TITLE: A SOFT-GOODS TYPE, FORMABLE ORTHOPEDIC CAST
European Patent EP0417213
 B1

ABSTRACT:
Abstract not available for EP0417213
Abstract of corresponding document: US4852557
A foldable, wrappable envelope sleeve orthopedic cast immobilizes and
conforms to the shape and configuration of a limb. The cast conforms to
the limb through the use of airtight pouches which encapsulate open
cell or fiberglass matrices impregnated with a water-activated urethane
polymer. After the tightening of the cast around the limb, the
injection of water into each pouch activates the urethane polymer which
conforms to the configuration of the limb encased. Supplemental
bendable ribs may be employed to splint the limb prior to activation of
the hardenable material. The soft goods type cast is held in place by
straps, and may be removed or adjusted by releasing or tightening the
straps. The splinting elements may be removed and replaced.

INVENTORS:
Grim, Tracy E. (3910 W. Boston Court, Broken Arrow, OK, 74012, US)

APPLICATION NUMBER: EP19890913280
PUBLICATION DATE: 10/19/1994
FILING DATE: 05/18/1989

ASSIGNEE: ROYCE MEDICAL COMPANY (3534 Hayden Avenue, Culver City, CA, 90232, US)
INTERNATIONAL CLASSES: A61F5/02; A61F5/058; A61F13/04; (IPC1-7): A61F5/04
EUROPEAN CLASSES: A61F5/058H; A61F13/04

FOREIGN REFERENCES:
3375822 Surgical cast and method of forming and applying to a body
  member
3643656 INFLATABLE SURGICAL CAST
3674021 PLASTIC BANDAGE OR SPLINT
4013070 Body part immobilizer
4483332 Construction and method for forming an orthopedic cast and
  method of producing the construction
4537184 Portable orthopaedic splint system
4572172 Molding cast system for fractures of the humerus and of the
  radius ulna
4683877 Orthopedic casting article and method
Attorney, Agent or Firm:
Abrams, Michael John (HASELTINE LAKE & CO. Hazlitt House 28 Southampton
Buildings Chancery Lane, London, WC2A 1AT, GB)

CLAIMS:
1. A soft goods type orthopaedic cast assembly (10; 200), comprising:
      sleeve means (70; 215) for folding or wrapping around a body limb
or joint thereby to immobilise said limb or joint; and
      water-permeable material (24,44), impregnated with
water-activated, hardenable material and associated with said sleeve
means (70; 215), said water-permeable material (24,44) conforming to
said limb or joint when activated,
characterised in that said assembly (10; 200) further comprises:
      one or more water and air impervious elongate pouches (12,42;
210), each of which is mounted as part of said sleeve means (70;215)
and encapsulates said water-permeable material (24,44);
      means (26,56; 242,248) for introducing water into the or each
elongate pouch (12,42; 210) to activate said water-activated,
hardenable material (24,44); and
      means for adjustably securing and releasing said sleeve means
(70; 215) to permit selective loosening and adjustment thereof around
the limb or joint that is to be treated.
2. An assembly (10;200) as claimed in claim 1, wherein said sleeve
means (70; 215) includes cushioning means (72,74) for contacting said
limb or joint and for thermally protecting said limb or joint from any
heat caused by the reaction of said water-activated, hardenable
material with water.
3. An assembly (10; 200) as claimed in claim 1 or claim 2, wherein said
sleeve means (70; 215) is a single elongate member whose longitudinal
edges are releasably secured together by said means for adjustably
securing and releasing said sleeve means (70; 215).
4. An assembly (10; 200) as claimed in any claim 1 or claim 2, wherein
said sleeve means comprises at least two separate elongate parts
foldably or hingedly secured to each other along one longitudinal edge
and releasably secured together along the other longitudinal edge by
said means for adjustably securing and releasing said sleeve means.
5. An assembly (10; 200) as claimed in any preceding claim, wherein
said sleeve means (70; 215) extends at least two thirds of the way
around said limb or joint that is to be treated.
6. An assembly (10; 200) as claimed in any preceding claim, wherein
said sleeve means (70; 215) has a generally U-shaped configuration.
7. An assembly (10; 200) as claimed in any preceding claim, wherein
said means for adjustably securing and releasing said sleeve means
comprises one or more straps (84,86,88,98; 262,264,266,272,274,276).
8. An assembly (10; 200) as claimed in claim 7, wherein the or each
strap (84,86,88,98; 262,264,266,272,274,276) comprises VELCRO material.
9. An assembly (10; 200) as claimed in claim 7 or 8, the or each strap
(84,86,88,98; 262,264,266,272,274,276) is received in corresponding
loops (92,94,96; 263,265,267,273,275,277).
10. An assembly (10; 200) as claimed in claim 7, 8 or 9, wherein the or
each strap (84,86,88,98; 262,264,266,272,274,276) extends only part of
the way around the assembly (10; 200), preferably less than half way
around said assembly (10; 200).
11. An assembly (10; 200) as claimed in any preceding claim, wherein
said means for introducing water includes an inlet port (26,56;
242,248) on the outer surface of said assembly (10; 200) and means for
directing water to contact the entire contents of said pouch.
12. An assembly (10; 200) as claimed in any preceding claim, wherein
said means for directing water is an apertured plastics sheet (22)
located in the or each pouch (12,42; 210) adjacent said water-permeable
material (24,44).
13. An assembly (10; 200) as claimed in any preceding claim, wherein
the or each pouch (12,42; 210) is removably mounted on said sleeve (70;
215).
14. An assembly (10; 200) as claimed in any preceding claim, wherein
the or each pouch (12,42; 210) is filled with a moisture-free gas.
15. An assembly (10; 200) as claimed in any preceding claim, wherein
the or each pouch (12,42; 210) is formed of successive layers of foil
and plastic.
16. An assembly (10; 200) as claimed in any preceding claim, wherein
said assembly (10; 200) further comprises splinting means (30,50;
230,232,234).
17. An assembly (10; 200) as claimed in claim 16, wherein said
splinting means (30,50; 230,232,234) is at least one bendable rib
member (34,50; 231,233,235).
18. An assembly (10; 200) as claimed in claim 17, wherein the or each
rib member (34,50; 231,233,235) is removably secured to said assembly
(10; 200).
19. An assembly (10; 200) as claimed in any preceding claim, wherein
said water hardenable material is a urethane compound.
20. An assembly (10; 200) as claimed in any preceding claim, wherein
said water-permeable material (24,44) is a water-permeable matrix.

DESCRIPTION:
This invention relates to a soft-goods type, formable orthopaedic cast,
of the type used for immobilizing body limbs or joints.
A traditional orthopaedic cast uses bandages loaded with Plaster of
Paris, which is then wrapped around the body limb which is injured or
broken. The traditional Plaster of Paris cast is bulky, weighty and
very uncomfortable for the wearer. Many techniques and systems have
been proposed either to cut down on the weight, decrease the bulkiness
or improve the comfort for the user. In addition, attempts have been
made to design and make portable casts which are to be used at the site
of an accident for quick reaction to injuries. Certain casts and
systems of this type are set forth in U.S. Patents Nos. 3,375,822;
3,643,656; 4,483,332; 4,537,147, and 4,683,877. While in whole or in
part these patented orthopaedic cast systems have claimed lightweight
or portability or an improved method as compared with Plaster of Paris
casts, in fact, many have not lived up to their promise. In the cases
noted above it appears that these cited references herein have reduced
weight, but not comfort, or in many instances ease of use has been
sacrificed. Also, none present the opportunity to remove the cast
during use for cleansing the body limb, for comfort, and for improved
X-ray examination.
In particular, US-A-4683877 discloses a casting article which is
arranged to envelop the body part to be treated. The article comprises
a layer of foam covered with fabric and is impregnated with a resin
which is curable, preferably in water. In use, the article is contacted
with water and is held in place around the body part until the resin
cures and the cast sets. US-A-3643656 discloses a water impervious cast
having a rigid outer wall and an inner foam layer which form between
them a cavity. This cavity is filled with freon-blown polyurethane foam
which hardens to conform with the outer surface of the limb to be
treated. US-A-3674021 relates to an elongate bandage for wrapping
around a limb to be treated. The bandage includes a layer of plastic
resin and a layer of a hardener or catalyst, separated by a barrier
layer. Manipulation of the bandage causes the barrier to open, thereby
exposing the resin to the hardener and causing the bandage to set.
Accordingly, principal objectives of the present invention are to
provide an orthopedic cast and splint system which is lightweight,
formable to the body limb and removable for ease of use. In
accomplishing those needs, the invention will also increase the
immobilization and stability of the limb to ensure the prevention of
unneeded movements which could complicate healing.
According to the present invention there is provided a soft goods type
orthopaedic cast assembly, comprising:
      sleeve means for folding or wrapping around a body limb or joint
thereby to immobilize said limb or joint; and
      water-permeable material, impregnated with water-activated,
hardenable material and associated with said sleeve means, said
water-permeable material conforming to said limb or joint when
activated,
characterised in that said assembly, further comprises:
      one or more water and air impervious elongate pouches, each of
which is mounted as part of said sleeve means and encapsulates said
water-permeable material;
      means for introducing water into the or each elongate pouch to
activate said water-activated, hardenable material; and
      means for adjustably securing and releasing said sleeve means to
permit selective loosening and adjustment thereof around the limb or
joint that is to be treated.
The present invention provides a new and improved orthopedic cast which
is foldable or wrappable and lightweight, which can circumferentially
conform to the unique configuration of an individual's limb, and which
is adjustable to accommodate limb swelling and muscle atrophy
variations.
In certain embodiments, the cast has at least one elongate, airtight
pouch containing water-activated, hardenable material, such as, for
example, urethane impregnated in an open cell foam or in a fibrous
matrix, and means for applying the water to reach and activate the
entire urethane impregnated material. The water-activatable urethane
impregnated matrix may be formed of material such as an open cell foam,
honeycomb material, fibreglass, KEVLAR ("KEVLAR" is a trademark),
carbonaceous fibers, or similar materials. The plastic pouch encloses
unpolymerized urethane, which only begins polymerization upon the
introduction of water.
In one embodiment the orthopaedic cast is similar to a soft goods type
orthopaedic brace in that it includes padding and straps for securing
it to a limb or a joint.
In use, the cast wraps around an injured limb, for example, an arm. The
cast surrounds the arm, and, through securing means, constrains and
immobilizes the arm. The injury to the arm such as a break or severe
sprain would need such immobilization to heal. As the wrappable,
foldable and lightweight sleeve wraps around the limb, the or each
airtight pouch can initially conform to the limb configuration. Upon
the secure tightening of the cast, the introduction of water into the
or each pouch will enable the hardenable material, for example urethane
polymer, to polymerize, harden and conform to the limb. While the time
to inject the water into the or each pouch does not have to be
immediately after the application of the cast, it is contemplated that
such injection would be within minutes of the setting of the injured
limb and its immobilization within the cast.
The hardening of the hardenable material, e.g. polymerization of the
urethane, improves the stability of the limb-case combination and
prevents and movement which would interfere with healing. Upon the
occurrence of an injury, the injured limb would be set and wrapped in
the cast. The cast is preferably firmly secured about the limb with the
use of strapping and VELCRO ("VELCRO" is a trademark) pads.
The or each pouch may have a predetermined amount of water injected by
a syringe or other suitable technique. It is contemplated that each
pouch or cast assembly could have a syringe associated with it for
containing the amount of water necessary for polymerization. The
syringe device could be for a one time use. With the syringe containing
the necessary quantity of water, there is be no need for measuring the
necessary water, which could result in too much or too little water
being injected.
The or each pouch should be airtight and moisture-proof, and may be
constructed of multiple layers of materials, typically layers of
plastic and metallic foil. This combination makes the pouches
structurally strong as well as airtight, with the plastic providing the
strength and the foils being airtight. Within the pouches could be one
or more substrates or matrices impregnated with the water-activatable
urethane polymer.
In one embodiment, arrangements are provided for distributing the water
from the inlet port to saturate and activate the entire matrix which is
impregnated with the water-activated hardenable material. This may be
accomplished through the use of a distribution manifold or plenum
separated from the matrix by a perforated plastic sheet. The sheet
distal from the port may be closer to the matrix and have larger holes,
at a higher density, as compared with near the port. Alternatively, a
tree type distribution channel with a series of branching channels may
be provided.
In use, the water is delivered into the pouch cavity by means of the
inlet port, which may include a one-way valve. The water contacts the
perforated plastic surface at a planar level closest to the inlet
opening, and flows through the distribution volume, and the water then
contacts the impregnated substrate or matrix initiating polymerization,
by means of the holes in the plastic sheet. The holes in the plane
closest to the water entry port are preferably the smallest and the
openings remote from the entry port and closest to the substrate
surface are preferably the largest. This arrangement is to ensure that
water flows and contacts the substrate in a uniform manner.
Alternatively, as mentioned above, there could be a water delivery
system wherein the entry port is coupled to tubes which break out in a
tree fashion incorporated within the pouch so that small tubes extend
to all areas of the matrix to ensure uniform contact with the
impregnated matrix.
In accordance with additional embodiments in accordance with the
present invention, the cast may be provided with bendable splint ribs
of aluminum or plastic for initial holding of the limb while the
water-activated hardenable material is being set up. It is also
desirable that the pouches be maintained free of moisture, and this may
be accomplished by manufacture in a dry environment, or by back-filling
the airtight pouches with an inert gas, such as nitrogen. It is also
noted that it is desirable that the cast systems be adjustable and
removable, preferably by having hinge lines in the cast or using
flexible sections of the soft goods assembly, and by the use of straps
having VELCRO securing arrangements. Further, both the pouches and the
bendable splinting members may be mounted in removably closed elongate
pockets in the soft goods cast assembly, so they may be removed and
replaced as desired. The inlet port may have a threaded cap for
resealing, and may be provided with a one-way valve. Alternatively, an
input membrane may be used, with water being injected through the
membrane by the needle of a medical syringe.
For a better understanding of the invention, and to show how the same
may be carried into effect, reference will now be made, by way of
example only, to the accompanying drawings, in which:-
  Figure 1 is a perspective view of a soft goods type cast in
accordance with one embodiment of the present invention, in use on the
right forearm;
  Figure 2 is a perspective view of the cast of Fig. 1 as seen from the
inside of the right forearm;
  Figure 3 is a cross-sectional view through an elongate pouch
containing water-activated hardenable material of the soft goods type
cast of Figs. 1 and 2;
  Figure 4 is a cross-section through plane 4-4 of Fig. 3, with a
detailed view of the pouch configuration;
  Figure 5 is a cross-section through plane 5-5 of Fig. 1;
  Figure 6 illustrates another embodiment in accordance with the
present invention, used on the left leg;
  Figure 7 is a detailed drawing of the soft goods cast of Fig. 6 shown
in its unfolded configuration; and
  Figures 8 and 9 are cross-sectional views showing the removable
nature of the splinting members.
Referring more particularly to the drawings, Figs. 1 and 2 show an
orthopedic cast 10 as it is used to immobilize the right forearm 6.
Fig. 1 shows the back of the right forearm in a perspective view, with
the cast 10 being mounted in place. In particular, it shows the pouch
12 wherein there is contained a water-activated hardenable urethane
impregnated matrix. Water may be injected into the pouch through water
inlet 26. The water activates the urethane polymer, which causes the
elongated pouch to harden and conform to the shape of an individual's
body limb upon the completion of the chemical reaction within pouch 12.
Through the use of VELCRO-covered straps 84,86, 88, the cast 10 is
firmly secured around the limb so that upon the introduction of water,
the activated polymer hardens and takes a form or set providing a
splint that conforms to the configuration of an individual's limb
therein constrained.
Shown in Fig. 1 is splint rib assembly 30, which adds stability and can
additionally be formed to the configuration of the arm and assist in
the immobilization of the limb; and is particularly useful when the
forearm is being initially set prior to the hardening of the urethane
material. The splint rib assembly 30 can be a single splint rib 34 or a
plurality of splint ribs. The splint rib 34 may be formed of a bendable
strip of aluminum or a plastic strip having similar properties.
Fig. 2 is a view of the cast 10 as seen from the inside of forearm 6.
The cast 10 has two airtight pouches, 12 and 42, containing
water-activated urethane impregnated substrates or matrices 24 (as
shown in Figs. 3 and 4). The inside forearm pouch 42 has a splint rib
assembly 50 with rib member 51, having a configuration which is
substantially the same as the splint rib assembly 30 noted on the front
forearm pouch 12, shown in Fig. 1, a water entry port 56 through which
water is injected into the foil and plastic pouch 42 to activate the
urethane polymer and a VELCRO attachment pad 99.
For further immobilization, the strap 98 having VELCRO attached thereto
is swung through the hand 8 and attached to VELCRO pad 99. This further
assists immobilization and securing of the soft goods splint in the
desired position on the forearm. As shown in Fig. 2, there are hinged
or pivotally mounted metal loops 92, 94, 96 through which the straps
84, 86, 88 loop to adjustably secure the cast circumscribably to the
limb. The metal loops 92, 94, 96 are attached to the cast assembly by
fabric loops 93, 95, 97. The cast body as indicated by reference
numeral 70 in Fig. 1 is lined with foam material for comfort, and the
unit is stitched closed around its circumferal edges with beads of
fabric as indicated at reference numerals 76 and 78 in Fig. 2.
Fig. 3 shows a cross-section of the pouch 12 from an orientation
perpendicular to the arm 6 and shows the aluminum splint rib 34 covered
with vinyl covering and padding 32. The covering could also be a sheet
of vinyl or other tear resistant fabric without any padding. The
elongated pouch 12 has an outside covering of vinyl 14 which is
impervious to water. Water is injected into the interior 20 of the
pouch 12 through input port 26 to activate the water-activated urethane
hardenable polymer so that the resultant splint conforms to the
configuration of the limb to which it is applied.
Fig. 4 shows a detailed cross-section through Plane IV of the pouch of
Fig. 3. The pouch 12 contains the substrate or matrix 24 impregnated
with the water-activated urethane polymer. The pouch in which the
impregnated substrate or matrix is enclosed, is mounted on the outer
surface 71 of the cast sleeve 70. The interior of the pouch 20 contains
substrate or matrix 24 impregnated with water-activated urethane
polymer, and a substantially parallel apertured plastic sheet 22 which
delivers a uniform water flow to activate the urethane polymer
impregnated into matrix 24.
Inlet 26 has a removable cap 29 attachable to stem 27, with a water
entry canal 28 contained therein. Optional one-way valving action may
be provided by plastic flap 31. A water injecting means such as a
syringe, is coupled to water canal 28 through which a pre-determined
fixed quantity of water is injected, so that the water comes into
contact with, and is distributed by, apertured plastic sheet 22. The
predetermined quantity of water could be supplied by a syringe which
would inject the requisite water into the pouch. Sheet 22 runs
generally parallel to the surface of matrix 24. It is desirable that
water applied to inlet port 26 be uniformly applied to the matrix 24 to
activate and harden the entire urethane impregnation. To facilitate
this action, the plastic sheet material 22, which need only be a few
thousandths of an inch thick, may be slightly further from matrix 24
adjacent inlet port 26, and may have fewer and smaller holes near the
port 26 than at the two remote ends of the pouch. The sheet plastic
element 69 may block direct flow of water through sheet 22 and may also
hold the adjacent portion of sheet 22 further away from matrix 24.
Substrate or matrix 24 can be impregnated open cell foam, fiberglass,
or any other suitable carrier material for the urethane polymer. A
honeycomb structure or a matrix of KEVLAR or other high strength fibers
of the types used in sports gear, could also be employed, impreganted
with water-activated hardenable material, and having an open
configuration to receive the water for activation.
The pouch 12 is mounted on the surface 71 of the sleeve 70, on a
surface opposite to that which contacts the surface of the limb. The
pouch 12 has a surface of vinyl 14 which is impervious to water.
Beneath that is padding 16, and beneath the layer of padding 16 is a
composite layer 18 which may be formed of several layers of foil and
plastic alternated with one another, which is impervious to water and
which completely encapsulates the interior 20. The composite layer 18
is airtight. Underneath composite layer 18 is a thin perforated plastic
sheet 22. Typically the foil included in layer 18 will be made out of
metals which are non-reactive to the urethane chemical reactions. The
pouch 12 is mounted on vinyl surface 71 which has padding foam 74 and
which may have a thin tricot material layer 72 which engages the skin
of the limb 6. This material will allow a certain amount of air to flow
to the skin, and the tricot is soft to the touch. Between tricot
surface 72 and foam 74 can be an additional layer of insulating
material (not shown) to further protect the limb from any heat of
reaction that could occur by the introduction of water into the foil
pouch 12. While small pouches such as those that are used with an arm
cast would normally not have a problem with heat reaction, some of the
large embodiments such as that indicated in Fig. 6, for use on a leg,
may generate sufficient heat which could cause discomfort to the
wearer. In such cases, a protective insulated layer may be appropriate.
Fig. 5 shows a cross-section of the soft goods cast as it would appear
on the right forearm 6. The cross-sectional view shows two pouches 12
and 42 sitting approximately parallel to each other on the arm. Fig. 5
shows how the cast 10 takes the shape of the arm. Securing strap 84
loops through the strapping hinge loop 96. Cast 10 with exterior 71
which is made of vinyl or other water impervious material, padding 74,
and interior 72, can be removed and replaced onto the arm to permit
washing of the arm, and can be adjusted in size to accommodate changes
in the arm involving reduction in swelling or slight muscle atrophy,
for example.
Aluminum or bendable plastic splint ribs 34 and 51 can be made
removable or permanent within the cast assembly. Additional rib members
could be introduced on top of pouch 12 as well within the body of the
cast 10 in areas below the foil pouches or in an area opposite to the
velcro strapping within the padding area 74. In alternative
embodiments, additional ribs can be added or removed depending on the
severity of the injury to the limb or to obtain a desired degree of
immobilization and stability. The splint ribs 34 and 51 are
particularly helpful prior to water activation of the major splinting
members in the pouch or pouches.
Fig. 6 illustrates another embodiment in accordance with the present
invention, which is used on the leg and which is shown in use on the
left leg. It runs from the ankle portion 302 to just below the left
buttock at 300. Obviously, the cast itself will be much larger than
that shown in Figs. 1-5, and utilizes one long continuous pouch 210
which will have two entry ports 242 and 248 for the introduction of
water, or there could be a plurality of individual smaller foil plastic
pouches. A predetermined quantity of water is injected into water ports
242 and 248 of the pouch 210. Pouch 210 encapsulates a urethane
impregnated substrate or matrix as noted above. For stability and
immobilization, before activation of the water hardening material,
there can be a single aluminum splint rib 231 which runs along the
surface of the foil plastic pouch 210, or a plurality of aluminum
splint ribs could be employed. The nature of the injury and constraint
desired would determine the number of splint ribs.
The cast 200 is shown in more detail in Fig. 7., where it is shown in a
flattened or unwrapped configuration. The strapping means shown could
be secured by various means such as VELCRO, buckles, hooks, tying or
any means to secure the cast around a limb. The number of securing
belts utilized on cast 200 is indicated by strapping 262, 264, 266,
272, 274, 276 which have mating attaching metal loops 277, 275, 273,
267, 265, 263 where each is located opposite to the other. The number
of securing straps can vary depending on the size of the limb or the
degree of immobilization and stability desired or required. As noted
previously, additional aluminum or plastic splint ribs can be
introduced as shown in Fig. 7. Splint ribs 233, 231, 235, with mating
vinyl pockets or padding which cover the splint ribs, can be added as
needed. In the embodiment here shown, the splint ribs 231, 233, 235,
and pouch 210 are permanent. In other instances, these ribs and the
hardened urethane splint and pouch assemblies can be removable, as
discussed below. The foil plastic pouch 210 has two water entry ports
or valves 248 and 242 into which pre-determined amounts of water are
injected for activation of the water-activated urethane, as noted
above. The cast surface 215 on which the foil plastic pouch is mounted,
can be of a waterproof material, typically of vinyl, or any other water
impervious material. Underneath, the construction would be the same as
shown above, with foam padding, tricot material, and with a stitched
nylon lip 214 around the edge. The cast 200 has a cut-out to conform to
the knee of the individual. Obviously, the cast will come in various
sizes and have the necessary cut-outs for each limb or joint
configuration. Also, the casts for legs, ankles, wrists, and the like
will vary according to a person's size and age.
Figures 8 and 9 showed alternative arrangements at the ends of the
splinting elements, so that they are removable. More specifically, with
reference to Fig. 8, the padded base layer 74 has the airtight pouch
assembly 402 mounted thereon, and secured in place by the outer
elongated enclosing sleeve 404. At one end of the pouch 402, which
becomes a splint when activated, the material of the sleeve 404 is
removably secured to the base layer 74 by matching VELCRO pads 406
which are on the inner surface of the end closure 408 of sleeve 404,
and on the outer surface of base layer 74. Accordingly, if it is
desired to change the splint configurartion, due to a reduction in
swelling off the limb, or for other medical reasons, the hardened
splint pouch 402 may be removed, and a new one reinserted. For use with
this type of removable pouch, a flush inlet port would be provided.
Figure 9 shows a similar alternative arrangement for splinting stays,
such as those shown at 233 and 235 in Figure 7. More particularly, an
underlying base member 422 may have an aluminum or bendable plastic
splinting stay 424 secured to it by the flexible sleeve 426. The end
closure 428 may be removably secured to the base member 422 by matching
VELCRO pads 430 so that the splinting stay 424 may be removed.
Thus, as indicated in Figs. 8 and 9, the cast units of Figs. 1-7 may be
modified and adapted to different needs and conditions by selective
removal and replacement of the splinting elements, either for the same
patient and condition, or for different patients.
Incidentally, regarding the nature of the water hardenable material, it
may be a urethane type material as described in U.S. Patent Nos.
4,376,438; 4,433,680; 4,442,833; 4,502,479 and 4,683,877. It is
available from W. R. Grace under their identification FHP2000. Other
water hardenable materials could also be used.
In other, alternative embodiments, instead of using foil plastic
pouches on the surface of the cast, they could be incorporated within
the cast material between the surfaces 72 and 71. In addition, the
various ribs as indicated above can be removable and constructed of
bendable plastic, which is similar to aluminum in its mechanical
properties. There can be many tie systems and many configurations for
the cast. Instead of layers of foil and plastic, a single layer of an
impervious flexible material could be employed in the construction of
the pouches. The use of a flexible wide zipper would have a different
configuration than that illustrated; and overlapping VELCRO-covered
portions on the fabric of the body of the soft goods cast could be used
to hold the unit in place. Also, the configuration of the cast for an
elbow would be much different than for a leg or a section of an arm. In
addition, the orthopedic cast's function should not be limited to
humans, but can be utilized on animals such domestic animals as dogs
and cats, and for the use with farm animals, such as horses, cows and
so forth. The veterinary uses as well as the medical uses of the
invention are self-evident and are not to be limited in any way to a
suggested specific animal or human use.