Moldable injury therapy device and method

1. A multi-phase orthopedic system, comprising:

(a) a sleeve formed of moisture-impervious material and sealable to prevent entry of moisture;

(b) a moldable splint positioned in the sleeve and sealed therein against entry of moisture until use, the splint comprising a substrate, a reactive system impregnated into or coated onto the substrate and remaining stable when maintained in substantially moisture-free conditions and hardening upon exposure to sufficient moisture to form a rigid, self supporting structure, and a removable cover enclosing the substrate along its length and forming a barrier between the substrate and a limb during an initial treatment phase during which the splint is worn by a patient on the limb;

(c) an elongate removable wrap for retaining the splint on the limb; and

(d) a removable cast for application to the limb during a subsequent treatment phase, and comprising:

(1) a cast body having an interior side and exterior side;

(2) a flap carried by the body and movable between an open position, and a closed position overlying a part of the cast body to be applied to a treatment area of the limb, the flap adapted to cover and retain between the cast body and the flap the splint worn by the patient during the initial treatment phase in the same position as the location of the splint during the initial treatment phase;

wherein the removable cover is configured to be removed from the substrate prior to placing the moldable splint between the flap and the cast body.

2. A multi-phase orthopedic system according to claim 1 , wherein the substrate is pre-formed into a shape suitable for application to a limb to be treated.

3. A multi-phase orthopedic system according to claim 1 , wherein the removable cast includes a plurality of straps and complementary strap fastening rings for being releasably positioned around the cast for securing the cast to the limb.

4. A multi-phase orthopedic system according to claim 1 , wherein the cast includes a padding layer positioned on the cast to overlie a part of the cast body to be applied to the treatment area of the limb.

5. A multi-phase orthopedic system according to claim 1 , wherein the cast comprises a short arm cast adapted for being placed on a forearm of a patient, and includes a thumb recess portion positioned for receiving the thumb and a retention strap for retaining the thumb recess portion around the thumb.

6. A multi-phase orthopedic system according to claim 1 , wherein the substrate comprises an elongate medical bandage material substantially the same length as the sleeve and positioned in the sleeve in a single length along length of the sleeve, and a seal for resealing the sleeve against entry of moisture after a predetermined length of the bandage material has been dispensed from the sleeve for use to prevent hardening of the substrate of the bandage material remaining in the sleeve.

7. A method of immobilizing a limb in multiple treatment phases, comprising the steps of:

(a) providing:

(i) a sleeve formed of moisture-impervious material and sealable to prevent entry of moisture;

(ii) a splint positioned in the sleeve and sealed therein against entry of moisture until use, the splint comprising a substrate, a reactive system impregnated into or coated onto the substrate and remaining stable when maintained in substantially moisture-free conditions and hardening upon exposure to sufficient moisture to form a rigid, self supporting structure, and a cover enclosing the substrate along its length and forming a barrier between the substrate and a limb during an initial treatment phase during which the splint is worn by a patient on the limb;

(iii) an elongate removable wrap for retaining the splint on the limb; and

(iv) a removable cast for application to the limb, and comprising a cast body having an interior side and exterior side, and a flap carried by the body and movable between an open position, and a closed position overlying a part of the cast body to be applied to a treatment area of the limb, the flap adapted to cover and retain the splint between the cast body and the flap;

(b) removing the splint from the sleeve and wetting the splint;

(c) molding the splint to the limb;

(d) securing the splint in its molded position to the limb for being worn during an initial orthopedic treatment phase;

(e) removing the splint from the limb;

(f) removing the cover from the substrate;

(g) placing the splint between the flap and the cast body of the cast; and

(h) releasably applying the cast and the splint to the limb for being worn during a subsequent orthopedic treatment phase; removing the cover from the substrate before placing the splint between the flap and the cast body of the cast.

8. A method according to claim 7 , and including the step of pre-forming the substrate into a shape suitable for application to a limb to be treated.

9. A method according to claim 7 , and including the step of providing an elongate medical bandage material substantially the same length as the sleeve and positioned in the sleeve in a single length along the length of the sleeve, and a seal for resealing the sleeve against entry of moisture after a predetermined length of the bandage material has been dispensed from the sleeve for use to prevent hardening of the substrate of the bandage material remaining in the sleeve.