Ankle brace and support and method

Abstract

Disclosed is an ankle support which includes a low temperature, formable plastic, closed-cell foam sewn to a soft orthopedic appliance to provide the desired rigidity and conformability, and a method of making the same. The closed-cell foam is in a skeletal configuration comprising a relatively wide collar for encircling the leg of a wearer and supporting a plurality of relatively narrow elongated stiffeners depending therefrom substantially normal thereto. At least one of the stiffeners terminates in a J-shape. In producing the new brace, a polyolefin foam is laminated with nylon fabric on both of its surfaces. The laminated foam is then cut to desired blank shape. This blank is then sewn to the fabric of the soft brace, also in flat blank shape. The soft brace is then sewn into its sock configuration. The combined foam sheet and attached soft brace blanks in a sock configuration are then mounted upon a male die and subjected to low temperature heat and pressure forming. The molding step transforms the previously soft foam into a semi-rigid skeletal “shell” that extends around but does not substantially completely encase the ankle. The soft appliance provides the basic support, while the skeletal shell provides tailored localized flexible stiffening.