Overmolding for an orthopedic walking boot

Abstract

An orthopedic walking boot including a base to support a user's foot; a support assembly extending from the base to support the user's lower leg; and an outer sole overmolded to the base.

What is claimed is: 
     
         1 . An orthopedic walking boot, comprising:
 a base extending from a toe of the walker to a heel, the base including a substrate section having a substantially smooth lower surface, the base further comprising a recessed section at the heel including holes that extend through the base;   an outer sole overmolded to the base, an upper surface of the outer sole chemically bonded to a lower surface of the base without adhesive; and wherein the holes in the recessed section anchor portions of the outer sole to add shear strength to a mating of the outer sole and the base; and   a vertical support assembly removably coupled to the base.   
     
     
         2 . The orthopedic walking boot of  claim 1 , further comprising a shock absorber insert mated with the base to provide shock absorption, at least a portion of the outer sole is overmolded to both the base and the shock absorber insert. 
     
     
         3 . The orthopedic walking boot of  claim 1 , wherein the base comprises a section configured to support the user's posterior portion of the heel, the orthopedic walking boot further comprising a heel cushion overmolded to an interior portion of the section, wherein the outer sole and the heel cushion comprise a continuous material overmolded to the base using one or more connective tunnels to facilitate resin flow. 
     
     
         4 . The orthopedic walking boot of  claim 3 , wherein the outer sole and said heel cushion comprise a continuous material using a connective tunnel to facilitate resin flow. 
     
     
         5 . An orthopedic walking boot, comprising:
 a base extending from a toe of the walker to a heel, the base including a substrate section having a substantially lower surface;   an outer sole overmolded to the base, an upper surface of the outer sole chemically bonded to a lower surface of the base without adhesive; and   a vertical support assembly removably coupled to the base.   
     
     
         6 . The orthopedic walking boot of  claim 5 , further comprising a shock absorber insert mated with the base to provide shock absorption, at least a portion of the outer sole is overmolded to both the base and the shock absorber insert. 
     
     
         7 . The orthopedic walking boot of  claim 5 , wherein the base comprises a section configured to support the user's posterior portion of the heel, the orthopedic walking boot further comprising a heel cushion overmolded to an interior portion of the section, wherein the outer sole and the heel cushion comprise a continuous material overmolded to the base using one or more connective tunnels to facilitate resin flow. 
     
     
         8 . The orthopedic walking boot of  claim 7 , wherein the outer sole and said heel cushion comprise a continuous material using a connective tunnel to facilitate resin flow.