Abstract:
A health product for sports use, in particular a joint support includes a main strap ( 5; 105; 205; 305 ) destined to surround the part of the body to be supported. The main strap includes: a bottom layer ( 2 ) destined to come into contact with the skin of the wearer, an intermediate layer of padding ( 3 ), and a top layer ( 4 ) destined to face outward. The main strap is obtained by die-punching and moulding along the peripheral edge.

Description:
FIELD OF THE INVENTION 
     The present invention refers to the field of products for medical or orthopaedic use for rehabilitation and prevention of injuries. It refers in particular to joint supports, such as splints, wrist braces, straps, thigh braces, ankle braces and the like. The present invention also extends to protective products for sports use, for sports in which there is a high stress on the joint, which must be protected. 
     BACKGROUND OF THE INVENTION 
     Various types of joint support are widely available on the market, such as, for example:
         thumb splints: indicated for dislocations, strains and fractures of the thumb or also for lesions of the thumb ligament in sports injuries;   wrist splints: indicated for dislocations and sprains of the wrist and for carpal tunnel syndrome;   wrist braces: indicated for dislocations, slight lesions and small injuries of the wrist;   epicondylitis straps: indicated for radial and/or medial epicondylitis and tendinitis of the elbow;   corsets: indicated for mild spinal injuries;   thigh braces: indicated for contractures, pulls and sprains of the quadriceps muscle;   knee braces: indicated for injuries of the knee joints;   ankle braces: particularly indicated in control of ankle eversion and inversion of the ankle; and   elastic ankle supports: indicated after mild tibio-tarsal injuries.       

     These joint supports generally include a main strap designed to surround the part of the body in which the joint to be protected is situated. This main strap is made of multilayer material comprising:
         a bottom layer, of anallegic material, destined to come into contact with the skin of the wearer,   a top layer of material suitable for Velcro-type fastening (mutually engageable hooks and loops), and   an intermediate layer of padding consisting of a soft, breathable material.       

     The bottom and top layers are edged and sewn along the whole perimeter of the main band so as to enclose the padding on their inside. 
     Pockets are sewn onto the top layer possibly to contain metal stiffening plates. 
     At one end of the main band a plurality of eyelets are created by cutting. At the other end of the main band a plurality of laces are sewn which are inserted into the respective eyelets so as to close the strap in a tubular shape. 
     Velcro type fastening elements consisting of a plurality of hooks able to engage with the hooked wires of the upper layer of the main strap are sewn to the free end of the main strap. 
     In this manner, by pulling the laces, the strap is suitably tightened around the part of the body on which it is applied and exerts an adequate pressure on the joints which are protected and immobilised. Once the desired pressure has been reached, the Velcro fastening element is applied to the top layer of the strap to keep it closed and suitably tightened. 
     The production procedure for these products is somewhat long, complex and costly because of the various operations of edging and sewing to which both the strap and the laces are subjected. 
     Furthermore, the product obtained presents some drawbacks. In fact it often happens that the laces come into direct contact with the skin, resulting in skin irritations due to the production material of the laces. As a result a further additional element must be provided in the support, in the form of a protective sock, which is sewn to the main strap so as to be interposed between the laces and the wearer&#39;s skin. 
     Furthermore, in the joint supports of the prior art, it is necessary to design the length of the laces to ensure that, when the support is suitably tightened, the Velcro fastening element is situated on the strap and not on the laces on which it has no grip. As a result, joint supports of the prior art are not very versatile and do not adapt well to the different sizes and shapes of the parts of the body to be protected. 
     SUMMARY OF THE INVENTION 
     The object of the present invention is to overcome the drawbacks of the prior art, providing a medical product also for sports use that is versatile, practical, inexpensive and easy to make. 
     These objects are achieved according to the invention with the article and the production method whose characteristics are listed in appended independent claims  1  and  12 , respectively. 
     Advantageous embodiments of the invention are apparent from the dependent claims. 
     The medical product, also for sports use, according to the invention, comprises a main strap designed to surround the part of the body to be supported. The main strap comprises: a bottom layer destined to come into contact with the wearer&#39;s skin, an intermediate layer of padding, and a top layer destined to face outwards. The main strap is obtained from a multilayer sheet obtained by bonding of a plurality of layers of different materials. The multilayer sheet is die-punched and moulded or welded or thermoformed along its outer edge. 
     As an alternative to moulding, welding or heat-forming, the multi-layer sheet can be die-punched cold along its outer edge or part of its outer edge. 
     In this manner the operations of edging and sewing of the outer edge of the strap to contain the padding between the top layer and the bottom layer are eliminated. 
     The tightening laces can advantageously be made in a single piece with said main strap during this stage of die-punching and moulding. Therefore, the tightening laces also have the advantage of having an undersurface of anallergic material and a top surface of material such as to allow Velcro type fastening. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Further characteristics of the invention will be made clearer by the detailed description that follows, referring to purely exemplary and therefore non-limiting embodiments thereof, illustrated in the appended drawings, in which: 
         FIG. 1  is a partially broken off perspective view in cross section, illustrating a multi-layer sheet used to make products according to the invention; 
         FIGS. 2-4  are three top plan views illustrating a strap spread out in three consecutive stages of processing for production of a product according to a first embodiment of the invention which provides a wrist splint; 
         FIG. 5  is a perspective view illustrating the last stage of production of the wrist splint according to the invention; 
         FIGS. 6-8  are three perspective views illustrating the wrist splint of  FIG. 5  in the stages of application and removal from the wearer&#39;s wrist; 
         FIGS. 9-11  are three plan views illustrating a spread-out strap during three successive stages of production of a product according to a second embodiment of the invention which provides a wrist support; 
         FIG. 12  is a perspective view illustrating the final stage of production of the wrist support according to the invention; 
         FIGS. 13-15  are three perspective views illustrating the wrist support of  FIG. 12  in the stages of application to a wearer&#39;s wrist; 
         FIG. 16  is a top plan view illustrating a spread-out strap for realization of a portion of knee support according to a third embodiment of the invention; 
         FIG. 17  is a perspective view illustrating the portion of knee support obtained with the strap of  FIG. 16 , disposed in an open position; 
         FIG. 18  is a perspective view illustrating the portion of knee support in  FIG. 17 , in the closed position; 
         FIGS. 19 and 20  are top plan views illustrating respectively two spread-out straps during two stages of production of a corset according to a fourth embodiment of the invention; and 
         FIG. 21  is a perspective view illustrating a corset obtained with the straps of  FIGS. 19 and 20 . 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     With reference for now to  FIGS. 1-8 , a first embodiment of a product according to the invention, in the form of a wrist splint, illustrated as a whole in  FIG. 5  and denoted by reference numeral  20 , will now be described. 
     Production of the wrist splint  20  and of all the other products according to the invention starts from a flat, multi-layer sheet  1 , as illustrated in  FIG. 1 , which forms the basic element for production of the products according to the invention. The multilayer sheet  1  is made up of several layers of material coupled to one another. Flame bonding is preferably used. The multilayer sheet  1  comprises:
         a bottom layer  2  destined to come into contact with the wearer&#39;s skin,   an intermediate layer of padding  3 , and   a top layer  4  destined to face outward.       

     The bottom layer  2 , being in contact with the skin, must be made of anallergic material, such as cotton fabric. 
     The intermediate layer  3  must be made of a cushioning, breathable material, such as, for example, open-cell foamed plastic material such as polyurethane. (PU). 
     The top layer  4  must have a top surface  40  suitable for a Velcro-type coupling. Therefore, the top surface  40  of the top layer  4  has a plurality of loops able to couple in a fastening relationship with a plurality of matching hooks of a Velcro-type fastening element, as will be described hereunder. 
     For this purpose the top layer  4  can be made of nylon fabric suitably treated so as to obtain an upper surface  40  with a plurality of loops. 
     Flame bonding of the multilayer sheet  1  takes place by feeding from two respective rolls the bottom layer  2  and the intermediate layer  3 , which is made to pass near a flame which heats it on the surface facing the bottom layer  2  to allow bonding thereof. Then, the two layers  2  and  3  are made to pass through a calender which performs bonding. Subsequently, the outside of the intermediate layer  3  is heated by means of a flame and bonded by means of a calender with the top layer  4  fed from a roll. 
     The intermediate layer  3 , made of PU, allows good adhesion with the bottom layer  2  and the top layer  4 , by means of flame bonding. Flame bonding is an example of the types of coupling that can be made between materials. Alternatively there are other methods such as spread or sprayed glue, hot glue, etc. 
     The multi-layer sheet  1 , having a substantially rectangular shape, is fed through a die-punching and pressure moulding machine. Then, the multilayer sheet  1  is compressed between two mould halves which simultaneously perform die-punching and moulding along the pre-established perimeter, so as to obtain a strap  5 , as shown in  FIG. 2 . 
     The strap  5  comprises a substantially rectangular central portion  6 . The longer sides of the central portion  6  follow the longitudinal direction of the strap  5 ; on the contrary, the shorter sides of the central portion  6  follow the cross direction of the strap  5 . 
     A trapezoidal side band  7  and a plurality of rectangular strips or laces  8 ,  8 ′, having a greater length and a smaller width with respect to the side band  7 , protrude from one side of the central portion  6 . The side band  7  and the laces  8 ,  8 ′ extend in the crosswise direction of the strap  5 . 
     By way of example, the laces  8 ,  8 ′ are eight in number and the first four laces  8  starting from the side band  7  have a slightly shorter length than the other four laces  8 ′. 
     In the central portion  6 , in a central position and level with the side band  7 , a slot  9  is formed by die-punching and is of such a size as to allow insertion of the thumb of a hand. The slot  9  extends in the lengthwise direction of the strap  5 . 
     It must be considered that pressure moulding is performed all along the outer peripheral edge of the central portion  6 , the side band  7  and the laces  8 ,  8 ′ and also all along the peripheral edge of the slot  9 . Hot moulding is preferably performed, so as to obtain heat welding or thermoforming of the intermediate layer  3  to the bottom and top layers  2  and  4 , along the peripheral edge. For this purpose the intermediate layer  3  must be of heat-weldable material, such as polyurethane for example. 
     Alternatively, instead of heat welding, ultrasound welding using a mould half vibrating at the frequency of ultrasound can be used. 
     Alternatively, for reasons of cost, hot moulding or ultrasound moulding of the peripheral edge of the multilayer sheet  1  can be avoided, using only cold die-punching. 
     As shown in  FIG. 3 , on the central portion  6  of the strap  5 , on one side and the other with respect to the slot  9 , two longitudinal pockets  10 , provided with respective openings  12  for insertion of metal plates for stiffening of the structure, are applied by sewing. 
     Again on the central portion  6 , at the side of one pocket  10 , near the opposite side to that in which the laces  8 ,  8 ′ are situated, a longitudinal reinforcing strip  11  is sewn. 
     The pockets  10  and the reinforcing strip  11  are preferably made of the same material as the top layer  4 , or in any case of a material suitable to allow Velcro-type fastening. 
     As shown in  FIG. 4 , a plurality of eyelets  13  are made in the reinforcing strip by die-punching, in a number equal to that of the laces  8 ,  8 ′ and in a position coinciding with said laces  8 ,  8 ′, in a crosswise direction. The eyelets  13  are wide enough to accommodate the respective laces  8 ,  8 ′. 
     As shown in  FIG. 5 , the laces  8 ,  8 ′ are inserted in the respective eyelets  13  and pulled so that the strap  5  takes on a substantially tubular shape. 
     At this point, three Velcro-type fastening elements  15  are applied to the strap  5 , by means of sewing  14 . To be precise, a first fastening element  15  is applied to the free end of the group of four longer laces  8 ′, a second fastening element  15  is applied to the free end of the group of four shorter laces  8  and a third fastening element  15  is applied to the end of the side band  7 . 
     Each fastening element  15  is shaped like a substantially semi-elliptical patch of such a size as to be able to be gripped easily by the wearer. The fastening element  15  has two end flaps  17 , disposed in a substantially V-shaped configuration, to be sewn to the ends of the laces  8 ,  8 ′ and of the side band  7 . On one surface of the fastening elements  15  there are provided a plurality of hooks  16  able to engage, in a fastening relationship, with the loops  40  disposed on the top surface of the strap  5  and of the laces  8 ,  8 ′. 
     In this manner, the wrist splint  20 , illustrated in  FIG. 5 , is obtained, ready to be worn on the wrist of a wearer. 
     As shown in  FIGS. 6 ,  7  and  8 , the splint  20  is fitted on the wrist of the wearer so that the thumb of the hand enters the slot  9  of the splint. Subsequently, the wearer, with the other hand, grips the first fastening element  15  so as to tighten the group of four longer laces  8 ′ as much as possible and thus block the fastening element  15  on the upper surface  40  of the strap  5 ; then the second fastening element  15  is gripped so as to tighten the group of four shorter laces  8  as much as possible and thus block the fastening element  15  on the upper surface  40  of the strap  5 ; and lastly the third fastening element  15  is gripped so as to tighten the side band  7  as much as possible and thus block the fastening element  15  on the upper surface  40  of the strap  5 . 
     To remove the splint  20 , the wearer disengages the fastening elements  15  and loosens the laces  8 ,  8 ′ to remove the splint  20  from the wrist. 
     It should be noted that during application of the splint  20 , the undersurface of the laces  8 ,  8 ′ can come into contact with the wearer&#39;s skin. This is not a problem since the undersurface of the laces is made of the same anallergic material as the undersurface of the strap  5 . 
     Furthermore, it should be noted that during application of the splint  20 , it can happen, depending upon the size of the wearer&#39;s wrist, that the position of the fastening elements  15  coincides with the laces  8 ,  8 ′ when the laces are perfectly tightened. This situation too does not prove to be a problem since the tipper surface of the laces is made of the same material suitable for Velcro-type fastening as the upper surface of the strap  5 . Therefore the fastening elements  15  can be fixed on the laces  8 .  8 ′. 
     Another product according to a second embodiment of the invention, which provides a wrist brace, illustrated as a whole in  FIG. 12  and indicated with reference numeral  120 , is described with the aid of  FIGS. 9-15 . 
     Production of the wrist brace  120  again starts from a multilayer sheet  1 , illustrated in  FIG. 1 . This sheet is fed toward a die-punching and moulding machine to be die-punched and moulded along its peripheral edge so as to obtain a strap  105  having the shape illustrated in  FIG. 9 . The strap  105  comprises a substantially rectangular main portion  106  destined to surround the wearer&#39;s wrist. 
     A plurality of laces  108 ,  108 ′ in the form of rectangular strips protrude from one side of the main portion. To be precise, five laces are provided: three shorter laces  108  alternating with two longer laces  108 ′. 
     As shown in  FIG. 10 , a reinforcing strip  111  disposed near the opposite side to that in which the laces  108 ,  108 ′ is sewn onto the main portion  106  of the strap  105 . 
     As shown in  FIG. 11 , coinciding with the reinforcing strip  111 , a plurality of eyelets  113 ,  113 ′ are made, by die-punching, coinciding with the laces  108 ,  108 ′ and able to accommodate said laces. To be precise, three eyelets  113  are aligned near the opposite side to the laces and another three eyelets  113 ′ are aligned slightly more towards the inside with respect to the three eyelets  113 . In this manner the shorter laces  108  engage in the outermost eyelets  113 ; the longer laces  108 ′, on the other hand, engage in the innermost eyelets  113 ′. 
     As shown in  FIG. 12 , after the laces  108 ,  108 ′ have been passed through the respective eyelets  113 ,  113 ′ a Velcro-type fastening element  15  is fixed, by means of sewing  14 , to the free ends of the laces  108 ,  108 ′. The fastening element  15  is substantially similar to that described in the first embodiment and has on one surface a plurality of hooks  16  able to engage, in a fastening relationship, with the loops  40  provided on the upper surface of the strap  105 . 
     With reference to  FIGS. 13 ,  14  e  15 , application of the wrist support  120  on the wearer&#39;s wrist is extremely simple. In fact the wearer grips the fastening element  15  with the other hand and pulls the laces  108 ,  108 ′ to tighten the strap  105  around the wrist. Then the fastening element  15  is applied to the upper surface of the strap  105  so that the hooks  16  of the fastening element engage with the loops  40  of the upper layer  4  of the strap  105 . In this manner the wrist brace  120  is in the closed, tightened position and any loosening thereof is avoided. 
     A third embodiment of the invention, which provides a portion of knee brace, illustrated as a whole in  FIGS. 17 and 18  and denoted by reference numeral  220 , is described with the aid of  FIGS. 16-18 . 
     Production of the knee brace  220  again starts from the multilayer sheet  1  illustrated in  FIG. 1 . This sheet is fed toward a die-punching and moulding machine to be die-punched and moulded along its peripheral edge so as to obtain a strap  205  having the shape illustrated in  FIG. 16 . The strap  205  comprises a substantially rectangular portion  206  destined to surround a part of the wearer&#39;s knee. 
     A plurality of laces  208 ,  208 ′ in the form of rectangular strips having the same length and the same width protrude from two opposite sides of the central portion  206 . To be exact, with reference to  FIG. 16 , ten laces  208  which protrude toward the right and nine laces  208 ′ which protrude toward the left are provided. The right and left laces  208 ,  208 ′ are of the same length and disposed offset from each other, so that a space  213  having a width equal to the width of the lace is formed between two adjacent laces. 
     In this manner, as shown in  FIG. 17 , the right-hand laces  208  are inserted in the spaces  213  defined between the left-hand laces  208 ′, whilst the left-hand laces  208 ′ are inserted in the spaces  213  defined between right-hand laces  208 . Subsequently two fastening elements  15  of the Velcro type, substantially similar to those described previously, are fixed to the free end of the right-hand laces  208 , and left-hand laces  208 ′. 
     It should be noted that in this embodiment, it is not necessary to perform any die-punching to obtain the eyelets for passage of the laces. 
     To tighten the strap  205  around the knee, it is necessary to pull the two fastening elements  15  and then apply them to the upper surface of the strap  205  to fix them in position, as shown in  FIG. 18 . 
     A fourth embodiment of the invention which provides for a corset, illustrated as a whole in  FIG. 21  and denoted with reference numeral  320 , is described with the aid of  FIGS. 19-21 . 
     Production of the corset  320  again starts from the multilayer sheet  1  illustrated in  FIG. 1 . This sheet is fed toward a die-punching and moulding machine to be die-punched and moulded along its peripheral edge so as to obtain two straps  205 ,  305 ′, substantially the same, having the shapes illustrated in  FIG. 19 . Each strap  205 ,  305  comprises a substantially rectangular central portion  306 . 
     A plurality of laces  308  in the form of rectangular strips having the same length and the same width, disposed equidistant from each other so as to define a plurality of spaces  313  of such a width as to receive the laces  308 , protrude from one side of the central portion  306 . To be precise, ten laces  208  are provide on each surface  305 ,  305 ′. 
     In this case, for reasons of economy, cold die cutting rather than hot moulding or ultrasound moulding of the peripheral edge of the multilayer sheet  1  proves particularly advantageous. 
     As shown in  FIG. 20 , in a subsequent step reinforcing strips  310  are sewn onto the top surface of each strap  305 ,  305 ′. 
     As shown in  FIG. 21 , the laces  308  of a strap are inserted into the spaces  313  of the other strap  305 ′. Subsequently, four fastening elements  15  of the Velcro type, substantially similar to those previously described, are fixed to the ends of the four groups of five laces  308 . 
     Lastly, in the bottom layer  2  of a strap  305 ′, near to the side opposite that of the laces  308 , a strip  315  of a Velcro-type fastening element, which provides a plurality of hooks  16  able to couple with the loops  40  provided on the outer surface of the top layer  4  of the strap  205 , is applied by sewing. 
     Numerous variations and changes of detail within the reach of a person skilled in the art can be made to the present embodiments of the invention without thereby departing from the scope of the invention as set forth in the appended claims.