Edge binding for orthopedic supports and method of using same

An orthopedic support includes a sheet of flexible material having a proximal edge and a distal edge configured to extend at least partially around a portion of the wearer's anatomy and a pair of opposing lateral edges configured to at least partially enclose the portion of the wearer's anatomy. The orthopedic support includes at least one strap attached to the sheet of material and configured to extend over one of the lateral edges, wherein the strap comprises an associated fastening element configured to attach to the sheet of material so as to secure the sheet about the portion of the wearer's anatomy. The orthopedic support further includes an edge binding molded to an edge of the sheet of material.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Embodiments of the present invention are related to the field of orthopedic supports, and more particularly, to orthopedic supports having edge binding for increasing comfort and/or support for the wearer during use.

2. Description of Related Art

Current techniques for binding edges for orthopedic braces include, for example, stitching the edges of the brace material to form a seam. However, stitching may potentially loosen or snag, which may result in unraveling of the edges of the brace material. In addition, the stitching seams may be irritating to the skin when improperly secured to the brace material. Furthermore, stitching often requires additional fabrication steps and material that could be avoided, such as applying an extra piece of material along the peripheral edges of the brace material and then using thread to stitch the extra piece of material to the brace material.

Techniques have been developed to utilize flexible or polymeric material to bind the edges of a material to prevent fraying. For example, U.S. Pat. No. 6,482,167 to Grim et al. discloses a technique for forming orthopedic supports that includes impregnating the edges of casting material with a non-rigid bonding material, such as a flexible urethane or silicone rubber. The casting material is impregnated with water hardenable material such that the casting material forms a rigid and stiff construction. As a result, the bonding material aids in reducing irritation of the skin and prevents the casting material from fraying.

Moreover, stays or splints, which are used to provide support for the injured joint, are typically inserted within pockets or secured to the brace with additional fabric using stitching and the like. Techniques have been developed to reduce the amount of material and steps to construct an orthopedic support. For example, U.S. Pat. No. 6,024,712 to Iglesias et al. discloses orthopedic supports having a flexible sheet material and an exo-skeleton that is molded directly onto the flexible sheet material. The exo-structure is applied by injection molding to stiffen the support. As such, the exo-structure is typically a plastic that melts and permeates into the pores of the sheet material such that the plastic bonds to the sheet material after cooling.

Despite these improvements in reducing fabrication materials and steps, additional innovations in orthopedic supports to promote better comfort and/or support for the wearer are also desired. In particular, although techniques other than stitching have been utilized to bind the edges of material, edge binding that is conducive for orthopedic supports having soft and flexible laminate or non-laminate materials is desired. Moreover, despite methods for stiffening orthopedic supports, improvements in adding stays or splints to stiffen the orthopedic support and provide support for the wearer is desired.

It would therefore be advantageous to provide an orthopedic support that imparts increased comfort and/or support for the wearer. In addition, it would be advantageous to provide an orthopedic support that includes edge binding that is capable of exhibiting rigidity or pliability for various orthopedic applications.

BRIEF SUMMARY OF THE INVENTION

Embodiments of the present invention address the above needs and achieve other advantages by providing an orthopedic support for supporting a portion of a limb of the wearer. The orthopedic support generally includes a sheet of flexible material for conforming to a portion of the wearer's anatomy, as well as straps and associated fastening elements for securing the sheet of material on the wearer. The support includes edge binding that may be secured at various locations on the sheet of material to provide comfort and/or support, as well as rehabilitate the supported area. The edge binding is preferably a polymeric material capable of exhibiting rigidity or pliability.

In one embodiment, a knee support of the present invention includes a sheet of material including a plurality of straps for securing the sheet of material about a wearer's knee. The knee support includes at least one stay secured to an edge of an opening defined in the sheet of material to provide support and rehabilitation to the wearer's knee.

The sheet of material, according to one variation of the present invention, is generally rectangular and includes opposing lateral edges and opposing proximal and distal edges. The sheet of material is configured to wrap about a wearer's knee between the thigh and calf, and may include a patellar opening for accommodating a wearer's patella. The sheet of material could be a laminate or non-laminate material.

The knee support includes a plurality of straps that may be formed integral to the sheet of material. Typically, a pair of straps extends from a first lateral edge and proximate to each of the proximal and distal edges of the sheet of material, while a third strap extends from an opposite lateral edge approximately midway between the top and bottom edges. Each of the straps includes fastening elements on a free end that attaches to complementary fastening material on the sheet of material.

The knee support may also include a plurality of bladders interconnected with conduit that carries air supplied by a pump to each of the interconnected bladders. The inflatable bladder typically includes a pump operable to inflate the bladder to a desired pressure, as well as a release valve for selectively releasing pressure from the bladder. The bladder may include a patellar bladder that substantially encircles the patella, as well as medial and lateral bladders that extend on respective medial and lateral sides of the knee. Furthermore, each of the medial and lateral bladders may be configured to extend adjacent to at least one stay. In one variation, the knee support includes a bladder cover secured to an inner surface of the sheet of material that encloses the bladder and secures the bladder in a predetermined position.

The knee support includes at least one stay secured to an edge of an opening defined in the sheet of material. In one aspect, the knee support includes a plurality of stays. At least one stay typically extends on each of the medial and lateral sides of the wearer's knee. A pair of stays may be aligned approximately end-to-end in a proximal-distal direction, although a small gap is usually located between each pair of stays. Moreover, each stay may be configured to conform to the natural flexion of the knee between the thigh and calf. Each stay may also include thinner material portions or openings defined therein. In addition, each stay is typically injection molded within a respective opening.

The knee support could include an edge material secured about the outer periphery of the sheet of material and/or a patellar opening. The edge material engages the edges of the sheet of material. The edge material is generally a soft polymeric material that does not reduce the pliability or flexibility of the sheet. The edge material may be injection or compression molded to the sheet of material.

Embodiments of the present invention may provide many advantages. For instance, the edge binding may be secured to the edges of the sheet of material for increasing comfort and/or support. Moreover, the edge binding eliminates additional material and fabrication steps to manufacture orthopedic supports, such as by eliminating stitching and pockets. The edge binding may be pliable and flexible or semi-rigid such that the edge binding is adaptable for various degrees of flexibility, support, and rehabilitation. Furthermore, the edge binding is adaptable for different orthopedic supports, such as a knee support.

The edge binding is capable of “grabbing” the edges of the sheet of material such that the edge binding may be secured to any number of locations on the sheet of material. In particular, the edge binding may be secured about the edges of the sheet of material to prevent fraying. The edge binding may be pliable such that the flexibility of sheet of material is not sacrificed. Another embodiment of the present invention provides edge binding configured as stays that may be formed at various locations on orthopedic supports for increasing support. The stays may be secured to the sheet of material within openings defined in the sheet of material by grabbing the edges of the openings. In addition, the positioning of the stays is capable of increasing the rehabilitative effects of various supports, such as by supporting the medial and lateral sides of the knee.

DETAILED DESCRIPTION OF THE INVENTION

Generally, embodiments of the present invention provide an orthopedic support that includes a sheet of flexible material for wrapping about and conforming to a portion of a wearer's anatomy. One or more straps having a fastening element thereon are configured for securing the sheet of material about the wearer's anatomy. In addition, the orthopedic support includes edge binding, generally polymeric material, that may be secured to the sheet of material at various locations. The edge binding is capable of binding to the edges of the sheet of material to provide the wearer with increased comfort and/or support depending on the properties of the polymeric material selected.

Thus, the term “edge binding” is not meant to be limiting, as the edge binding could be configured as a rigid or semi-rigid member, such as stays or splints for increasing the rigidity and support of the orthopedic support. In addition, the edge binding could be a soft and flexible material, such as edge material that is secured to the outer edges and/or openings defined within the sheet of material to prevent fraying and irritation of the skin. Therefore, the edge binding is adaptable for use with various orthopedic supports. The orthopedic support could be worn on a limb or portions of a limb of a wearer, such as, for example, on a wrist, knee, elbow, back, arm, forearm, leg, or thigh.

Referring now to the drawings and, in particular, toFIG. 1, there is shown a knee support10. The knee support10is designed to wrap around a wearer's knee between the wearer's thigh and calf. The knee support10is adjustable with a plurality of straps that allow the knee support to be custom fitted depending on the size of the wearer's leg. In addition, the knee support10is easy to fit and remove, as the knee support is a generally planar structure that is wrapped around the wearer's leg instead of being pulled up the wearer's leg like a sleeve.

As shown inFIG. 1, the knee support10according to one embodiment includes a sheet of material12constructed of a laminate material having multiple plies, including a soft, skin-friendly inner layer, a foam middle layer, and an outer layer. Advantageously, the inner layer is worn against the skin and has a low skin irritant, soft feel, and can have moisture-wicking properties, while portions of the outer layer allows attachment of complementary fastening elements30, as discussed below. For example, the sheet of material12could be a laminate of polyester hook engaging loop material, a polyurethane foam, and a polyester jersey knit material.

The sheet of material12includes opposing lateral edges14,16and opposing top and bottom edges18,20, respectively. According to one embodiment, the area defined by the lateral ends and edges is approximately 10″×11″, although the sizing may vary depending on the application and wearer of the knee support10. However, it is preferred that the sheet of material12, as defined above, remains generally rectangular or square in dimension. The lateral edge16is relatively flat or linear and intersects the top18and bottom20edges at approximate right angles. In one embodiment, the opposing top18and bottom20edges are substantially parallel to one another, although a slight taper occurs at a pair of integral straps22,24, as discussed below. The sheet of material12also defines a patellar opening26that is located generally in the center of the sheet of material. The patellar opening26is generally triangular with rounded corners, where the apex of the patellar opening extends distally when the opening is placed over a wearer's patella.

The knee support10includes a pair of laterally extending top and bottom straps22,24, respectively, that are integral with the sheet of material12and extend from the lateral edge14of the sheet of material. In one embodiment, each of the integral straps22,24has a fastening element30attached thereto. The fastening element30preferably includes fastening material on one surface for mating with complementary fastening material on the sheet of material12. As mentioned above, the integral straps22,24have a slightly tapering outer edge. The inner edge of the integral straps22,24is also tapering or curved such that the straps define a gap28therebetween at the lateral edge14of the sheet of material12. The gap28according to one embodiment of the present invention is about 4½ inches at the widest point. Furthermore, integral strap22may be slightly shorter than integral strap24. In this regard, integral strap24is typically placed above the knee and about the wearer's thigh, while the shorter integral strap22is positioned below the knee and about the wearer's calf. In one embodiment, integral strap22is about 7½ inches in length measured from lateral edge14, while integral strap24is about 8 inches in length.

The knee support10also includes a lateral edge strap32that extends from the lateral edge16of the sheet of material12in a direction opposite the integral straps22,24. The lateral edge strap32is positioned approximately midway between the top18and bottom20edges such that the lateral edge strap is capable of wrapping behind a wearer's knee and overlapping the lateral edge14in the gap28defined by the upper and lower integral straps. Unlike the integral straps22,24, the lateral edge strap32is attached to the sheet of material12with stitching. The lateral edge strap32of the knee support10includes a fastening element30attached to its free end. In one embodiment, the lateral edge strap32is approximately 6½ inches in length measured from the lateral edge16.

The aforementioned features of the knee support10are not meant to be limiting, as there may be many modifications in alternative embodiments of the present invention. For instance, there may be any number of integral22,24and lateral edge32straps in various embodiments of the present invention to provide a range of support for the wearer. Thus, there could be one or more integral straps22,24defined along the lateral edge14, and one or more lateral edge straps32defined along the lateral edge16. Furthermore, each of the integral22,24and lateral edge32straps may be various sizes and configurations for accommodating different sizes of wearers. For example, although the lateral edge strap32is shown as being formed of a separate material and affixed to the sheet of material12, the lateral edge strap could be formed integral with the sheet of material.

An outer surface of the sheet of material12includes a fastening material that is complementary to fastening material carried by the fastening elements30. Typically, the fastening material of the fastening elements, as well as the fastening material on the outer surface of the sheet of material12, are constructed of a complementary hook and loop material such as VELCRO®. However, the term “fastening material,” as used herein, denotes any type of chemical, mechanical, or other fastener that allows connection of two separate components, such as snaps, hook and loop connectors, adhesives, buckles, etc. Notably, the fastening material of the fastening elements30(hooks), and the fastening material (loops) of the outer surface of the sheet of material12mate to, and attach with, one another when brought into contact. These fastening materials, therefore, are referred to herein as being complementary.

The opposite surface of the fastening material of the fastening elements30is a flexible polymeric support. The fastening material is attached to the polymeric support with an adhesive or similar attachment technique. Therefore, the polymeric support provides increased support and durability for the fastening elements30, which are typically unsupported. The polymeric support could be a polymeric material, such as polyethylene, and formed by injection molding or compression molding. In one aspect of the present invention, the fastening elements30are secured to a respective strap by injection molding the polymeric support directly to the integral22,24and lateral edge32straps. However, the fastening elements30could be attached with similar techniques or combination of techniques, such as with an adhesive, stitching, RF welding, etc. It is understood that the fastening material of the fastening elements30are not required to be supported by polymeric supports, which is typical of most conventional fastening elements. For a further discussion of the fastening elements, see U.S. patent application Ser. No. 11/609,115, entitled “Fastener Tabs and Strapping System for Orthopedic Supports and Method of Using Same,” which is assigned to the present assignee and incorporated herein by reference.

The knee support10also includes an inflatable bladder34, as shown inFIG. 3. The inflatable bladder34is positioned on an inner surface of the sheet of material12and is encased, or otherwise enclosed, by a bladder cover36, as depicted inFIG. 2. As such, the bladder cover36prevents the inflatable bladder from moving out of a predetermined position on the sheet of material12. The bladder cover36may be any suitable skin-friendly material, such as polyester, nylon, or a polyester/spandex blend.FIG. 2demonstrates that the bladder cover36is configured in a substantially rectangular shape and includes an opening that conforms to the patellar opening26. However, the bladder cover36could be various sizes and configurations in aspects of the present invention. For example, the bladder cover36could substantially cover the entire sheet of material12or only portions of the inflatable bladder.

The bladder cover36is typically attached to the sheet of material12with RF welding, although the bladder cover could be attached to the sheet of material with any suitable technique or combinations of techniques, such as stitching, spray adhesive, adhesive film, etc. For example, the bladder cover36could be pre-coated with a polyurethane adhesive over its entire inner surface. Moreover, the bladder cover36could be attached to the sheet of material12using at least a portion of the inflatable bladder34as an adhesive, such as by RF welding proximate to pin holes38defined in the inflatable bladder. The remaining portions of the bladder cover36could then be secured to the sheet of material12using an adhesive. In addition, the inflatable bladder34could be directly attached to the inner surface of the sheet of material12, or at least partially attached to the sheet of material, such as with RF welding or adhesive.FIGS. 1-3illustrate that pin holes38are employed to locate the inflatable bladder34within the mold and on the sheet of material12prior to securing the bladder cover36to the sheet of material12. An indentation40is formed in both the bladder cover36and the sheet of material12about the periphery of the bladder cover indicating where the bladder cover is secured to the sheet of material.

The inflatable bladder34substantially surrounds the patellar opening26, and may include various configurations of interconnected bladders in fluid communication with one another.FIG. 3depicts an inflatable bladder34having a patellar bladder42and a pair of stay bladders44. In this regard, each of the patellar42and stay44bladders are in fluid communication with one another. The patellar bladder42generally surrounds the patellar opening26and includes a bottom portion46that extends downwardly from the patellar opening. The bottom portion46includes spot welds49that are utilized to define channels and raised portions. Each of the stay bladders44includes channels generally arranged in a C-shape. When the knee brace10is worn, the stay bladders44align with the medial and lateral portions of the knee, as well as stays58, which are discussed in further detail below.

FIG. 3illustrates that a pump50is in fluid communication with the inflatable bladder34. A conduit48carries air supplied by the pump50to each of the stay bladders44. An opening52is defined in the sheet of material12for readily locating and accessing the pump50, as shown inFIGS. 4 and 5. Moreover, the sheet of material12also includes a small hole54that corresponds to the size of a release valve56, such that the release valve protrudes through the hole to remain accessible by the wearer. A washer (not shown) is typically positioned around the circumference of the release valve56to provide support and proper positioning of the release valve. The washer could be injected molded directly to the sheet of material12or be configured to fit over the release valve. Furthermore, a back plate (not shown) is typically employed to support the pump50. The back plate is secured to the pump50, such as with an adhesive, to provide support during operation of the pump.

The inflatable bladder34is formed by RF welding layers of air impermeable material to form the shape shown inFIG. 3. The pump50includes a flexible thermoplastic material having an air inlet hole defined in a surface of the pump. The pump50could have an open-cell foam material encased therein to aid in pumping and replenishing the pump chamber. The pump50operates by covering the air inlet and squeezing the pump such that air is forced into the inflatable bladder34. Air is forced through a check valve, and pressure within the inflatable bladder34causes the check valve to close to prevent air from escaping the bladder through the check valve. The pump50is replenished by uncovering the air inlet hole. Typically, the inflatable bladder34is filled by repeatedly squeezing the pump50until a desired amount of pressure is achieved. Air is released from the bladders by depressing the release valve56.

It is understood that the inflatable bladder34should not be limited to any particular size or configuration shown inFIG. 3. For instance, the inflatable bladder34could be pre-inflated such that a pump50and release valve56are optional. In addition, the inflatable bladder34could include one of a patellar bladder42, stay bladders44, or various other bladders positioned on the sheet of material12. Furthermore, although an inflatable bladder34is preferred, it is understood that various techniques could be used for increasing comfort, such as with foams, gels, pads, or any other suitable cushioning or padding material.

The knee support10also includes a plurality of stays58secured to the sheet of material12. The stays58are generally positioned on opposite sides of the patellar opening26. When the knee support10is secured to the wearer's knee, the stays58are rendered relatively immobile on the medial and lateral sides of the knee and provide reinforcement for the knee. Furthermore, if an inflatable bladder34is employed, the stays58are positioned adjacent to the stay bladders44, as shown inFIG. 3. Thus, the stay bladders44provide increased cushioning and comfort adjacent to the stays58.

FIG. 1demonstrates that a pair of stays58is positioned on each side of the patellar opening26. Each pair of stays58is aligned generally end-to-end, although a small gap is present between each stay. A small circular member61could be positioned within the gap between each pair of stays58. Each pair of stays58is positioned in a proximal-distal direction such that each pair collectively extends along the medial and lateral sides of the knee. As shown, each of the stays58is generally trapezoidal and has an angled edge59, such as 5°-15°, that is biased toward the patellar opening26such that when the knee support10is worn, the stays conform to a more natural position compared to stays that are flat and longitudinal. For example, each of the stays58may be approximately 3 inches in length, 1 inch in width at its wider end, and ½ of an inch at its narrower end. There could be a gap of about ¼ to ½ of an inch between each pair of stays58.

FIGS. 4 and 5illustrate the sheet of material12without the inflatable bladder34or bladder cover36secured thereto. Thus, when secured to the sheet of material12, each of the stays58extends completely through the sheet of material. As shown inFIG. 7, each of the stays58“grabs” the edge of the opening defined through the sheet of material12. In this regard, each of the stays58includes a substantially C-shaped cross section about its perimeter. As a result, each stay58encapsulates an edge62of the sheet of material12about the entire periphery of the opening in the sheet.

FIG. 6shows that each stay58includes a reduced material portion60that is of a reduced thickness compared to the remaining portions of the stay. The reduced material portions60are generally trapezoidal in configuration. The reduced thickness facilitates greater flexibility, lighter weight, and reduced material consumption. As shown inFIG. 5, the opposite surface of the stays58is generally smooth. Thus, the smooth portion of the stays58lies adjacent to the stay bladders44when the inflatable bladder34is secured to the sheet of material12.

The stays58are typically formed of a polymeric material, such as low density polyethylene (“LDPE”). The stays58are semi-flexible such that the stays provide support while also allowing some range of motion during use. The stays58are formed and secured to the sheet of material12with injection molding, compression molding, or similar technique. The inflatable bladder34is positioned on the sheet of material12such that the pin holes38of the inflatable bladder align with the pin holes of the sheet of material and bladder cover36. The pump50and release valve56are also aligned with respective holes52and54defined in the sheet of material12. The inflatable bladder34and bladder cover36are then secured to the sheet of material12with any suitable technique, as described above.

The stays58may be various sizes and configurations in additional aspects of the present invention. For example,FIG. 9illustrates that a single stay58could be positioned on each side of the patellar opening26. Each stay58includes a tapered portion68extending between proximal and distal portions of the stay. Thus, each stay58is longitudinal and unitary, while also including a tapered portion68for promoting flexion and flexibility proximate to the knee joint. Each stay58includes a curvature that substantially aligns with the natural flexion of the knee between the thigh and calf. In addition,FIG. 9illustrates that each stay58includes holes64, which provides similar benefits to the reduced material portions60described above. Similarly,FIG. 10depicts another aspect where each stay58is similar to a pair of stays described with respect toFIGS. 1-8. However, the stays58shown inFIG. 10include a tapered portion68extending between proximal and distal portions such that each stay58is a unitary member. The stays58are also slightly tapered to accommodate the natural flexion of the knee, as discussed previously. The stays58also include slots66to increase flexibility of the knee support10, while also reducing weight and the amount of material required.

Moreover, although the stays58are shown as being generally trapezoidal and including a biased or angled edge that conforms to the natural flexion of the knee, it may also be possible for the stays to be straight if desired. The stays58may also be a solid member such that reduced material portions60, holes64, and/or slots66are not required. Furthermore, there may be any number of stays58in alternative embodiments of the present invention, and the stays may be positioned at any desired location on the sheet of material12. Thus, the stays58are capable of engaging and encapsulating an edge of the sheet of material12within various openings defined in the sheet of material to achieve a desired amount of support. Furthermore, although the stays58are described as being semi-flexible, it is understood that the stays could be rigid in additional aspects of the present invention, such as where further support is required. The circular member61could be various configurations and extend between a pair of stays58, and may be secured to the outside of the sheet of material12or completely through the sheet of material (i.e., similar to the stays) using injection molding. However, the circular member61could also be omitted such that the circular member is optional.

FIG. 8illustrates another embodiment of the present invention wherein a pair of stays58is interconnected with a slotted connector63or hinge. A post57extends from a respective stay and is sized and configured so that the slotted connector63is positioned over each of the posts57. In particular, the slotted connector63is generally a dog-boned shape having two slots65or openings defined to receive a respective post57. The slots65defined in the slotted connector57are sized to allow each of the stays58to pivot and/or slide therein. Thus, each post57is capable of both pivoting and sliding within a respective slot65defined in the slotted connector63. The slots65reduce binding between the posts57and slotted connector63during flexion and extension of the knee. The cooperation of the posts57and slotted connector63provides a “living hinge” that facilitates freedom of movement, i.e., flexion and extension of the knee. The two-point pivot of the stays58and slotted connector63closely mimics the natural flexion of the knee such that the stays provide stability without limiting the motion of the knee. In addition, the configuration of the stays58and slotted connector63reduces the incidence of binding between the slotted connector and the posts57, which allows more freedom of movement of the knee during use. The slotted connector63is typically a polymeric material such as nylon but could be various materials capable of interconnecting the stays.

Additionally,FIGS. 5 and 8show that the posts57extend from the inner surface of the stays58and are typically formed when securing the stays to the sheet of material12. For instance, the stays58and posts57could be formed during the same injection-molding process. The slotted connector63is typically formed in a separate manufacturing process. The slotted connector63would then be positioned over the posts57and the posts pivotally attached thereto, such as by heat staking the posts to mushroom around the slots defined in the slotted connector. As such, the slotted connector63is pivotally attached to the stays58.

It is understood that the slotted connector63and posts57shown inFIG. 8are not meant to be limiting, as the slotted connector and posts could be various sizes and configurations while still providing stability and motion of the knee. Furthermore, the term “slotted connector” is not meant to be limiting, as hinges or similar mechanisms could be employed to interconnect a pair of stays58and provide pivotable and/or sliding motion therebetween. In addition, it is understood that the slotted connector63, stays58, and posts57could be formed with various processes, such as injection molding, and could be formed in the same operation if desired. For a further discussion of the interconnected stays, see U.S. patent application Ser. No. 11/609,105, entitled “Stay Hinge for Orthopedic Supports and Method of Using Same,” which is assigned to the present assignee and incorporated herein by reference.

FIGS. 11 and 12illustrate another embodiment of the present invention. In particular,FIG. 11illustrates a knee support100including an edge material116that is secured about the perimeter of the sheet of material112, whileFIG. 12shows the edge material secured about the edge of the patellar opening126. Thus, the edge material116encapsulates the edges of the sheet of material112in a similar fashion as that shown inFIG. 7. The edge material116is adaptable for use on various thicknesses of sheets of materials112that could be a laminate material (e.g., jersey, foam, and fleece laminate) or non-laminate material. The edge material116is pliable and resistant to fraying such that the edge material does not reduce the flexibility of the sheet of material112or irritate the skin. These characteristics make the edge material116useful for a range of orthopedic applications, such as braces, supports, bandages, straps, etc.

The edge material116is typically a soft and flexible polymeric material. For example, the edge material116could be thermoplastic elastomers such as Versaflex® (GLS Corporation), Dynaflex® (GLS Corporation), or Santoprene® (Advanced Elastomer Systems). Generally, the edge material116is injection molded or compression molded to the edges of the sheet of material112. The edge material116is typically applied into a die in liquid form, compression molded or injection molded to the sheet of material112, and trimmed to remove any excess edge material if required.

It is understood that the edge material116may be various sizes and configurations in aspects of the present invention. For instance, the edge material116may be secured at any number of locations on the sheet of material112, such as proximate to areas that contact the wearer's skin and may be susceptible to irritation. The edge material116may be various thicknesses, and may be configured to provide different material properties, such as a high resistance to friction for preventing movement of the knee support100during use. Furthermore, there may be instances where decreased mobility is desired such that the edge material116is capable of providing rigidity for supporting the knee joint. For instance, the edge material116could be rigid for forming a splint-like support, where the edge material provides support for an injured area, and the sheet of material112remains soft and flexible for comfort.

The knee support10is applied to a wearer's knee area by positioning the support such that the patella registers with the patellar opening26, and then wrapping the integral straps22,24about the wearer's leg such that the upper strap24is positioned above the popliteal region of the knee and attaches to the sheet of material12, and the lower strap22is positioned below the popliteal region and attaches to the sheet of material. The lateral edge strap32is then wrapped behind the knee until the fastening element30of the lateral edge strap overlaps lateral edge14and is secured to the complementary fastening material on the outer surface of the sheet of material12. In this regard, the fastening elements30of the integral straps22,24can be adjusted to the wearer's leg size by releasably securing the fastening elements to the outer surface of the sheet of material12. When properly positioned, the inflatable bladder34provides cushioning and support about the wearer's patella. The flexible stays58provide bending resistance with flexion of the knee and medial/lateral support in order to support the knee area and prevent excessive movement thereof. Furthermore, the inflatable bladder34may be inflated or deflated to a desired pressure to provide cushioning and support on an opposite surface of the flexible stays.

Embodiments of the present invention may provide many advantages. For instance, the edge binding may be secured to the edges of the sheet of material for increasing comfort and/or support. Moreover, the edge binding eliminates additional material and fabrication steps to manufacture orthopedic supports, such as by eliminating stitching and pockets. The edge binding may be pliable and flexible or semi-rigid such that the edge binding is adaptable for various degrees of flexibility, support, and rehabilitation. Furthermore, the edge binding is adaptable for different orthopedic supports, such as a knee support.

The edge binding is capable of “grabbing” the edges of the sheet of material such that the edge binding may be secured to any number of locations on the sheet of material. In particular, the edge binding may be secured about the edges of the sheet of material to prevent fraying. The edge binding may be pliable such that the flexibility of sheet of material is not sacrificed. Moreover, the edge binding may also be configured as stays that may be formed at various locations on orthopedic supports for increasing support. The stays may be secured to the sheet of material within openings defined in the sheet of material by grabbing the edges of the openings. In addition, the positioning of the stays is capable of increasing the rehabilitative effects of various supports, such as by supporting the medial and lateral sides of the knee.