Three-Layer Breast Prosthesis with Gradient Silicone Firmness
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Solution Overview
Problem
Conventional breast prostheses made from soft silicone gel are uncomfortable to wear and have an unnatural appearance due to insufficient firmness and drape.
Innovation Solution
A multi-chamber breast prosthesis with three layers of silicone gel enclosed in polyurethane film, where the outer layer is soft for comfort, the middle layer is firm for support, and the inner layer is soft for natural drape, using varying concentrations of methyl hydrosiloxane polymer cross-linker to achieve desired firmness levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If silicone gel is cured to have firmness to maintain breast shape, then shape stability is improved, but comfort and natural drape deteriorate
Solution Approach 1:
The breast prosthesis is divided into three distinct layers with different firmness levels. The first layer (20-25mm penetration) provides softness for comfort, the second layer (10-15mm penetration) provides structural support, and the third layer (5-10mm penetration) provides firm shape maintenance. This segmentation allows each layer to perform its specific function without compromise.
Solution Approach 2:
Different regions of the breast prosthesis are assigned different material properties (firmness levels) based on their functional requirements. The outer layer has lower firmness for comfort and drape, the middle layer has intermediate firmness for support, and the inner layer has highest firmness for shape stability. This local differentiation resolves the contradiction between overall comfort and shape maintenance.
2Strength
If silicone gel concentration of cross-linker is increased to improve firmness, then shape maintenance is improved, but comfort and natural appearance deteriorate
Solution Approach 1:
The cross-linker concentration is varied locally across different layers of the prosthesis. The first layer uses 0.5-1.5% cross-linker for softness, the second layer uses 1.5-2.5% for intermediate firmness, and the third layer uses 2.0-3.0% for maximum firmness. This gradient approach allows each region to have the appropriate firmness for its function.
Solution Approach 2:
The prosthesis is segmented into three chambers, each containing silicone gel with a specific cross-linker concentration. This segmentation enables precise control over the firmness profile throughout the prosthesis, with softer outer layers for comfort and firmer inner layers for shape support.
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 breast prosthesis provides comfort, natural drape, and maintains a natural breast form shape during use, addressing the discomfort and asymmetry issues of previous designs.
Implementation Method 1
The first material includes a silicone gel with a first concentration of a methyl hydrosiloxane polymer cross-linker. The second material includes a silicone gel with a second concentration, greater than the first concentration, of a methyl hydrosiloxane polymer cross-linker. The third material includes a silicone gel with a third concentration, less than the second concentration, of a methyl hydrosiloxane polymer cross-linker.
Implementation Method 2
The mold, the breast form envelope, the first material, the second material and the third material are heated to a temperature sufficient to cure the first material to the first firmness, the second material to the second firmness and the third material to the third firmness.
Data Source
AI summary
A breast prosthesis that includes an outer first layer, a middle second layer and an inner third layer. The outer first layer includes a first material that has a first firmness. The first firmness allows for a 20 mm to a 25 mm penetration by a cone penetrometer. The first layer has a shape corresponding to a shape of a breast form. The middle second layer is disposed adjacent to the first layer and includes a second material that has a second firmness that is greater than the first firmness. The inner third layer is disposed adjacent to the second layer opposite from the first layer and includes a third material that has a third firmness that is less than the second firmness.