Quick deployment cast

A quick deployment cast comprises a flexible outer sleeve fitted for a human appendage. The cast has a bladder network within the sleeve, a fluid capable of expanding and hardening when in the presence of a curing agent, stored within the bladder network and a mechanism for exposing the fluid to the curing agent.

TECHNICAL FIELD

This invention relates to casts in medical applications in orthopedics, including specific applications for military field use and prevention of compartment syndrome. Utilizing a method and device along with an algorithm comparing normative and patient-specific data, the user and practitioner are provided with early detection for complications associated with immobilizing a traumatized limb.

BACKGROUND OF THE INVENTION

The subject invention generally relates to casting, monitoring, alerting and removing casting materials. Typically, application and removal of casts on a broken or sprained limb requires special tools, materials and expertise. These present challenges including superficial and cosmetic inconveniences, in addition to life-threatening and longer-term risks, such as lung cancers from chronic inhalation of fiberglass shavings. Additionally, trauma and compression of a limb through casting can lead to compartment syndrome which can require procedures that present significant risk and downside for the patient and orthopedic community.

BRIEF SUMMARY OF EMBODIMENTS OF THE INVENTION

According to one embodiment of the invention,

DETAILED DESCRIPTION OF THE EMBODIMENTS OF THE INVENTION

From time-to-time, the present invention is described herein in terms of example environments. Description in terms of these environments is provided to allow the various features and embodiments of the invention to be portrayed in the context of an exemplary application. After reading this description, it will become apparent to one of ordinary skill in the art how the invention can be implemented in different and alternative environments.

The following terms are used throughout this document:

check valve ports15

The present invention is directed toward a cast10or splint or tourniquet for a broken or traumatized limb that may be quickly and easily deployed in the battlefield or any other environment that is remote from a hospital. The invention may also be used in a hospital or clinic environment. The quick deployment cast10may be used as a tourniquet, with desired pressure being selected, thereby allowing the device to expand to create greater tension/pressure against the limb.

In a variant, referring toFIGS. 1-5 and 10-12, the cast comprises a sleeve20having a graphene fabric outer covering. The cast is pulled onto the wearer's limb similar to pulling on a sock. The cast includes a number of check valve ports15and a number of balloon ports25. The valves15have a release mechanism18that when actuated permit air to enter the valve and enter bladder tubes30. The cast10has a framework consisting of a web or network of bladder tubes30(which preferably are made of a graphene material) that is covered by the fabric outer covering, which is graphene or other fabric. The bladder network30may be oriented in any combination of patterns, including but not limited to double, triple or quadruple helical, with one set of tubes running parallel and another helical set intersecting the first set a various points.

Referring also toFIGS. 13-14, the bladder tubes30, which are in fluid communication with the check valve15and balloon ports25, contain a polyurethane gel35. The polyurethane gel expands to a multiple of its initial volume (depending on desired properties like rigidity) when exposed to air. Referring toFIG. 3, when the cast is stored in a state ready for use, the interiors of the tubes30containing the gel are kept at near vacuum, with the check valves15closed, and the overall device compressed like a spring.

In an optional variant, a cellulose sponge is embedded in the bladder network30, and the sponge is soaked in the polyurethane gel. In a variant, the sponge is a dehydrated, compressed cellulose sponge. The soaked sponge and polyurethane gel are activated by water that is introduced from reservoirs atop the check-valves when the sleeve is pulled onto the limb, similar to the variant having polyurethane and graphene spires within the bladder. The bladder tubes30, which are in fluid communication with the check valve15and balloon ports25, contain the sponge soaked polyurethane gel35, and the sponge-gel may expand to a multiple of 3 to 4 times (or more) its initial volume when exposed to water.

In a variant, referring toFIGS. 4 and 5, when the cast is pulled onto a wearer's arm, the check valves15automatically open so that air enters the bladder tubes and the polyurethane gel expands and cures so that a rigid or semi-rigid cast is formed.FIGS. 4-5, show the bladders partially cut away for the purpose of illustrating the presence of the polyurethane gel35inside the bladders30. Optionally, the valves15may be manually opened.

In another variant, referring toFIG. 8, the bladder tube framework may also contain sensors40for detecting tension or pressure, so that when the proper tension on the bladder tubes is reached, the excess or surplus polyurethane may be directed into balloons45which are housed in balloon ports25as illustrated inFIGS. 6 and 7. After the polyurethane cures, the user may snap the balloons off of the cast manually.

In yet another variant, the sensors40also monitor conditions of the cast and the user's limb, such as the integrity, shape and pressure of the cast. Additionally, bio-sensors including, but not limited to pH, pulse, blood-flow, blood oxygen are monitored. The sensors40communicate this information to a portable device, such as a smart phone with close-in communication software, which transmits this data to a hospital or other location for monitoring of the patient and cast. Optionally, the cast10may function without a sleeve20. Optionally, the sleeve comprises a flexible compression-sock fabric.

Data derived from monitoring bio-sensor feedback across a volume of users serves as a constantly updating normative baseline for casting metrics and then reconciled with the individual user's baseline to achieve an optimal fit, with proper pressure. An algorithm(s) is derived and serves as a proper casting standard and an early warning to complications of casting. An example would include, but not be limited to, compartment syndrome. The problems that would be addressed are the latitude and variability in traditional casting methods and lack of uniform standards, and the resulting inconsistency and inability to predict complications. In a variant, a processor and memory has computer readable instructions stored thereon configured to cause the processor to receive data from the sensors to determine and monitor proper fit of the cast, progression of healing, and along with the patient's individual baselines normative sensor data, can issue an early warning of complications based on the objective.

In one example embodiment, once deployed, the cast begins collecting data, and when the desired pressure is achieved and the cast is hardened and set, the data set collected, along with normative data, and an algorithm, becomes the baseline for this specific incident. Once deployed, the sensors continue monitoring for deviations from the baseline, so that the cast can alert a monitoring practitioner to problems. In one example, a combination of a decrease in blood oxygen levels at the distal casting point, a weaker pulse, lower blood pressure, decreased pH, and other bio-data that runs automatically through an algorithm, determines via the processor, the earliest possible point, whether there is a threat of compartment syndrome.

Graphene wires55or spires are also housed within the bladder tubes and are electrically conductive. The wires55may be graphene, graphene composite or graphene oxide or other electrically conductive materials. Electronic pulses or vibrations, for example, at low frequency, may be provided through the wires55within the bladder network30to promote healing of the broken bone.

In a variant, referring toFIG. 15, to remove the cast, the user pulls two or more wires60that cause the outer covering to separate along seams65. This is analogous to pulling a full-length-pin out of a very long, curved hinge. As a result, the cast comes apart so that the user may easily remove it. In a variant, referring toFIG. 9, a zipper mechanism may be configured to hold together or allow separation of the seams65, thus providing a mechanism for removing the cast.

The cast may be constructed in a number of alternative configurations, such as, for example illustrated inFIG. 10, a hinged knee brace70inserted in bilateral sleeves75between two casts and/or a body cast embodiment.