Patent ID: 6186966
Filing Date: 2001-02-13
Classification: A61F,D04B,D10B

Abstract:
An orthopaedic method comprising the steps of:a) forming an integral double layer fabric having spaced interwoven layers formed of high strength filaments and an open-work matrix of filaments interconnecting said layers, said high strength filaments being selected from the group consisting of fiberglass, aramids, and carbon fibers, said fabric further including at least 20% by weight of thermoplastic fibers; said method including forming said integral double layer fabric including an upper layer and a lower layer and said open work matrix of filaments, in a single manufacturing step with said filaments being woven or knitted into both said upper and said lower layer, to space said layers apart;b) impregnating said open-work matrix of filaments with a water-hardenable material under low humidity conditions, while retaining the configuration of said matrix permeable to receive water;c) applying a water resistant layer of padding material to one side of said fabric and a layer of porous plastic on the other side thereof, to form a support assembly, said padding material having a cloth outer surface for engaging the skin;d) packaging said assembly in a water vapor impermeable package;e) subsequently opening said package;f) supplying water to said open-work matrix through said porous layer following opening of said package to rapidly wet said water-hardenable material; andg) locating the assembly including the impregnated double layer material adjacent the injured part of the anatomy so that said material conforms to the configuration of the anatomy, with the layer of padding material adjacent the skin;whereby the open-work matrix of said double layer fabric facilitates rapid and uniform impregnation by the water-hardenable material, 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, and wherein the combination of high strength fibers and thermoplastic material permits concurrent cutting and heat bonding of the edges of the fabric.