Welded back brace

Abstract

A welded orthopedic back brace is disclosed. In an embodiment, at least one belt member is coupled to a spinal support element. The materials of the belt member are thermally fused to form a unitary segment. In another embodiment, an anterior portion of a posterior pad of the spinal support element includes thermally fused materials to provide a user with an added degree of comfort.

1 - 30 . (canceled) 
     
     
         31 . An orthopedic back brace, comprising:
 a spinal support element; and   a waist belt for positioning the spinal support element, the waist belt comprising a layer of a thermoplastic polyurethane having a first elasticity and a pre-welded thickness, and a second material having a second elasticity and a pre-welded thickness, the thermoplastic polyurethane and second layer thermally fused such that a thickness of the thermally fused layers is less that a sum of the pre-welded thicknesses.   
     
     
         32 . The orthopedic back brace of  claim 31 , further comprising a hybrid layer formed in the fusion process between the thermoplastic polyurethane and the second material, the hybrid layer having characteristics of both the thermoplastic polyurethane and the second material. 
     
     
         33 . The orthopedic back brace of  claim 32 , wherein voids in the thermoplastic polyurethane are used to create directional control of an elasticity of the belt. 
     
     
         34 . The orthopedic back brace of  claim 31 , further comprising an adhesive layer applied between the thermoplastic polyurethane and the second material prior to the thermal fusion thereof. 
     
     
         35 . The orthopedic back brace of  claim 31 , wherein the second material is a spacer mesh material. 
     
     
         36 . The orthopedic back brace of  claim 31 , further comprising a thermally fused belt connection member. 
     
     
         37 . The orthopedic back brace of  claim 31 , wherein the belt is contoured in a direction normal to the plane of the belt during the thermal fusion process. 
     
     
         38 . An orthopedic back brace, comprising:
 a spinal support element; and   a waist belt for positioning the spinal support element, the waist belt comprising a layer of a thermoplastic polyurethane having a first elasticity and a pre-welded thickness, and a second material having a second elasticity and a pre-welded thickness, the thermoplastic polyurethane and second layer thermally fused to form a hybrid layer between the thermoplastic polyurethane and the second material, the hybrid layer having characteristics of both the thermoplastic polyurethane and the second material.   
     
     
         39 . The orthopedic back brace of  claim 38 , wherein voids in the thermoplastic polyurethane are used to create directional control of an elasticity of the belt. 
     
     
         40 . The orthopedic back brace of  claim 38 , further comprising an adhesive layer applied between the thermoplastic polyurethane and the second material prior to the thermal fusion thereof. 
     
     
         41 . The orthopedic back brace of  claim 38 , wherein the second material is a spacer mesh material. 
     
     
         42 . The orthopedic back brace of  claim 38 , further comprising a thermally fused belt connection member. 
     
     
         43 . The orthopedic back brace of  claim 38 , wherein the belt is contoured in a direction normal to the plane of the belt during the thermal fusion process. 
     
     
         44 . The orthopedic back brace of  claim 38 , wherein the thermoplastic polyurethane is has a smaller surface area than the second material such that the thermoplastic polyurethane and the second material are both visible after the thermal fusion.