Patent ID: 7749423
Filing Date: 2010-07-06
Classification: A61F

Abstract:
1. The method of producing the orthotic brace comprising an orthotic shell having a load bearing frame integrally formed therewith, said method comprising the steps of: creating an anatomical mold or cast of that portion of the patient's anatomy upon which the orthotic brace or prosthetic device is to be applied; applying at least one inner layer of nonstick separation material to at least a portion of the surface of the anatomical mold or cast; applying at least one layer of epoxy resin to at least a portion of the nonstick separation material; applying at least one layer of substrate shell forming fabric to at least a portion of the surface of the epoxy resin; compressing an elongated load bearing frame forming multidirectional braid member longitudinally against a portion of the outer surface of said layer of substrate shell forming fabric; applying at least one outer layer of nonstick separation material to at least a portion of the substrate shell forming fabric; ventilating the outer layer of nonstick separation material; applying at least one layer of a first porous material to the ventilated outer layer of nonstick separation material; placing the anatomical mold or cast into a heat resistance enclosure; placing the enclosed anatomical mold or cast in a treatment chamber; creating a vacuum in the treatment chamber; heating the interior of the treatment chamber to melt the epoxy resin and impregnate the substrate shell forming fabric with liquid epoxy resin; allowing the resin impregnated shell to harden; removing the anatomical mold or cast from the treatment chamber; removing the layer of the first porous material and the outer layer of nonstick separation material from the resin impregnated shell and elongated multidirectional braid member; removing the resin impregnated shell and elongated multidirectional braid member from the anatomical mold or cast; shaping the resin impregnated shell and elongated multidirectional braid to form the orthotic brace or the prosthetic device.