Overmolding for an orthopedic walking boot

Abstract

A method of manufacturing an orthopedic walking boot, comprising providing a base configured to support a user's foot and receive a support assembly configured to support the user's lower leg; and overmolding an outer sole to the base.

What is claimed is: 
     
         1 . A method for constructing an orthopedic walking boot, comprising:
 providing a plantar boot base having a substantially smooth lower surface;   placing the plantar boot base into a mold;   introducing a molten resin material into the mold to form a overmolded outer sole, the overmolded outer sole covering a lower surface and peripheral edges of the plantar base, wherein the molten resin material is selected to chemically bond to the plantar boot base without adhesive; and   connecting a vertically disposed leg support member to the plantar base.   
     
     
         2 . The method for constructing an orthopedic walking boot of  claim 1 , further comprising forming a plurality of channels on the lower surface of the plantar boot base, and wherein the molten resin material fills plurality of channels to add shear strength to a mating of the overmolded outer sole and the plantar boot base. 
     
     
         3 . The method for constructing an orthopedic walking boot of  claim 2 , wherein a density of channels in the plantar boot base is higher near a toe portion. 
     
     
         4 . The method for constructing an orthopedic walking boot of  claim 2 , wherein the channels comprise stepped walls. 
     
     
         5 . The method for constructing an orthopedic walking boot of  claim 1 , wherein the plantar boot base is formed from a polypropylene. 
     
     
         6 . A method for constructing an orthopedic walking boot, comprising:
 providing a plantar boot base having a substantially smooth lower surface;   placing the plantar boot base into a mold;   introducing a molten resin material into the mold to form a overmolded outer sole, the overmolded outer sole covering a lower surface of the plantar base, wherein the molten resin material is selected to chemically bond to the plantar boot base without adhesive; and   connecting a vertically disposed leg support member to the plantar base.