Method of manufacturing a tack-free gel for a surgical device
First Claim
1. A method of making a tack-free gel for a surgical device, comprising the steps of:
- providing a mold defining a mold cavity;
spraying the mold cavity with a plastic material;
pouring a molten gel being at a molding temperature into the mold cavity;
melting a layer of the plastic material of the mold cavity onto the molten gel by permitting the molten gel to contact the mold cavity;
cooling the molten gel to form a solidified gel; and
increasing thickness of the melted layer of plastic material by selecting a plastic material that has a melting temperature lower than the molding temperature of the molten gel and increasing the temperature differential between the melting temperature of the plastic material and the molding temperature of the molten gel.
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Accused Products
Abstract
A process of making a tack-free gel is disclosed comprising the steps of providing a mold defining a mold cavity, the mold cavity comprising a plastic material; pouring or injecting a molten gel having a high molding temperature into the mold cavity; and forming the tack-free gel as a thin layer of plastic of the mold cavity is melted over the gel. The forming step further comprises cooling the gel from the molten state to a solidified state. The melting temperature of the plastic material is lower than the molding temperature of the gel; and the higher the temperature differential, the greater the melting of the plastic material and the thicker the layer of the plastic material on the surface of the gel. The mold may be formed of low-density polyethylene (LDPE).
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Citations
19 Claims
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1. A method of making a tack-free gel for a surgical device, comprising the steps of:
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providing a mold defining a mold cavity; spraying the mold cavity with a plastic material; pouring a molten gel being at a molding temperature into the mold cavity; melting a layer of the plastic material of the mold cavity onto the molten gel by permitting the molten gel to contact the mold cavity; cooling the molten gel to form a solidified gel; and increasing thickness of the melted layer of plastic material by selecting a plastic material that has a melting temperature lower than the molding temperature of the molten gel and increasing the temperature differential between the melting temperature of the plastic material and the molding temperature of the molten gel. - View Dependent Claims (2, 3, 4)
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5. A method of making a tack-free gel for a surgical device, comprising the steps of:
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providing a mold cavity comprising a first portion being exposed and free of a plastic material and a second remaining portion of the mold hole comprising a plastic material; pouring or injecting a molten gel being at a molding temperature into the mold cavity; melting a layer of the plastic material of the second remaining portion of the mold cavity onto the molten gel by permitting the molten gel to contact the plastic material of the second remaining portion of the mold cavity; cooling the molten gel to form a solidified gel having a portion remaining tacky; and applying a low-friction material to the tacky portion of the solidified gel to make the solidified gel entirely tack-free. - View Dependent Claims (6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A method of making a tack-free gel for a surgical device, comprising the steps of:
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providing a mold cavity comprising a first portion being exposed and free of a plastic material and a second remaining portion of the mold hole comprising a plastic material; pouring or injecting a molten gel being at a molding temperature into the mold cavity; melting a layer of the plastic material of the second remaining portion of the mold cavity onto the molten gel by permitting the molten gel to contact the plastic material of the second remaining portion of the mold cavity; cooling the molten gel to form a solidified gel having a portion remaining tacky; and applying a low-friction material to the tacky portion of the solidified gel to make the solidified gel entirely tack-free, wherein applying a low-friction material to the tacky portion of the solidified gel further comprises applying a film to the tacky portion of the solidified gel. - View Dependent Claims (16, 17, 18, 19)
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Specification