Compression brace material with spacer fabric inner layer
The present invention provides a composite material for use in making orthopedic elastic braces for supporting a body part by compression. One embodiment of the invention is a compression brace material ( 400 ) having an elastic outer layer ( 410 ), a first fabric layer ( 420 ), a spacer fabric layer ( 425 ), and a second fabric layer ( 430 ). The spacer fabric layer permits and promotes airflow laterally through the brace material. The outer layer may have a plurality of slits ( 550 ) therethrough to permit and promote airflow transversely through the composite material. The plurality of slits may be arcuate to further improve transverse airflow through the composite brace material.
1. A composite material for use in constructing compression braces, the composite material comprising:
a first layer comprising an elastically stretchable material having an inner face and an outer face;
a flexible second layer having an outer face affixed to the first layer inner face, the second layer further having an inner face;
a third layer comprising a spacer fabric having an outer face affixed to the second layer inner face, the third layer further having an inner face; and
a flexible fourth layer having an outer face affixed to the third layer inner face.
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 therethrough.
4. The composite material of claim 3 , wherein the plurality of slits in the first layer are arcuate.
5. The composite material of claim 3 , wherein the second and fourth layers comprise knitted sheets of fabric made from synthetic fibers.
6. The composite material of claim 5 , wherein a plurality of longitudinal channels are formed in the inner face of the first layer.
7. The composite material of claim 1 , wherein the layers are affixed with an adhesive.
8. The composite material of claim 1 , wherein the spacer fabric comprises a pair of spaced-apart ground fabrics interconnected by a plurality of transverse strands.
9. The composite material of claim 8 , wherein the spacer fabric is produced on a rib-knitting Raschel machine.
10. The composite material of claim 8 , wherein the spacer fabric has a thickness in the range of 1 mm to 10 mm.
11. A compression brace comprising an elastic tubular structure formed from a sheet of the composite material of claim 1 , wherein the tubular structure is formed by sewing oppositely disposed edges of the composite material sheet together.
12. The compression brace of claim 11 , wherein the compression brace is a unitary member comprising first and second tubular portions that are angularly connected.
13. A composite orthopedic support material comprising:
a first panel made from an elastically stretchable material, the first panel having an inner face and an outer face;
a porous, elastic second panel attached to the first panel and overlying the inner face of the first panel, the second panel having an inner face;
a third panel comprising a spacer fabric, the third panel attached to the second panel and overlying the inner face of the second panel, the third panel further having an inner face; and
a porous, elastic fourth panel attached to the third panel and overlying the inner face of the third panel.
14. The composite orthopedic support material of claim 13 , wherein the first panel comprises a polychloroprene elastomer.
15. The composite orthopedic support material of claim 14 , wherein the porous, elastic second and fourth panels comprise a knitted sheet of material made from synthetic fibers.
16. The composite orthopedic support material of claim 13 , wherein the first panel inner face includes a plurality of arcuate slits therethrough.
17. A compression brace comprising an elastic tubular structure formed from a sheet of the composite material of claim 13 , wherein the tubular structure is formed by sewing oppositely disposed edges of the composite material sheet together.
18. The compression brace of claim 17 , wherein the compression brace is a unitary member comprising first and second tubular portions that are angularly connected.