I have tried yo understand this problem but have resorted eventually to AI. This version of AI is American so excuse spellings!! 
This is what it suggests:
1. A Custom Silicone Orthodigital Device (The Modern Separator)
^Since your old separator broke, you need a replacement. Instead of buying cheap, generic gel wedges from a pharmacy (which often slip out of place or don't fit right), you can ask a podiatrist to mold a custom silicone toe orthosis directly to your foot. They mix a putty that cures right on your toes, creating a perfect, durable separator that props the third toe up and keeps the fourth toe straight.^
2. Budin Toes / Toe Straightening Sleeves
These are elasticated bands or small pads that sit under the ball of your foot with a little loop that goes over the tucked toe. When you tighten the loop, it physically pulls the tucked toe upward and straight, keeping it from diving under its neighbor.
3. Tenotomy (A Simple, Permanent Fix)
If you want a permanent solution so you never have to worry about separators again, ask a podiatrist or foot surgeon about a flexor tenotomy.
This is a very simple, 10-minute in-clinic procedure done under local anesthetic. The practitioner makes a tiny pinprick poke under the toe and releases the tight tendon that is pulling the toe downward. The toe instantly relaxes, flattens out, and stops tucking under. There are usually no stitches required, and walking recovery is immediate.
When you look for your next foot care professional, look for a Podiatrist rather than a traditional chiropodist, and ask specifically about structural solutions.
When you book, say: "I have a painful underlapping fourth toe that tucks under the third. I need an appointment to look at a custom silicone separator or to discuss a tendon release (tenotomy)."
I do hope thus helps. If ig were me with this problem I'd definitely be drawn to the Trnotomy option.
I'd want to research it of course but the idea of immediate release sounds extraordinary and blissful.
All the very best.
