A BREATHABLE AND CUSTOMIZED CAST FOR IMMOBILIZATION OF FRACTURED LIMB

Abstract

The present invention provides a breathable orthopedic cast device for immobilizing and stabilizing at least one fracture limb. The breathable orthopedic cast device comprising: a customizable cast member having hollow tubes pre-injected with at least one infusion material, said hollow tubes interlinked with each other to form a mesh structure to provide breathability to said fracture limb. The breathable orthopedic cast device either a flat unfolded geometry that can be applied over said injured body member by wrapping, or can be customized to a shape corresponding to the contours of the body member and thereby wearable like a glove over said injured body member.

Claims

1. An improved breathable orthopedic cast device comprising: customizable cast member of single layer cavity structure of hollow tubes interlinked with each other to form a mesh structure; an inlet to receive at least one infusion material; customizable cast member is flexible material consisting of silicone rubber, latex rubber, synthetic rubber or any combination thereof.

2. An improved breathable orthopedic cast device as claimed in claim 1, wherein said customizable cast member is a flat unfolded geometry with varied sizes preshaping the network to conform to the portion of the body.

3. An improved breathable orthopedic cast device as claimed in claim 2, further comprising at least one locking member provided on at least one periphery surface of said customizable cast member, and said locking member is adapted to secure said periphery surface to other end when said customizable cast member.

4. An improved breathable orthopedic cast device as claimed in claim 1, wherein said applied customizable cast member is having a shape corresponding to the contours of the body member and wearable like a glove over said body member.

5. An improved breathable orthopedic cast device as claimed in claim 1, said infusion material is pre-injected before the application to the body member or post injected after the application to the body member into single layer cavity of customizable cast member.

6. An improved breathable orthopedic cast device as claimed in claim 5, wherein said infusion material is selected from a group consisting of low viscosity epoxy material that includes epoxy resins, acrylate fillers and activators, polyurethane, polymer or any combination thereof.

7. An improved breathable orthopedic cast device as claimed in claim 6, wherein the process of hardening or curing of infusion material comprises external UV light or thermal curing at room temperature or chemical reaction curing.

8. An improved breathable orthopedic cast device as claimed in claim 1, wherein at least one dimension of said cast member is adjusted according to the contour of a patient's limb because of its elasticity and flexibility.

9. A method of implementation of breathable orthopedic cast system on a body member comprising the steps: a) the customizable cast member have a shape corresponding to a contour of a body member; b) pre-injected at least one infusion material into said customizable cast member into single layer cavity structure of hollow tubes interlinked with each other to form a mesh structure; c) applied customizable cast member to the contours of the body member and securing it by means of a locking member; d) hardening of the said customizable cast member by unwrapping said polythene layer or allowing the injected infusion material to harden by external UV light curing.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0050] The above and other aspects, features, and advantages of certain exemplary embodiments of the present invention will be more apparent from the following description taken in conjunction with the accompanying drawings in which:

[0051] FIG. 1 illustrates 3-Dimensional view of flexible cast member before application to a fractured limb, in accordance with an embodiment of the present subject matter.

[0052] FIG. 2 illustrates the flexible cast member with a cavity to receive infusion material, in accordance with an embodiment of the present subject matter.

[0053] FIG. 3 illustrates the flexible cast member with a locking member provided on one periphery surface of the said flexible cast member, in accordance with an embodiment of the present subject matter.

[0054] FIG. 4 illustrates the flexible cast member being wrapable around a fracture site, in accordance with an embodiment of the present subject matter.

[0055] FIG. 5 illustrates the flexible cast member after application to an individual's limb, in accordance with an embodiment of the present subject matter.

[0056] FIG. 6 illustrates application of an infusion material to the flexible cast member, in accordance with another embodiment of the present subject matter.

[0057] FIG. 7 illustrates cast cutter to cut the flexible cast member, in accordance with an embodiment of the present subject matter.

[0058] Persons skilled in the art will appreciate that the elements in the figures are illustrated for simplicity and clarity and may have not been drawn to scale. For example, the dimensions of some of the elements in the figure may be exaggerated relative to other elements to help to improve understanding of various exemplary embodiments of the present disclosure. Throughout the drawings, it should be noted that like reference numbers are used to depict the same or similar elements, features, and structures.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

[0059] The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of exemplary embodiments of the invention. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary.

[0060] Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope of the invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.

[0061] The terms and words used in the following description and claims are not limited to the bibliographical meanings but are merely used by the inventor to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustration purpose only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.

[0062] It is to be understood that the singular forms a, an, and the include plural referents unless the context clearly dictates otherwise.

[0063] Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments.

[0064] It should be emphasized that the term comprises/comprising when used in this specification is taken to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

[0065] The objects, advantages and other novel features of the present invention will be apparent to those skilled in the art from the following detailed description when read in conjunction with the accompanying drawings.

[0066] In one implementation, as shown in FIG. 1, 3-Dimensional view of flexible cast member (1) before application to a patient's injured body member, wherein the injured body member can be a fractured limb. The flexible cast member comprises: a customizable cast member (1) having plurality of hollow tubes (4) injected with an infusion material, said hollow tubes interlinked with each other to form a mesh structure (3) to provide breathability to said fracture limb. As shown in FIG. 2, the infusion material can be injected into a cavity (5) provided on the surface of the cast member (1).

[0067] In one implementation, the flexible cast (1) further comprises at least one locking member (6) as shown in FIG. 3 that can be provided on a periphery surface of said customizable cast member (1). The locking member (6) adapted to secure said periphery surface to other end when the customizable cast member may be wrapped around an injured body member. The locking member can be selected from, but not limited to, snap fit, Velcro or any combination thereof.

[0068] In one implementation, the flexible cast member (1) can be a flat unfolded geometry which can be wrapped over a fractured limb and the said flexible cast member can be fixed with the locking means. This structure of the breathable orthopedic cast device gives more feasibility during application, less pain to patient and faster application. The flat, unfolded design of flexible cast member reduce requirement of size variation.

[0069] In one implementation, as shown in FIG. 2, the flexible cast member (1) with a cavity (5) to receive infusion material using an external techniques. The flexible cast member (1) comprises hollow tubes (small and inflated) and infused with infusion material.

[0070] In one implementation, the said infusion material can be pre-injected into the cavities of the hollow tubes of the said flexible cast member (1) before application to a fractured limb. This may remove the need of an infusion assembly in the cast member as shown in FIG. 6. Due to the removal of the Infusing assembly from the device, the application process and expected time to apply has been reduced from 20 minutes to 10 minutes Curing of the infusion material can be initiated externally using a specific technique. This can reduce the total application of the breathable orthopedic cast device around the fractured limb from 20 minutes to 10 minutes. The pre-injected material may be a visible light curable epoxy resin which can be cured when exposed natural day light.

[0071] In one implementation, as shown in FIG. 4, the flexible cast member is capable of being wrapped in a particular direction (7) around a fracture site and gets securely locked by engaging the said locking member (6) as illustrated in FIG. 3.

[0072] In another implementation, as shown in FIG. 5, the flexible cast member (2) after application to an individual's limb wherein the flexible cast member can be used like a Flexible Glove (2). The Flexible Glove like structure of the cast device (2) can be rolled down initially and then while wearing on the limb it is rolled up on the selected limb. The glove like structure identical to rubber gloves comprising interlinked network of hollow tubules (4) which may be worn on the fractured limb and the infusion material may be post-injected at the time of application for hardening the cast to immobilize the limb. The infusion/injection of a material is required after wearing flexible cast as shown in FIG. 6. Flexible Glove like structure is rolled down initially and then while wearing on the limb, it is rolled up on the selected limb. The cavity/hole provided in said flexible cast member facilitates infusion material to be infused inside the cast member after application to the fractured limb. The Flexible Glove like structure can easily cut by means of a cutting tool as shown in FIG. 7. The cutting tool can be hand operated device works without electricity. The tool has a hinge and blunt blades facing inside for safe cutting. Cutter can also be mechanically powered as it requires no external power source and safe even in unskilled hands.

[0073] In all implementation, the size of the flexible cast member (1 & 2) can be customized according to the patient's limb size. The cast member can be made up of a material selected from a group of a flexible/elastic material that may include but not limited to a silicon rubber, latex rubber, synthetic rubber or any combination thereof. The material are stretchable and provide ability to accommodate external features of a patient's limb. The mesh like structure (3) of the flexible cast member (1 & 2) enables doctors or technician to monitor normal circulation or swelling around the fracture site.

[0074] In all the implementation, the infusion material can be selected from a group of low viscosity epoxy material that includes epoxy resins, acrylate fillers and activators, polyurethane or any combination thereof.

[0075] In all the implementation, the curing of the infusion material is done using a curing technique that may be selected from any composite material curing technical that may include but not limited to, thermal curing, ultra violet curing, visible light curing electromagnetic or electron curing and the like. In the implementation of the present invention, light curable composite epoxy resin can used as an infusion material. Therefore, the property of light curing techniques gives freedom to cure material by exposing it to light and plain epoxy is mixed with filler material such as nanofibers to increase strength of cured material. The curing technique have to be carried out under the strict medical supervision if used in orthopedic practices.

[0076] In all implementation, the breathable orthopedic cast device for immobilizing and stabilizing comprises following components:

[0077] 1. Customizable cast (1 or 2);

[0078] 2. Hardening or infusion material; and

Customizable Cast:

[0079] In one implementation, the customizable cast member (1) may be a flat unfolded geometry which can be wrapped over a fractured limb and may be fixed with specially designed locks. The customizable cast member may be made of a material selected from a group of a flexible material that includes a silicon rubber, latex rubber, synthetic rubber or any combination thereof. The customizable cast member may be customized into 4-5 sizes according to anthropometric data. The Cast has different small geometry's inspired from nature to give strongest structure. Cast shape may vary according to fracture site and purpose of application that may include but not limited to short arm cast, full arm cast, barrel cast for both limbs, Spica, neck collar. On choosing appropriate size, cast will take shape according to contours of patient's limb. The cast member (1) may be provided with a locking member (6) to secure the cast member when it is wrapped around a fracture limb.

[0080] In another implementation of the invention, the flexible cast may be identical to rubber gloves (2) that comprises interlinked network of hollow tubules (4) which may be worn on the fractured limb. The flexible cast (2) can be cut by means of a cutting tool as shown in FIG. 7 during removal.

[0081] In both the implementation, the cast member may be in the form of mesh structure (3) made of hollow tubes (small and inflated) interlinked with each other such as to form a network like structure (3) forming the customizable cast. The hollow tubes (4) of the cast may pre-infused or post-infused with the infusion material. The cast comprises an opening/hole through which the infusion material is infused in the cast.

Infusion Material/Hardening Material:

[0082] In one implementation, the infusion material can be a monomer material which is selected to give adequate strengthening for immobilization. Material will be provided as two premix forms which will be mixed by infusing system and infused into flexible cast. Polymerization may start within 5-10 minutes and can give basic hardening strength within 15 minutes. On complete polymerization, the infusion material may strengthens the cast member to give strength. The infusion material can be pre-infused or post-infused into channels of gloves from infusion port. Infusion material is fast curing, low viscosity epoxy material which will be provided in the form of two cartridge or premixed cartridge with flexible cast packing. Infusion may take place by infusion assembly as shown in FIG. 6, which work alike syringe pump, is mechanical or electrical powered and having tubes to connect with infusion port. Infusion can be done in reduced fracture position and maintained for 10-15 minutes after infusion. The flexible cast thereafter can achieve capable enough strength for stabilization of bone or damaged tendons. The mesh like structure of the cast provides breathability and insight to skin under cast. No padding is used in cast so the flexible cast member can be washed and cleaned whenever required.

[0083] The infusion material used in the present invention can be any material which has lower viscosity, which is skin friendly so that it does not harm even if it gets in contact with skin accidentally and which is able to be transformed into hard material within 10 minutes after the infusion.

[0084] In one implementation, breathable orthopedic cast device can be supplied to a hospital as flat, elastic and highly flexible structure (1) in specialized design and having hole for finger or any particular anatomical bone mark, other holes for breathability and lock on surface. The whole device can be covered by dark nontransparent polythene layer which can later be removed after application. The purpose of polythene layer is to block sunlight to epoxy material which may get cured if exposed to sunlight for prolonged period. In the implementation, any material which blocks sunlight and can be removed when required, is suitable for this purpose.

[0085] According to another implementation of the present invention, the flexible cast is made like a rubber pouch in shape of hand glove (2) with multiple holes (4). Cast part made of the rubber can be adapted to the shape and size of the limb and enables the hardening material from being exposed to skin. Hardening material is filled in the cavity.

[0086] In the present invention, the breathable cast device (1) can be applied by wrapping over the fractured body part, secure lock after keeping proper tension over device. The breathable cast device can also be worn like a glove (2). Fracture bone can be aligned into normal anatomical position and initiate curing by unwrapping dark polythene layer. Light curable material can be pre-infused or post-infused into the hollow tube (4) and cured within 5 minutes after unwrapping polythene layer. In some case artificial light may be required when natural light is not adequate at time i.e. night or place i.e. closed room of the application. The time of curing can be reduced from 10 minutes to 5-7 minutes. For removal of the device, either the locking means can be released or the breathable cast device (2) can be cut by mean of a cutting tools.

[0087] The present invention provides a cost effective and highly efficient casting system/assembly. The breathable cast device has following advantageous technical features: [0088] lighter in weight; [0089] breathable: due to the mesh/network structure, the device facilitates air to enter the skin and prevents sweating; [0090] washable; [0091] able to be customized according to the need of an individual patient; [0092] is capable of maintaining a uniform pressure though out the covered area allows to see the skin to keep a gaze for swelling under the covered skin part; [0093] The complete cast system/assembly works in a low resource settings; [0094] Supports dry curing, that is, the cast member doesn't require water for curing; [0095] Supports programmable Time to operate, that is, control over curing process; [0096] Application of breathable orthopedic cast device can be extend to muscle or tendon sprains, joint injury, Scoliosis or other condition which requires short-term or long term immobilization. [0097] There is no need of padding material or padding layer because the flexible part of the cast is made up of skin safe material. [0098] There will be uniform pressure because the flexible part of the cast adapts shape and size of limb. [0099] The elastic material, i.e., silicon rubber, itself provides cushning because of its compressibility

[0100] Although implementations for a breathable and customized cast for immobilization of fractured limb have been described in language specific to structural features and/or methods, it is to be understood that the appended claims are not necessarily limited to the specific features or methods described. Rather, the specific features and methods are disclosed as examples of implementations for a breathable and customized cast for immobilization of fractured limb.