Method for overmolding a painted silicone rubber human extremity prosthesis

• US 7,316,795 B1
• Filed: 03/02/2004
• Issued: 01/08/2008
• Est. Priority Date: 03/02/2004
• Status: Active Grant

• Current Assignee: Stefan Johannes Knauss
• Original Assignee: Stefan Johannes Knauss
• Inventors: Knauss, Stefan Johannes
• Primary Examiner(s): Johnson; Christina
• Assistant Examiner(s): Daniels; Matthew J.
• Application Number:
  US10/792,548
• Time in Patent Office: 1,407 Days
• Field of Search: 62/53, 427/2.1, 264/279, 264/313
• US Class Current: 264/313
• CPC Class Codes: A61F 2/5046 for designing or making customized prostheses, e.g. using templates, finite-element analysis or CAD-CAM techniques
• CPC Class Codes: A61F 2002/5001 Cosmetic coverings
• CPC Class Codes: A61F 2002/5053 using a positive or a negative model, e.g. casting model or mould
• CPC Class Codes: A61L 27/18 obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: C08L 83/04 Polysiloxanes

Abstract

The invention relates to method for overmolding a painted silicone prosthesis of a human extremity. A silicone prosthesis is first molded from a solid replica of a human extremity and then painted to closely resemble the color of the recipient person. An elasotmeric polymer material having the properties of elasticity, transparency, and non-adhesiveness to cured silicone rubber is applied to the replica to form a transparent glove-like overmold. The glove has an inner surface that is mirrored by the surface of the replica. The distal portion of the glove-like overmold is partially filled with a predetermined amount of viscous uncured silicone liquid and the painted silicone prosthesis is then inserted into the glove which is stretched tightly over the prosthesis. A compressive force is externally applied in a radial compressive and proximate direction to uniformly distribute the liquid silicone over the painted surface of the prosthesis. The silicone is allowed to cure and bonds to the surface of the prosthesis but does not adhere to the transparent glove-like overmold.

Claims

1. A method for overmolding a silicone rubber prosthesis of a human extremity, said silicone rubber prosthesis of the type where the silicone rubber prosthesis is molded from a replica made of said human extremity, said silicone rubber prosthesis having a distal end, a proximate end, comprising,

(a) painting said surface features of said silicone rubber prosthesis;

(b) forming a transparent glove-like overmold of desired thickness of said replica, said glove-like overmold having an inner surface and outer surface where said inner surface has surface features substantially identical to said replica and where said transparent glove-like overmold has a distal portion, an intermediate portion, and a proximate portion, said proximate portion having an opening therein sufficiently dimensioned to permit said transparent glove-like overmold to receive said painted surface of said silicone rubber prosthesis, and where said transparent glove like overmold is made of an elastomeric polymer material having the property of being non-adhesive to cured silicone rubber and transparent;

(c) after step (b), filling said distal portion of said transparent glove-like overmold at least in part with a viscous uncured silicone rubber material;

(d) after step (c), inserting said silicone rubber prosthesis into said opening such that each said distal end of said silicone rubber prosthesis is enclosed by said distal portion of said transparent glove-like overmold,

(e) after step (d), stretching said inner surface of said transparent glove-like overmold over said painted surface features and aligning said inner surface features with said painted surface features and then applying an external force to said transparent glove-like overmold so as to distribute said viscous uncured silicone material uniformly over said painted surface; and

(f) after step (e), curing said viscous uncured silicone rubber material and removing said transparent glove-like overmold from said silicone rubber prosthesis.

2. The method recited in claim 1 where said silicone rubber prosthesis of said human extremity is a silicone rubber hand prosthesis.

3. The method recited in claim 1 where said silicone rubber prosthesis of said human extremity is a silicone rubber foot prosthesis.

4. The method recited in claim 1 wherein said elastomeric polymer material is a thermoplastic elastomer.

5. The method recited in claim 1 wherein said elastomeric polymer material is a polyurethane elastomer.

6. The method recited in claim 1 further comprising after step (e), the step of curing said uncured viscous silicone rubber material.

7. The method recited in claim 6 wherein said elastomeric polymer material is a thermoplastic elastomer.

8. The method recited in claim 6 wherein said elastomeric polymer material is a polyurethane elastomer.

9. In a method for overmolding the geographic surface features of a silicone rubber prosthesis of a human extremity, said silicone rubber prosthesis of the type where the silicone rubber prosthesis is molded from a replica made of said human extremity, where said replica has a distal end surface, an intermediate surface portion, and a proximate end surface substantially identical respectively to the distal portion, intermediate portion, and proximal portion of said silicone rubber prosthesis and where said silicone rubber prosthesis has a painted surface, the improvement comprising the steps of:

(a) applying an elastomeric polymer material having the property of being transparent and non adhesive to cured silicone rubber to said replica to form a transparent glove-like overmold of desired thickness, said transparent glove-like overmold having an inner surface and outer surface where said inner surface has surface features substantially identical to the surface features of said replica;

(b) separating said transparent glove-like overmold from said replica where said inner surface features of said transparent glove-like overmold are substantially identical respectively to said distal end surface of said replica, said intermediate surface portion of said replica, and said proximate end surface of said replica;

(c) after step (b), filling said transparent glove-like overmold at least in part with a viscous uncured silicone rubber material;

(d) after step (c) inserting said painted silicone rubber prosthesis into said transparent glove-like overmold sufficiently such that said silicone rubber prosthesis extends into said transparent glove-like overmold and where said inner surface of said transparent glove-like overmold and said painted surface of said silicone rubber prosthesis are oppositely disposed in mirror image relationship;

(e) after step (d) stretching said inner surface of said transparent glove-like overmold over and into alignment with said painted surface features of said silicone rubber prosthesis and then applying an external force to said transparent glove-like overmold so as to distribute said viscous uncured silicone material uniformly over said painted surface of said silicone rubber prosthesis; and

(f) after step (e), curing said viscous uncured silicone rubber material and removing said transparent glove-like overmold from said silicone rubber prosthesis.

10. The method recited in claim 9 where said silicone rubber prosthesis of a human extremity is a silicone rubber hand prosthesis.

11. The method recited in claim 9 where said silicone rubber prosthesis of a human extremity is a silicone rubber foot prosthesis.

12. The method recited in claim 9 wherein said elastomeric polymer material is a thermoplastic elastomer.

13. The method recited in claim 9 wherein said elastomeric polymer material is a polyurethane elastomer.

14. The method recited in claim 9 further comprising after step (d), the step of curing said uncured viscous silicone rubber material and removing said transparent glove-like overmold from said silicone rubber prosthesis.

15. The method recited in claim 14 wherein said elastomeric polymer material is a thermoplastic elastomer.

16. The method recited in claim 14 wherein said elastomeric polymer material is a polyurethane elastomer.

17. The method recited in claim 9 wherein said elastomeric polymer material is applied to said replica by dipping said replica in said elastomeric polymer material.

18. The method recited in claim 9 wherein said elastomeric polymer material is applied to said replica by spraying said replica with said elastomeric polymer material.

19. The method recited in claim 9 wherein said elastomeric polymer material is applied to said replica by brushing said elastomeric polymer material onto said replica.