Patent ID: 8034010

Claim:
A progressive resistance knee pad coupled to the inner surfaces of an orthotic support appliance (a knee brace) to prevent metal components of an orthotic support from contacting clothing, tissue or skin surface of the wearer of the orthotic support appliance comprising: a cushion layer having a contoured contact surface and a support surface, a middle layer having a mating surface and a base surface, a base layer, the base layer having a top surface and a mounting surface, and an imbedded mounting plate imbedded in the base layer, the cushion layer being formed from a first predetermined Durometer material, and having a uniform thickness, the middle layer being formed from a second predetermined Durometer material having a lower Durometer value than the base layer, the middle layer being formed as a homogenous and void free layer having a varying cross section, the middle layer mating surface being contiguous and congruent with and bonded to the cushion layer support surface, the middle layer mating surface being formed to shape the cushion layer contact surface to conform with a predetermined contoured surface, the thickness of the middle layer being controlled and adjusted to provide a substantially planar base surface, the base layer top surface being contiguous and congruent with and bonded to the middle layer base surface, the base layer imbedded mounting plate having a plurality of threaded holes for receiving screws from the inner surfaces of the knee brace for coupling the progressive resistance knee pad to the orthotic support appliance and, a plurality of post mooring holes that permit the material forming the base layer to pass through the post mooring holes and around the imbedded mounting plate to support the imbedded mounting plate from moving within the base layer.