Orthopedic device, use of orthopedic device and method for producing same

Abstract

An orthopedic device includes an elongate and rigid or semirigid strut assembly, an arcuate cuff pivotally secured to the strut assembly, and a strap securing to the cuff and forming an adjustable circumferential configuration therewith. A tensioning device may be mounted on the cuff and coupled to the strap in order to incrementally adjust the tensioning device among a plurality of preselected levels such that a first end of the strap secures to the tensioning device and a second end of the strap couples to the cuff. A soft-good assembly connects to the strut assembly and has a flexible stay embedded within with a plurality of layers. The soft-good assembly is adapted to form an adjustable circumferential loop with the stay only located within a segment short of the circumference of the loop.

1 . An orthopedic strap assembly, comprising:
 a panel portion having an elongate shape, and including first and second textile layers laminated to one another;   a stay formed from a polymeric material and located between the first and second textile layers, wherein the stay has a length shorter than a length of the panel portion;   an adhesive layer securing the first and second layers to one another.   
     
     
         2 . The orthopedic strap assembly of  claim 1 , wherein the stay is substantially flexible and resilient. 
     
     
         3 . The orthopedic strap assembly of  claim 1 , wherein the stay is fixedly located within the panel portion. 
     
     
         4 . The orthopedic strap assembly of  claim 1 , wherein the stay has greater rigidity than the first and second textile layers. 
     
     
         5 . The orthopedic strap assembly of  claim 1 , wherein the stay has a width less than a width along a segment of the panel portion corresponding to the stay. 
     
     
         6 . The orthopedic strap assembly of  claim 1 , further comprising:
 an outer strap secured to the panel portion at a first end and securing to the panel portion at a second end, the outer strap extending over a pocket formed by the panel portion.   
     
     
         7 . The orthopedic strap assembly of  claim 6 , further comprising a plate removably received by the pocket. 
     
     
         8 . The orthopedic strap assembly of  claim 7 , wherein a segment of the panel portion proximate the pocket is formed from a stretchable material. 
     
     
         9 . The orthopedic strap assembly of  claim 1 , wherein a first end of the panel portion defines a finger pocket adapted to receive a user's fingers. 
     
     
         10 . The orthopedic strap assembly of  claim 1 , further comprising an outer strap having a first end secured to the panel portion, and a second end removably securable over a surface of the panel portion. 
     
     
         11 . The orthopedic strap assembly of  claim 1 , further comprising a panel extension arranged to a secure to a first end of the panel portion and extend a length of the orthopedic strap assembly. 
     
     
         12 . The orthopedic strap assembly of  claim 1 , further comprising a plate removably securable to the panel portion and located adjacent or spaced away from the stay. 
     
     
         13 . A method for making an orthopedic strap assembly, comprising the steps of:
 applying a first layer formed from a textile material to a first plate;   placing a stay formed from a polymeric material onto the first layer;   applying a second layer formed from a textile material over the first layer and stay;   applying a second plate over the first plate;   pressing the first plate against the second plate to laminate the first and second layers with the stay located therebetween.   
     
     
         14 . The method of  claim 13 , further comprising the step of:
 applying an adhesive layer over at least one of the first and second layers, prior to applying the second layer to the first layer.   
     
     
         15 . The method of  claim 13 , further comprising the step of heating at least one of the first and second plates to melt the adhesive layer and bind the first and second layers together with the stay fixedly positioned between the first and second layers. 
     
     
         16 . The method of  claim 13 , wherein the first plate forms a cavity defining a definitive shape of the orthopedic strap assembly. 
     
     
         17 . The method of  claim 13 , wherein the stay has a length less than a length of the orthopedic strap assembly. 
     
     
         18 . The method of  claim 13 , further comprising the step of applying a layer of foam material between the first and second layers.