UV-Cured Polymer Sheet for Immobilization with Localized Cross-Linking
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Solution Overview
Problem
Existing methods for manufacturing polymer sheets for immobilization elements lack the ability to variably control mechanical properties both in the molten state and the final product, which is crucial for precise positioning and comfort in applications like radiation therapy and diagnostic imaging.
Innovation Solution
A method involving a polymer sheet made from polycaprolactone, polyethylene copolymers with α-olefins, and a photo-initiator, partially cured by UV radiation to control cross-linking and mechanical properties, allowing for adjustable thickness and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the polymer sheet is fully cross-linked to provide stability and rigidity for precise positioning, then the immobilization stability is improved, but the flexibility and wear comfort deteriorate
Solution Approach 1:
The patent applies different degrees of cross-linking to different zones of the polymer sheet. The first zone (contacting the body part) has a first degree of cross-linking providing flexibility and comfort, while the second zone (support structure) has a second degree of cross-linking providing rigidity and stability. This local differentiation resolves the contradiction between overall stability and localized comfort.
2Strength
If the polymer sheet thickness is increased to provide adequate support and stability, then the structural strength is improved, but the flexibility and adaptability to body contours deteriorate
Solution Approach 1:
The patent creates zones with different cross-linking degrees within the same thickness profile. The first zone with lower cross-linking maintains flexibility and adaptability to body contours, while the second zone with higher cross-linking provides the necessary structural strength and support, eliminating the need to increase overall thickness.
3Ease of manufacture
If conventional manufacturing methods are used, then the production process is simple, but the ability to control mechanical properties in both molten and final states deteriorates
Solution Approach 1:
The patent controls the degree of cross-linking as a key parameter to adjust mechanical properties. By varying the cross-linking degree in different zones (first zone vs. second zone), the patent achieves precise control over flexibility, rigidity, and other mechanical properties in both the molten state and final product, while maintaining a relatively simple manufacturing process using UV irradiation.
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
Enables precise control over the mechanical properties of the polymer sheet, providing stability and comfort by varying cross-linking, which is essential for accurate and reproducible positioning of body parts during treatments.
Implementation Method 1
a method according to any one of the preceding claims, characterized in that a polymer sheet, having a thickness of 1.0 to 5.0 mm, which is at least partly made of a polymer material comprising a polymer from the group of polycaprolactone, a copolymer of polyethylene with at least one α-olefin with 3-10 C atoms, or a mixture of two or more of the aforementioned polymers, and a photo-initiator, is at least partially cured by exposure to UV radiation for the at least partial cross-linking of the polymer
Data Source
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AI summary
The present invention relates to a method for manufacturing a polymer sheet for use as an immobilization element, wherein the sheet is at least partly made of a polymer material comprising a polymer from the group of polycaprolactone, a copolymer of polyethylene with at least one α-olefin having 3-10 C atoms, or a mixture of two or more of the aforementioned polymers, a photoinitiator, and a photo-cross-linker, wherein the polymer sheet has a thickness of 1.0 to 5 mm and wherein the polymer sheet is at least partially cured by exposing to UV radiation for the at least partially cross-linking of the polymer.