Self-Sealing Prosthetic Membrane via Layered Elastic Recovery
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Solution Overview
Problem
Current prosthetic implants, such as tissue expanders, lack effective and reliable self-sealing capabilities, leading to fluid leaks when punctured or expanded, which can require additional surgical interventions.
Innovation Solution
A method involving the application of tension to a first layer of cured elastomeric material, followed by the application and curing of additional uncured elastomeric layers, creating a self-sealing membrane with contraction properties that prevent fluid leakage when punctured.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional dip-molding process is used to form implant shell, then manufacturing simplicity is maintained, but self-sealing capability is lost leading to fluid leaks when punctured
Solution Approach 1:
The implant shell is divided into multiple layers: a base cured elastomeric layer and additional uncured elastomeric layers applied while the base layer is under tension. This segmentation allows the uncured layers to be held in contraction by the tensioned base layer, creating self-sealing pockets that can close puncture sites and prevent fluid leaks.
Solution Approach 2:
The base layer is put under tension before the additional uncured layers are applied and cured. This preliminary tensioning creates a contracted state in the additional layers that will automatically seal punctures when the implant is later punctured during normal use. The tension is maintained throughout the curing process to ensure proper contraction.
2Reliability
If patch is applied to seal mandrel opening, then fluid imperviousness is achieved, but self-sealing capability against punctures is not provided
Solution Approach 1:
The implant shell combines cured and uncured elastomeric materials in a multi-layer construction. The uncured elastomeric layers provide unique self-sealing properties when held in contraction, while the cured base layer provides structural integrity. This composite approach creates both fluid imperviousness and self-sealing capability against punctures.
3Manufacturing precision
If shell is stretched over disk to apply layers, then uniform layer distribution is achieved, but manufacturing time increases
Solution Approach 1:
The base layer is stretched over the disk and tension is applied before the additional uncured layers are applied. This preliminary tensioning ensures uniform distribution of the additional layers across the shell surface. The tension is maintained throughout the curing process, ensuring consistent contraction and self-sealing properties throughout the implant.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The self-sealing membrane effectively prevents fluid leakage by holding the additional layers in contraction, enhancing the self-sealing properties of prosthetic implants and reducing the risk of further surgical interventions due to fluid loss.
Implementation Method 1
applying tension to a first layer of a cured elastomeric material to stretch the first layer
Implementation Method 2
after the second layer is cured, tension is released from the first layer whereupon the first layer returns to a non-stretched configuration for holding the second layer in contraction
Data Source
AI summary
A method of making a self-sealing membrane for a prosthetic implant includes applying tension to a first layer of a cured elastomeric material to stretch the first layer, and while the first layer remains stretched, applying a second layer of an uncured elastomeric material over a first major surface of the first layer. After the second layer is cured, the tension on the first layer is released, whereupon the first layer returns to a non-stretched configuration for holding the second layer in contraction. The method includes, while the first layer remains stretched, applying a third layer of an uncured elastomeric material over a second major surface of the first layer. After curing the second and third layers, tension is released from the first layer, which returns to the non-stretched configuration for holding the second and third layers in contraction.