through a pressure
supply line 148 whereby the laminate is forced into tight operative
engagement with the mold for setting the plastic sheet 130 into the
desired configuration. The air pressure supplied through the line
148 is cool or at atmospheric temperature to aid in cooling the
plastic on the mold and obtain a relatively rapid setup of the
same. Or cooling air could be flowed over the mold 136 with the
laminate operatively engaged therewith.
In the molded article, FIG. 17a shows that the foam layer 134
extends slightly beyond the adjacent edge of the plastic sheet 130
which has a smoothly rounded edge 131 provided thereon by its
initially shaping and retained throughout the brace or girdle
forming action. Thereafter the edge of the plastic and foam layers
are brought into alignment by trimming the foam layer as indicated
in 17b.
When initially engaging the rubber carrier sheet and members
thereon with the mold 136, at that time the plastic sheet will have
some adhesive afinity to the rubber sheet because of the contacting
surfaces of the hot plastic-hot rubber sheet. Such rubber carried
sheet 122 can have a rough textured surface thereon to provide a
complimentary textured surface on the shaped girdle on the outer
surface thereof.
Of course, the girdle formed can be removed from the mold readily
by first removing the rubber sheet 122 from the outer surface of
the laminate and then removing the resilient girdle from the mold
after the plastic sheet has been cooled sufficiently to retain its
given shape. Such sheet 122 can be peeled off of the plastic sheet
after such plastic sheet has been partially cooled if desired.
In the girdle 70 shown in FIG. 7, an attachment strap 71 is also
shown that removably connects to suitable members, or includes
suitable means, such as snaps 73 thereon that are adapted to engage
with companion members carried by the posterior portions of the
girdle. Thus, when a person is applying the girdle, the retainer
strap 71 can be released from one end thereof and then be
reconnected to the companion snap members for retaining the girdle
in good tight association with the wearer. The cross bar 78 can
also be made in the form of a flexible strap or the like and be
releasably secured to its carrier uprights. Obviously, any type of
securing means can be provided on the separated posterior portions
of the girdle for entry and disengagement purposes. Likewise, all
of the other structures of invention normally would have a similar
removable attachment strap, or two of such straps provided on the
posterior portions of the girdle for attaching same to the wearer
but permitting convenient disengagement therefrom when desired.
It should be realized that various types of braces and/or pelvic
girdles can be made by the method or process of the invention. By
forming a unitary shaped structure from the relatively rigid outer
plastic layer having a soft compressible inner lining layer
thereon, a comfortable brace can be provided and these braces can
be formed in a number of predetermined sizes. Then by attaching
removable brace securing means to a girdle or brace of the correct
size, the braces will readily be adapted to fit onto individual
wearers for the specific brace or corrective action required.
Attachments also can be secured to the molded girdle or brace as
required.
Various known types of back braces particularly are adapted to be
formed by the method of the invention wherein, in each instance, a
flat layout of the brace is made and the initial flat plastic sheet
is cut and/or machined to predetermined size. Such sheet is then
processed by building up a laminate therefrom and applying to a
mold for permanent shaping action. Naturally the particular type of
a mold used for brace shaping action can be varied with the
individual braces to be produced, but the same method steps or
operations would be required or used to make the different braces
as desired. Special localized pads can be applied as desired in
building the laminate.
When localized pads, as the pads 132, are applied to the plastic
sheet, they preferably are spaced from the margins of the plastic
sheet and their upper surfaces smoothly blend into the top surface
of the plastic sheet. Hence, the foam cover layer 134 retains, or
aids in retaining the pad or pads in position by such layer's
lamination to the plastic sheet.
In making up the mold forms of the invention by which vacuum forces
are applied to the laminate used in forming the brace of the
invention, obviously the vacuum applying holes provided in the mold
normally are made of sufficiently small diameter that the closed
cell foam layer thereadjacent will not be excessively distorted or
drawn into the mold during the article shaping action. The molds
naturally are of a size for full operative engagement with the
unitary brace to be produced.
Obviously, in forming the various uprights attached to the pelvic
girdle of the invention such as the strap member 46 of FIG. 5, or
the uprights 106 and 110 as shown in FIGS. 11 and 12, any suitable
type of a plastic material can be used. Thus, more rigid material
than polypropylene can be used and it can be preformed to suitable
shape, have a number of holes drilled or otherwise formed therein
for vertically adjustable engagement with the carrier pelvic
girdle. Of course, other substantially rigid thermoplastic
materials as conventionally known can be used in place of the
polypropylene as referred to hereinbefore for forming the outer
layer 12 of the pelvic girdle as shown and described.
Standard size braces of the invention can readily be modified to
the individual wearer's requirements by taking one of the standard
pelvic girdles of the invention and by applying attachments
thereto, and/or by applying special pressure pads to localized
areas of the girdles or to attachments thereon as would be required
for individual corrective and/or support or brace action.
Braces of the invention, especially those as shown in FIGS. 9 and
10 and also FIGS. 11 and 12 of the drawings have been particularly
desirable in treatment and correction of spinal problems inasmuch
as corrective forces can be applied to the patient without the use
of neck rings as have been required in previous styles of braces.
The embodiment of the invention shown in FIGS. 11 and 12 is
particularly suitable when modified to use only an anterior strut
in the brace. The hyper extension brace of FIGS. 9 and 10 embodies
the standard five point pressure principle to manage both the
lumbar lordosis and the thoracic kyphosis. It can be worn easily
under clothing and is very effectively used in the post operative
period following spinal fusion for kyphosis of the thoracic
spine.
Use of braces and the process of the invention shortens delivery
time, makes the braces more comfortable to wear, and does not lose
any of the effectiveness of previous styles of braces known for use
in correction and treatment of spinal problems.
From the foregoing, it is believed that the objects of the
invention have been achieved and that a novel and improved girdle
has been provided by the invention and also that a new and improved
method has been provided for forming pelvic girdles, back braces
and the like. Thus, the objects of the invention are thought to be
achieved.
While several complete embodiments of the invention have been
described herein, it will be appreciated that modification of these
particular embodiments of the invention may be resorted to without
departing from the scope of the invention.
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