Elastic material for compression braces and the like

Abstract

An elastic material is disclosed, including a breathable, closed cell foam panel. The elastic panel ( 310 ) includes recessed portions or channels ( 312 ) on at least one side, and apertures ( 314 ) therethrough, the apertures disposed in the channels ( 312 ). The channels may intersect to produce a network of flow paths for heat and sweat transfer, or may comprise nonintersecting channels that establish a directional flow path. In another embodiment, the channels define a plurality of protrusions, such as circular protrusions ( 332 ) or rectangular protrusions ( 342 ). The elastic panel is preferably formed by compressing a sheet of closed cell foam between a pair of oppositely disposed, heated plates ( 410, 420 ), wherein one of the plates includes a plurality of pins ( 422 ), and the other of the plates includes apertures ( 414 ) adapted to receive the pins. One or both of the plates includes protrusions ( 412 ) for forming the recessed portions or channels.

1 . A method of manufacturing a material suitable for use in a compression brace material, the method comprising the following steps: 
 providing a sheet of closed cell foam material between a first plate having a plurality of spaced-apart pins extending from a first surface, and a second plate having a plurality of spaced-apart apertures, wherein the apertures are sized and spaced to slidably engage the pins when the first plate and second plate are suitably aligned, and further wherein at least one of the first plate and the second plate further includes a plurality of protrusions;    heating at least one of the first plate and the second plate to a selected temperature;    urging the first plate and the second plate together such that the pins on the first plate penetrate the sheet of closed cell foam material and slidably engage the apertures on the second plate;    maintaining a pressure between the first plate and the second plate for a period of time such that the protrusions impress a plurality of depressions on the sheet of closed cell foam material; and    separating the first plate from the second plate and removing the closed cell foam material.    
   
   
       2 . The method of  claim 1 , wherein the sheet of closed cell foam material is neoprene, having a thickness between about 2.0 mm and about 10.0 mm.  
   
   
       3 . The method of  claim 2 , wherein at least one of the first plate and the second plate is heated to a temperature between 145° C. and 160° C.  
   
   
       4 . The method of  claim 3 , wherein the pins have a diameter of between 0.5 mm and 3.0 mm.  
   
   
       5 . The method of  claim 3 , wherein the pressure maintained between the first plate and the second plate is about 50 kg/cm 2 .  
   
   
       6 . The method of  claim 3 , wherein the pressure between the first plate and the second plate is maintained for between about 4 minutes and about 6 minutes.  
   
   
       7 . The method of  claim 3 , wherein the protrusions are between about 1.0 mm and 2.0 mm deep.  
   
   
       8 . The method of  claim 7 , wherein the protrusions consist of a plurality of elongate parallel protrusions having a spacing of between about 10.0 mm and 15.0 mm.  
   
   
       9 . The method of  claim 7 , wherein the protrusions are shaped to form a plurality of circular protrusions in the sheet of closed cell foam material.  
   
   
       10 . An elastic panel formed from a sheet of closed cell foam, the elastic panel having a first side defining a plurality or recessed channels that are formed by compressing the sheet of foam with oppositely-disposed heated plates, and a plurality of apertures through the sheet of foam that are formed by penetrating the panel with heated pins, such that the channels and apertures are formed without cutting any material away from the sheet of closed cell foam.  
   
   
       11 . The elastic panel of  claim 10 , wherein the sheet of closed cell foam is a neoprene sheet.  
   
   
       12 . The elastic panel of  claim 10 , wherein the plurality of recessed channels comprises two sets of intersecting, parallel, elongate channels.  
   
   
       13 . The elastic panel of  claim 10 , wherein the plurality of recessed channels defines a plurality of rectangular protrusions on the first side of the foam sheet.  
   
   
       14 . The elastic panel of  claim 10 , wherein the plurality of recessed channels comprises a single set of parallel elongate channels.  
   
   
       15 . The elastic panel of  claim 11 , wherein the neoprene sheet is between about 2.0 mm and 10.0 mm in thickness.  
   
   
       16 . The elastic panel of  claim 10 , wherein the apertures are disposed in the plurality of recessed channels.  
   
   
       17 . The elastic panel of  claim 12 , wherein the apertures are circular, with a diameter of between about 0.5 mm and 3.0 mm.  
   
   
       18 . The elastic panel of  claim 17 , wherein the apertures are disposed in the elongate channels.  
   
   
       19 . The elastic panel of  claim 12 , further comprising a porous inner fabric layer affixed to the first side of the elastic panel.  
   
   
       20 . The elastic panel of  claim 14 , wherein the apertures are disposed in the elongate channels.