HK1066717B - Compression brace material with spacer fabric inner layer - Google Patents

Description

Compression brace material with inner spacer fabric layer

Cross reference to related applications

This was a continuation-in-part of prior U.S. patent application No.10/004, 469 filed on 23/10/2001. U.S. patent application No.10/004, 469 is itself a continuation-in-part application of U.S. patent application 09/846, 332 filed on 5/2/2001, and claims priority on the filing date in accordance with 35u.s.c. delta 120.

Technical Field

The present invention relates generally to orthopedic supports and, more particularly, to a composite material for forming elastic compression braces having improved compression support, body temperature retention, and breathability in use.

Background

Elastic compression braces can be made in many forms. Often such bandages are made of a soft, elastic material so that they provide a certain amount of support to the damaged joint when worn. Bandages of this type are often purchased without prescription or professional fitting to the skilled person, have been in use for many years and are commonly available as bandages for the knee, ankle, thigh, wrist, elbow, chest or lower back. These elastic, flexible compression braces can be used to treat sprains and strains, arthritis, aponeurosis, bursitis, various inflammatory conditions, or to reduce post-operative discomfort or treat post-traumatic discomfort.

Elastic compression braces are often made of synthetic rubber (e.g., polychloroprene). This particular material is desirable because it combines the advantageous properties required for elastic compression braces. Polychloroprene rubber has good elasticity and relatively high density, thereby providing good compression support and shear strength.

Polychloroprene rubber is a closed cell material and therefore does not dissipate heat well when in use. Its closed cell nature can retain heat in the use of bones and joints that reflect radiant heat back to the affected area. This localized concentration of heat helps venous flow and reduces edema and makes the soft tissue less susceptible to injury.

While the use of polychloroprene rubber can concentrate heat within elastic compression braces, the natural tendency of the closed cell material to prevent heat scattering can still present problems to the patient. When worn, the polychloroprene material brace is tightened to apply a compressive load around the affected body area. This tight fit, combined with the high density of the material, and the lack of air circulation and dissipation through the material, can lead to thermal discomfort and sweating and cause heat eruptions. Prolonged use of such bandages can lead to constant sweating of the patient, making it uncomfortable to such an extent that the user often stops wearing the bandage too soon. In effect, the material itself defines the length of time that the orthopedic brace can be worn. It is not uncommon for the user to stop wearing such a bandage after about 1 to 2 hours. In an attempt to improve breathability, some existing polychloroprene rubber bandages are manufactured with perforations or perforations through the entire thickness of the material. However, these braces may not maintain sufficient structural integrity to be effective compression braces for the wearer because a portion of the polychloroprene material is removed by the brace.

Accordingly, there is a need for an elastic compression brace that has sufficient structural strength and integrity to provide a sufficient level of compression support while at the same time dissipating heat during use to reduce or avoid excessive perspiration and thermal discomfort, particularly during prolonged use.

Disclosure of Invention

The present invention provides a composite material for use as compression braces and the like, characterized in that the composite material comprises an elastically extensible first layer, a flexible second layer secured to the first layer, a third layer secured to the second layer comprising a spacer fabric, and a flexible fourth layer secured to the third layer. The first layer may not be the outermost layer, as it is understood that an outer layer may cover the first layer.

In one embodiment of the invention, the resilient outer layer includes a plurality of slits therethrough that permit and promote air flow in a transverse direction through the composite material.

One embodiment of the present invention provides a flexible, elastic composite material for forming an elastic compression brace for encircling and supporting a body part by compression. The composite has a central elastic layer, an inner fabric layer, and an outer fabric layer. The central elastic layer is preferably comprised of a sheet of closed cell material having a plurality of grooves or channels on one side thereof to intersect to form a grid. The pattern of channels provides channels along the width and length of the central layer for the dissipation of heat and moisture from the body part being supported.

The central layer may also have a plurality of cuts extending through the entire depth of the central layer and distributed across the surface area of the central layer, while the central layer still has sufficient structural strength and integrity to provide orthopedic compression support.

The composite material may also have an inner layer of flexible, resilient, porous fabric material bonded to the grooved side of the center layer. The outer fabric layer may also be composed of a flexible, elastic, porous material bonded to the non-grooved side of the center layer.

In one embodiment of the invention, the plurality of slits extend through the central layer and are arcuate slits, such as circular slits extending between about 180 and 270, the arcuate slits defining a matrix of tabs, the tabs being hingedly connected to the central layer, such that stretching the composite creates a gap in the central layer, thereby forming an air flow path between the inner and outer layers.

In another embodiment of the present invention, a composite material includes an elastic outer layer, a first fabric layer, a spacer fabric layer, and a second fabric layer. The spacer fabric layer provides a lightweight component that allows for lateral air flow through the composite material.

Drawings

The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a side elevational semi-schematic view of a knee brace made of an orthopedic material according to the principles of the present invention;

FIG. 2 is a semi-schematic perspective view of the knee brace of FIG. 1;

FIG. 3 is a schematic cross-sectional view of a component of the composite orthopedic material of the present invention;

FIG. 4 is a front top view of a perforated center layer segment of the composite of the present invention;

FIG. 5 is a rear top view of the perforated center layer segment of FIG. 4;

FIG. 6 is a perspective view of an elbow brace made from the composite material of the present invention;

FIG. 7 is a perspective view of a wrist bandage made from the composite material of the present invention;

FIG. 8 is a side view of an ankle brace made from the composite of the present invention;

FIG. 9 is a top view similar to FIG. 4 showing another pattern of channels formed in the center layer of composite material;

FIG. 10 is a top view of a center layer according to another embodiment of the present invention;

FIG. 11 is a top view of the center layer shown in FIG. 10, with the center layer stretched lengthwise as indicated by the large arrows;

FIG. 12 is a top view of a center layer according to another embodiment of the present invention;

FIG. 13 is a cross-sectional view of the center layer shown in FIG. 12 taken along line 13-13;

FIG. 14 is a cross-sectional view of the center layer shown in FIG. 13, with the inner and outer layers attached to the center layer;

FIG. 15 is a cross-sectional view similar to FIG. 14, showing the composite material stretched lengthwise as indicated by the large arrows.

FIG. 16 is a partial cross-sectional view of another embodiment of the present invention using a spacer fabric;

FIG. 17 is a partial perspective view showing the spacer fabric of FIG. 16 in isolation; and

FIG. 18 is a perspective view of an embodiment of the present invention using a spacer fabric and an outer layer having slits through the outer layer.

Detailed Description

Figures 1 and 2 illustrate a knee brace 20 made of an orthopedic material in accordance with the principles of the present invention. The orthopedic material is shown in figures 3, 4 and 5. The knee brace is made from a flexible elastic composite 100 in the flat shape shown in figures 3, 4 and 5. The flat shaped composite is cut to shape and sewn or otherwise assembled into a tubular knee brace 20 as shown in figures 1 and 2.

Referring to fig. 1 and 2, a sheet of composite material 100 in the shape of a flat sheet is folded upon itself. The overlapping long edges on opposite sides of the fold are secured with long upstanding seams 50. The flat sheet of material is cut to shape so that when sewn along seam 50 as shown in figures 1 and 2, a generally tubular curved knee support is formed having an open top opening 60 and an open bottom opening 70. Peripheral stitching 80 at the upper edge and similar peripheral stitching 90 at the bottom edge provide the final edge for the finished knee support.

The components that make up the composite material 100 can be better understood with reference to fig. 3, 4, and 5. Fig. 3 shows a cross-sectional view of a component of the composite material 100 of the present invention. The composite has a flexible and foldable central elastic layer 110 and inner and outer fabric layers 130, 120. The central elastic layer 110 is preferably made of closed cell foam in sheet form. One preferred elastic closed cell material is polychloroprene rubber, commonly known as neoprene. The most preferred neoprene materials are commercial products. Another suitable material for the center layer 110 is styrene-butadiene rubber (SBR). These materials can be in a wide range of densities, so it is not difficult to find a material of the required density to provide the desired level of support and good orthopedic compression in use. It is desirable for the purposes of the present invention for such materials to have a thickness of from 1.5mm to 8 mm. However, other thicknesses may be used. In addition, other elastic closed cell materials may be used to form the central layer 110. The central elastic layer 110 has a plurality of intersecting grooves or channels 140 on one side thereof. In a non-limiting example, one embodiment of the present invention illustrates a pattern of intersecting channels 140 formed by placing neoprene sheet material down onto a metal grid and then placing a loaded heat source on top of the flat sheet material. The pressure and heat cause the metal mesh to be pressed into the sheet material so that the bottom surface where the mesh pattern of the metal mesh is pressed into permanently takes the shape of the metal mesh. In addition, or as an alternative, the metal mesh may be preheated.

In another embodiment of the invention, the pattern of intersecting grooves 140 is formed on both surfaces of a flat sheet of material. One way this is accomplished is by sandwiching a center layer 110 between top and bottom metal grids and hot pressing the two metal grids against the center layer 110, resulting in the two metal grids being pressed into both surfaces of the flat sheet material. The grid pattern may be the same on both surfaces of the center layer 110 or may be different shapes.

In the embodiment shown in fig. 3 and 4, a plurality of intersecting grooves 140 are formed in the central elastomeric layer 110, which define a pattern or grid that is generally matrix or square. It will be appreciated that the pattern may be of any other shape, such as diamond-shaped (see fig. 9), triangular, oval, circular, etc., so long as the grooves 140 intersect one another to provide a continuous or interconnected passageway across the flat sheet material along the length of the material.

The central elastic layer 110 may be punched to form a plurality of repeated punches or slits 150 through the central layer. For simplicity, the cut-outs 150 are not shown in fig. 3, but the cut-outs 150 are shown in fig. 4 and 5. The front top view of fig. 4 shows a section of the punched central layer 110. The rear top view of fig. 5 shows a section of the punched core layer 110 shown in fig. 4. The repeated cuts 150 are distributed across the central elastic layer 110 and extend through the entire depth of the central layer so that fluids, including perspiration and air, can pass from one side of the central layer to the other through the cuts 150, particularly when the central layer is stretched.

In one embodiment of the invention, the cuts 150 are only in the groove portions 140 of the recording. In another embodiment, the cuts 150 are not only in the grooved portions 140, but also in the ungrooved portions of the elastic layer 110. In another embodiment, the cuts 150 'are only at the intersections of the grooves 140'. The repeating cuts 150 may be in a uniform pattern and uniformly spaced along the central elastic layer 110. Ideally, the repeated cuts 150 should not be so large or spaced so closely that the overall structural integrity of the neoprene material is reduced beyond the ability of the material to provide adequate orthopedic compression support during use.

The repeating cuts 150 may define a cut pattern. The cut pattern shown in fig. 4 and 5 has three "leg lines" radiating from a common point. It is understood, however, that the cut pattern may be any shape, such as a straight line, a curved line, a cross, or a 5-foot line, without departing from the scope of this invention. It should also be understood that it is desirable that the punch hole, if any material is removed from the central elastomeric layer 110 or the channel 140, should not actually remove any substantial amount of material, rather the punch hole extends purely through the channel. Thus, the punched holes should not form holes or passages through the neoprene material except when the material is stretched.

The pattern of repeating cuts 150 may be formed in a series of ways in the central elastic layer 110. One method of forming the cut pattern in the neoprene material is by a roller having a cylindrical outer surface with protruding punches of the desired cut pattern to cut the desired pattern as the roller is rolled over the flat surface of the neoprene material.

Referring to fig. 3, composite material 100 also has a soft, flexible, porous inner fabric layer 130. Inner layer 130 may be a woven, flexible and collapsible, stretchable fabric material of fibers, the pores of which are permeable to air and moisture due to the inherent porosity of the woven fabric. Composite 100 also has a flexible and elastic, porous outer fabric layer 120, which is also made of a stretchable knitted fabric, of the same type as or different from inner layer 130. Inner and outer fabric layers 130 and 120, respectively, may be made of other stretchable woven fabrics, such as nylon, dacron, or other synthetic fibers.

After the central elastic layer 110 is altered and punched with a plurality of intersecting channels 140 on one side thereof in an incision pattern 150, the inner textile layer 130 is attached to the grooved surface of the central layer 110 and the outer textile layer 120 is attached to the non-grooved surface of the central layer 110. Inner fabric layer 130 may be adhered to center layer 110 using an adhesive technique that prevents glue or other adhesive from being placed into channels 140. As such, the cement does not close or block the groove 140. Outer fabric layer 120 may also be attached to center layer 110 using glue or other adhesive. The adhesive joins the entire contact surface area of the central layer 110 and the adjacent inner and outer fabric layers 130 and 120, respectively. It should be noted that the adhesive should not disrupt the porosity of the central layer 110 and the inner or outer fabric layers 130 or 120.

Returning to FIGS. 1 and 2, knee brace 20 is worn against the user's body with grooved sides, which provides the benefit of maintaining heat to the body while allowing knee brace 20 to be breathable. In addition, because knee brace 20 is made of a composite material, it has sufficient porosity to completely avoid internal heat build-up during use. Knee brace 20 may also provide good compression around the portion of the human body supported by knee brace 20 in its stretched state. The elastic center layer retains substantially all of its ability to apply a compressive load to the enclosed body portion because material is not actually removed from the neoprene center layer as in some conventional bandages. In addition, knee brace 20 has sufficient density to provide the necessary compression for a useful knee brace due to the selection of neoprene, styrene-butadiene rubber, or other material. The inner and outer fabric layers 130 and 120 also provide additional compressive strength to the knee brace.

Knee brace 20 also provides good breathability. When knee brace 20 is in use, it stretches in a bi-directional manner, thereby creating a pumping action that causes air to flow through channels 140 of knee brace 20. The sweat thus carried by the body is discharged from the distal end of the knee brace through the channels 140. Knee brace 20 also allows fresh, cool air to flow inwardly through knee brace 20 to the body, so that when the brace is stretched during use, an amount of heat can flow from the interior of knee brace 20 to the exterior through the plurality of open cuts 150.

In accordance with another aspect of the present invention, silicone 152 in the form of a gel or bead may be applied along the interior of knee brace 20 along the length of the brace, perhaps on opposite sides of the brace. Additionally or alternatively, silicone balls 154 may be placed along the inner perimeter of the bandage, perhaps near the ends of the bandage. The silicone may be placed in a strip line or band of a certain width or other pattern. Furthermore, the silicone thread or strip may be straight or curved. The silicone material causes the bandage to stay in place on the body by friction between the silicone and the body. However, silicone does not cause discomfort or excessive scratching of the human body.

In one embodiment, silicone may be applied to the interior of knee brace 20 after the brace is fully manufactured. In another embodiment, silicone is applied to the interior of inner fabric layer 130 of knee brace 20 and then inner fabric layer 130 is applied to the interior of central layer 110. It will be appreciated by those skilled in the art that other materials besides silicone may be used to cause the bandage to stay in place on the body without departing from the scope of the present invention.

Fig. 6-8 illustrate further applications of composite material 100 in compression braces. Fig. 6 shows an elbow brace 160 with composite material 100 folded and seamed along its length. The bandage may have an intermediate seam 170 to form a generally L-shaped tubular elastic bandage. The top and bottom edges of the tubular bandage have stitched peripheral seams 180 for edge reinforcement. Fig. 7 shows a wrist brace 190 made from composite material 100 which is folded and seamed along its length to form a generally straight tubular brace having peripheral stitched seams 200 at its opposite ends for edge reinforcement. Fig. 8 shows an ankle brace 210 made from composite material 100. Ankle brace 210 is formed as a generally L-shaped tubular brace having peripheral stitched seams 220 at opposite ends thereof, and 230 around a peripheral stitched seam of an edge portion of the brace which fits around the heel of the user. The bandage may have a central stitched seam 240 for securing adjacent central edges of the L-shaped ankle brace.

These compression braces can be used to provide a desired level of anatomical compression support while improving ventilation of the support area to reduce discomfort due to perspiration and overheating. Thus, the improved composite of the present invention can improve the anatomical support provided by compression braces formed from such materials because the brace can be worn by a user for extended periods of time without premature removal of the brace due to thermal discomfort.

Fig. 9 shows an alternative embodiment of the invention, in which a composite material 100 'constitutes an elastic center layer 110' having a diamond pattern of intersecting grooves. Again, the cuts 150 'are at the intersections of the grooves 140'. The channels 140 'and incisions 150' may be formed in the same or similar manner as described above for the central layer 110. Still further, in other aspects the composite material 100' can be the same or similar material 100 as described above.

Figure 10 shows a centre layer 210 according to a third embodiment of the invention. In this embodiment, the center layer 210 has a plurality of arcuate slits 250 that extend through the entire thickness of the center layer 210. The arcuate slit 250 is preferably a semi-circular or partially circular slit that defines about 180 to 270 of a full circle. The arcuate slits define tab portions 255 that remain hingedly attached to the center layer 210, but can open to allow air to flow through the center layer 210. The curved geometry of the slits 250 provides longer slits over a shorter lateral distance of the center layer 210.

The plurality of arcuate slits 250 are arranged in a rectangular offset array as shown in fig. 10. The thickness of the center layer 210 is desirably between about 1.5mm and 8mm, and more desirably about 3 mm. The arcuate slit 250 has a diameter D that is desirably between 3mm and about 10mm, and more desirably about 4 mm. The offset of the offset lines adjacent to the slits spaced from each other in the vertical and horizontal directions shown in fig. 10 is denoted as OS, and is desirably between about 3mm and about 10mm, and more desirably about 6 mm. The composite material using the center layer 210 in combination with the inner and outer fabric layers 130, 120 described above (not shown in figure 10) achieves adequate compressive strength for use in orthopedic applications, such as compression braces.

The slits 250 are made in the center layer 210 without removing a substantial amount of the material of the center layer 210, and the slits 250 are substantially closed when the center layer is relaxed or unstretched.

FIG. 11 shows the center layer 210 of FIG. 10 with the composite material elastically stretched in the lengthwise direction (i.e., to the left and right in FIG. 11). The crescent-shaped air flow channels 250' in the stretched center layer 210 are open. It will be appreciated that the curvature of the arcuate slits 250 deforms to a greater flow area for air and moisture to pass across the center layer 210. This is due to the geometry of the tab portion 255, which is hingedly attached to the central layer 210 along one edge, which isolates the tab portion 255 from the tensile stresses in the central layer 210. Thus, the tab portion 255 is not stretched as much as the surrounding portion of the composite opposite the tab portion 255, thereby creating a larger air flow channel 250'.

When the central layer 210 is relaxed, i.e., when the stretching force is removed, the crescent-shaped air flow channels 250' close, essentially returning to the slits 250 shown in FIG. 10. Specifically, the tab portion 255 is laterally displaced relative to the surrounding portion of the composite material opposite the tab portion 255. This opening and closing movement of the tab portions 255 creates a pumping action within the air flow channels 250' that enhances air flow through the center layer 210. It will be appreciated that when wearing a flexible compression brace, such as the knee brace shown in figures 1 and 2, the movement of the wearer results in elastic bending of the brace. Such bending of a bandage made of the above-mentioned composite material will thus produce a pumping action which improves the air flow across the bandage. Furthermore, when the heat generated by the wearer is relatively small, the air flow generated by the pumping action of the air channel 250' is also small.

Figure 12 shows a core layer 310 for a fourth embodiment of the present invention, the core layer 310 being substantially identical to the core layer 210 shown in figure 11 and having a plurality of elongate shallow grooves 340 extending transversely across the inner surface of the core layer 310. As described above, the intersecting grooves 340 provide channels that allow air to flow along the inner surface of the composite adjacent the wearer's skin. As seen in fig. 13, which shows a cross-sectional view of the center layer, slits 350 are preferably located near the grooves 340 or at the intersections of the grooves 340, so that air and steam are directed to the slits 350 or, conversely, air is directed from the slits to the grooves 340.

Fig. 14 and 15 show cross-sectional views of composite materials 300 using a center layer 310. Composite material 300 has an elastic inner fabric layer 330, which is preferably a woven synthetic fiber layer, bonded to the inner surface of center layer 310. An elastic outer fabric layer 320 is adhered to the outer surface of the central layer 310. The inner and outer fabric layers 320, 330 are bonded to the center layer in a manner that allows at least a portion of the arcuate slits 350 to open as the composite material is stretched.

The inner and outer fabric layers 320, 330 are porous so that air and vapor can flow through the inner fabric layer 330, through the arcuate slits 350 (when the slits are open), and evaporate gases from the wearer through the outer fabric layer 320, as well as providing cooling air in the opposite direction beneath the composite.

Fig. 15 shows composite 300 stretched in the transverse direction (i.e., to the left and to the right in fig. 15). The slits 350 are in an open position due to stretching of the fabric. Fig. 14 shows the composite material 300 in an unstretched shape with the slits 350 substantially closed. It will be appreciated from a comparison of fig. 15 and 14 that the sequential bending and unbending (stretching and unstretching) of the composite material will produce the pumping action described above, which facilitates the flow of air through the composite material.

While the slits of the preferred embodiment are semi-circular (i.e., 180-270 of the arc), any number of other shapes are possible and it is contemplated that, for example, slits that create a tab portion with a curved free end and a hingedly connected rear end may be used.

FIG. 16 shows another embodiment of a compression brace material 400 according to the present invention. In this embodiment, the multi-layer compression brace material 400 is a multi-layer structure comprising: (i) a flexible outer layer 410, preferably made of a closed cell foam material such as neoprene; (ii) a first fabric layer 420 attached to outer layer 410; (iii) a spacer textile layer 425 attached to the first textile layer; and (iv) a second fabric layer 430 attached to spacer fabric layer 425. In one embodiment, the layers are attached to each other with cement, although other attachment methods may be used, as other attachment methods including stitching are known in the art.

Spacer fabric as used herein refers to a 3D textile fabric, typically formed on a warp knitting machine such as a rib raschel machine. Figure 17 shows a somewhat stylized cross-sectional view of the spacer fabric 425 in isolation. Spacer fabric 425 features a pair of spaced apart panels 427, 429, sometimes referred to as ground fabrics 427, 429. The faces 427, 429 are interconnected by a plurality of transverse threads or spacer filaments 428 to produce a light weight fabric with loose apertures. The spacer filaments 428 are spaced apart a relatively large distance relative to the thickness of the thread, thereby creating a three-dimensional porous mesh which has the advantage of allowing air to flow in at least a portion parallel to the faces 427, 429 in the present invention. Suitable spacer filaments 428 are typically polyamide or polyester monofilaments. Suitable spacer fabrics may have a thickness in the range of less than 1mm to 10mm or greater than 10 mm.

Referring again to fig. 16 and as indicated by the arrows therein, the bandage material 400 of the present invention allows air, heat, and evaporated sweat to flow laterally through the second fabric layer 430 and then generally laterally along the spacer fabric 425 to the edges of the bandage material 400. It has been found that such a composite structure provides a particularly comfortable compression wrap. This superior performance is believed to be related to the fact that the compression material 400 is resiliently wrapped around the user's area during use. When wearing such a compression material, the user's activity causes elastic deformation of the brace material 400, and in particular of the spacer fabric 425. The spacer fabric 425 alternately contracts and relaxes slightly in use to create a pumping action that promotes air flow through and along the spacer fabric 425. Thus, the compression material allows and promotes air flow adjacent the user's body, while the elastic outer layer 410 helps to keep all heat adjacent the user and promotes thermal treatment of the wrapped body part. The outer layer 410 and the other fabric layers 420, 425, 430 cooperate together to also provide the desired compression to the user. Although in the illustrated embodiment the resilient outer layer 410 is shown as the outermost layer, the present invention contemplates that another layer, such as a flexible strip, may be attached to the outer surface of the outer layer 410, for example, for the purpose of improving the aesthetic appearance of the material, protecting the outer layer from debris, making the outer layer smoother, and for other reasons known in the art.

Figure 18 shows another embodiment of a compression brace material 500 that is substantially similar to the compression brace material 400 described above, including an outer layer 510, first and second fabric layers 420, 430, and a spacer (spacer) fabric layer 425 between the first and second fabric layers 420, 430. In this embodiment, however, the outer layer 510 includes a plurality of slits 550 through the thickness of the outer layer 510 to allow for enhanced ventilation through the compression brace material 500. The advantages of the above-described slits through the outer layer 510 are discussed in detail in the embodiment shown in fig. 5 and 10. Although fig. 18 shows arcuate slits 550, it will be apparent that other slit shapes including single straight slits, angled slits, and the like may alternatively be used.

It will also be readily appreciated that the outer layer 510 may include a plurality of transverse grooves or channels 340 (shown in fig. 12) along its inner surface to provide another transverse channel for air flow along and through the compression brace material 500. The aspects and advantages of the lateral groove 340 are discussed in detail above.

While the preferred embodiments of the invention have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit of the invention.

The uniqueness or privilege of an embodiment of the present invention is set forth in the claims that follow.

Claims (18)

1. A composite material for forming a compression brace, the composite material comprising:

a first layer comprising an elastically extensible material, the first layer having an inner surface and an outer surface;

a flexible second layer having an outer surface secured to the inner surface of the first layer, the second layer further having an inner surface;

a third layer comprising a spacer fabric, the third layer having an inner surface secured to the second layer

The third layer further having an inner surface; and

a flexible fourth layer having an outer surface secured to the inner surface of the third layer.

2. The composite material of claim 1, wherein the first layer comprises a closed cell material.

3. The composite material of claim 1, wherein the first layer further comprises a plurality of slits through the layer.

4. The composite material of claim 3 wherein said slits in said first layer are arcuate.

5. The composite of claim 3, wherein the second and fourth layers are comprised of woven fabric sheets made of synthetic fibers.

6. The composite material of claim 5, wherein a plurality of transverse grooves are formed on the inner surface of the first layer.

7. The composite of claim 1, wherein the layers are secured together with a bonding agent.

8. The composite of claim 1, wherein the spacer fabric comprises a pair of spaced apart base fabrics interconnected by a plurality of transverse threads.

9. The composite of claim 8, wherein the spacer fabric is produced on a rib-raschel warp knitting machine.

10. The composite of claim 8, wherein the spacer fabric has a thickness in the range of 1mm to 10 mm.

11. A compression brace having a flexible tubular structure formed from a sheet of composite material according to claim 1, wherein the tubular structure is formed by stitching opposed edges of the sheet of composite material.

12. The compression brace of claim 11, wherein the compression brace is a compression brace

Is a single element consisting of first and second tubular portions connected angularly.

13. A composite orthopedic support material, the support material comprising:

a first layer made of an elastically extensible material, the first layer having an inner surface and an outer surface;

a porous, resilient second layer secured to the first layer and overlying the inner surface of the first layer, the second layer having an inner surface;

a third layer comprising a spacer fabric, the third layer being secured to the second layer and overlying the inner surface of the second layer, the third layer further having an inner surface; and

a porous, resilient fourth layer secured to the third layer and overlying the inner surface of the third layer.

14. The composite orthopedic support material of claim 13,

the first layer is composed of a polychloroprene elastomer.

15. The composite orthopedic support material of claim 14,

the second and fourth layers of porous elastic fabric are composed of a woven fabric sheet made of synthetic fibers.

16. The composite orthopedic support material of claim 13,

the first layer includes a plurality of arcuate slits therethrough.

17. A compression brace having a flexible tubular structure made from a sheet of composite material according to claim 13, wherein the tubular structure is formed by stitching opposed edges of the sheet of composite material.

18. The compression brace of claim 17, wherein the compression brace is a compression brace

Is a single element consisting of first and second tubular portions connected angularly.