Thermoplastic Immobilization Material Using Crosslinked Regrind
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Solution Overview
Problem
Existing thermoplastic materials for immobilization devices require a costly and complex chemical crosslinking step, which is not environmentally friendly and limits production flexibility, while also failing to achieve the right balance of properties such as melt strength, stretchability, and patient comfort.
Innovation Solution
A composition comprising 55 to 90 wt% of a first polymer with a low melting temperature, 5 to 35 wt% of a second chemically crosslinked regrind material, and optionally 2.5 to 15 wt% of a thermoplastic elastomer, eliminating the need for chemical crosslinking and providing a balanced set of properties suitable for immobilization devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If chemical crosslinking is used to improve melt strength and stability, then the material becomes more stable and stronger, but the production process becomes more complex and costly
Solution Approach 1:
The patent changes the chemical composition parameters by incorporating specific ratios of polycaprolactone (55-90 wt%), chemically crosslinked regrind (5-35 wt%), and thermoplastic elastomer (2.5-15 wt%). This parameter optimization achieves the required melt strength and stability without requiring chemical crosslinking steps in the production process, thus resolving the contradiction between strength and process complexity
Solution Approach 2:
The patent creates a composite material system combining three components with different properties: polycaprolactone for low melting temperature and formability, chemically crosslinked regrind for strength and stability, and thermoplastic elastomer for flexibility and comfort. This composite approach achieves the desired performance without complex production processes
2Reliability
If chemical crosslinking is applied to enhance material stability, then the material becomes more reliable, but environmental friendliness deteriorates
Solution Approach 1:
The patent incorporates chemically crosslinked regrind (5-35 wt%) into the composition, which represents recovered and reused material. This recycling approach maintains material stability and reliability while reducing environmental impact by avoiding the need for additional chemical crosslinking steps and minimizing waste
Solution Approach 2:
The patent uses thermoplastic elastomer (2.5-15 wt%) and polycaprolactone based materials that can be easily processed and disposed of or recycled after use. These materials provide sufficient performance for immobilization devices while being environmentally friendly compared to permanently crosslinked alternatives
3Ease of manufacture
If the melting temperature is lowered to enable direct molding on body parts, then the material becomes more adaptable and easier to manufacture, but the material may not maintain sufficient stability
Solution Approach 1:
The patent optimizes the melting temperature parameter by selecting polycaprolactone with a melting point between 40-75°C, enabling direct molding on body parts. The addition of chemically crosslinked regrind and thermoplastic elastomer modifies the material properties to maintain stability after molding, thus resolving the contradiction between ease of manufacture and stability
Solution Approach 2:
The patent combines polycaprolactone (providing low melting temperature and formability) with chemically crosslinked regrind (providing stability) and thermoplastic elastomer (providing flexibility and comfort). This composite structure enables direct molding while maintaining the necessary material stability for clinical applications
4Manufacturing precision
If molding time is extended to achieve detailed shaping, then the manufacturing precision improves, but the productivity decreases
Solution Approach 1:
The patent modifies the material parameters by incorporating chemically crosslinked regrind (5-35 wt%) and thermoplastic elastomer (2.5-15 wt%) into the polycaprolactone base. This composition modification extends the working time window, allowing detailed shaping to be completed within a reasonable time frame while maintaining high molding precision, thus balancing productivity and precision
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 solution produces a thermoplastic material that is sustainable, comfortable for patients, and suitable for demanding applications like radiation therapy and diagnostic imaging, with improved production efficiency and reduced equipment costs.
Implementation Method 1
the sheet or template is heated (e.g. in a warm water bath) in order to achieve that the sheet becomes flexible and moldable
Implementation Method 2
the mask is left to cool and stiffen to a rigid structure with a desired positioning and fixation ability
Data Source
AI summary
A composition for use in an immobilization device for immobilizing at least a portion of a body part comprising, based on total weight of the composition, a. 55 to 90 wt%, preferably 60 to 80 wt%, more preferably 65 to 75 wt% of a first polymer and/or a first regrind by-product thermoplastic material derived from such a first polymer which is not chemically crosslinked, with a melting temperature of below 100°C, preferably of between 40 and 75°C; b. 5 to 35 wt%, preferably 10 to 30 wt%, more preferably 15 to 20 wt% of a second regrind by-product thermoplastic material derived from such a first polymer which is at least partially chemically crosslinked; c. optionally 2.5 to 15 wt%, preferably 5 to 10 wt% of a thermoplastic elastomer; d. 0 to 5 wt% of total additives.