GB2085351A - A method of making an artificial limb component - Google Patents

A method of making an artificial limb component Download PDF

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Publication number
GB2085351A
GB2085351A GB8126954A GB8126954A GB2085351A GB 2085351 A GB2085351 A GB 2085351A GB 8126954 A GB8126954 A GB 8126954A GB 8126954 A GB8126954 A GB 8126954A GB 2085351 A GB2085351 A GB 2085351A
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GB
United Kingdom
Prior art keywords
mandrel
mould
composite material
component
sheets
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB8126954A
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GB2085351B (en
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Chas A Blatchford and Sons Ltd
Original Assignee
Chas A Blatchford and Sons Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Chas A Blatchford and Sons Ltd filed Critical Chas A Blatchford and Sons Ltd
Priority to GB8126954A priority Critical patent/GB2085351B/en
Priority to US06/303,860 priority patent/US4397048A/en
Priority to DE19813137652 priority patent/DE3137652A1/en
Priority to FR818117992A priority patent/FR2490951B1/en
Priority to SE8106035A priority patent/SE445515B/en
Publication of GB2085351A publication Critical patent/GB2085351A/en
Application granted granted Critical
Publication of GB2085351B publication Critical patent/GB2085351B/en
Expired legal-status Critical Current

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Classifications

    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/50—Prostheses not implantable in the body
    • A61F2/5044—Designing or manufacturing processes
    • A61F2/5046—Designing or manufacturing processes for designing or making customized prostheses, e.g. using templates, finite-element analysis or CAD-CAM techniques
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/50—Prostheses not implantable in the body
    • A61F2/60—Artificial legs or feet or parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/22—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure
    • B29C70/228—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure the structure being stacked in parallel layers with fibres of adjacent layers crossing at substantial angles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B29C70/342—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using isostatic pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • B29C70/446—Moulding structures having an axis of symmetry or at least one channel, e.g. tubular structures, frames
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/50—Prostheses not implantable in the body
    • A61F2/5044—Designing or manufacturing processes
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/50—Prostheses not implantable in the body
    • A61F2/5044—Designing or manufacturing processes
    • A61F2/5046—Designing or manufacturing processes for designing or making customized prostheses, e.g. using templates, finite-element analysis or CAD-CAM techniques
    • A61F2002/5053—Designing or manufacturing processes for designing or making customized prostheses, e.g. using templates, finite-element analysis or CAD-CAM techniques using a positive or a negative model, e.g. casting model or mould
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/50—Prostheses not implantable in the body
    • A61F2/5044—Designing or manufacturing processes
    • A61F2002/5055—Reinforcing prostheses by embedding particles or fibres during moulding or dipping, e.g. carbon fibre composites
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2250/00—Special features of prostheses classified in groups A61F2/00 - A61F2/26 or A61F2/82 or A61F9/00 or A61F11/00 or subgroups thereof
    • A61F2250/0014—Special features of prostheses classified in groups A61F2/00 - A61F2/26 or A61F2/82 or A61F9/00 or A61F11/00 or subgroups thereof having different values of a given property or geometrical feature, e.g. mechanical property or material property, at different locations within the same prosthesis
    • A61F2250/0028—Special features of prostheses classified in groups A61F2/00 - A61F2/26 or A61F2/82 or A61F9/00 or A61F11/00 or subgroups thereof having different values of a given property or geometrical feature, e.g. mechanical property or material property, at different locations within the same prosthesis differing in fibre orientations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/10—Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies
    • B29C43/12—Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies using bags surrounding the moulding material or using membranes contacting the moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0809—Fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2307/00—Use of elements other than metals as reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2023/00—Tubular articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/753—Medical equipment; Accessories therefor
    • B29L2031/7532—Artificial members, protheses
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S273/00—Amusement devices: games
    • Y10S273/23—High modulus filaments

Description

1 GB 2 085 351 A 1
SPECIFICATION
A method of making an artificial limb component This invention relates to a method of making an artificial limb component, and in particular to a method of moulding a fibre reinforced plastics structural component of an artificial leg.
Fibre reinforced plastics materials are known as lightweight high strength materials from which a variety of moulded articles can be produced. Carbon fibre reinforced plastics material in particular is known for its relatively high strength-to-weight ratio. In one known method of producing a carbon fibre reinforced plastics moulding, resin impregnated bundles of carbon fibres are laid up in an open mould and are then heated and compressed by forcing a rigid mould-closing member onto the laid-up fibres and applying heat to the mould to cure the resin. This method has been widely used but is limited to the moulding of relatively simple shapes.
It is an object of this invention to provide a method of making a fibre reinforced plastics structural component having a relatively complex shape.
According to this invention there is provided a method of making a structural component of an artificial limb, the method comprising the steps of providing a composite material of reinforcement fibres and plastics material, placing the composite material between an expandable internal mandrel and a rigid external mould, and expanding the mandrel to compress the composite material be tween the mandrel and the mould. Preferably the composite material is placed on the expandabie mandrel so that when the mandrel is expanded the composite material is expanded and compressed between the mandrel and the mould. The mandrel is preferably a moulded silicone rubber elementwhich is hollow so that it can be inflated inside the external mould. The reinforcement fibres are preferably 105 carbon fibres.
The invention also includes a mould apparatus for making an artificial limb component, the mould comprising a rigid two-part external mould and an expandable internal mandrel, the inner surface of the external mould and the outer surfaces of the internal mandrel being shaped to co-operate in forming the component when adomposite material of reinforcement fibres and resin is compressed between the mould and the mandrel by expansion of 115 the mandrel. The invention also includes a compo nent of an artificial limb whenever produced by the method of the invention.
The method of the invention can be used to produce a moulded fibre reinforced structural com ponent having a partly enclosed interior space, for example a channel section or tubular section compo nent. The use of an expandable mandrel allows such a structural component to be produced with a relatively complex internal shape.
The mandrel is preferably moulded in one piece and corresponds approximately to the internal shape of the structural component to be produced so that the composite material can be laid up on the surface of the mandrel in a required pattern and to a required thickness. The mandrel and the laid-up composite material are placed in one half of the external mould, which is then closed by fitting the other half of the external mould over the mandrel and composite material. This assembly can then be placed in a press which has means for heating the external mould for curing the resin of the composite material.
The invention will now be described byway of example with reference to the drawings in which- Figure 1 is a perspective view of a structural component of an artificial leg shin produced by the method of the invention; Figure 2 is a perspective view of an expandable internal mandrel; Figure 3 is a perspective view of one half of a rigid external mould; Figure 4 is an enlarged transverse section through the mandrel with sheets of a composite material of fibres and resin laid up on three sides of the mandrel to form the channel section portion of the component of Figure 1; Figures 4, 5 and 6 are plan views of three different shapes of sheets of the composite material used in making the component of Figure 1; and Figure 7 is a diagram showing the sequence of laying sheets of the composite material on the expandable mandrel.
Referring to Figure 1, an artificial leg shin compo- nent has an upper portion 1 of three-sided channel section, a hollow transition portion 2, and a lower hollow portion 3 of circular cross- section. The top end of the upper portion 1 is shaped to house correspondingly shaped members of a knee chassis (not shown) which forms part of a knee joint mechanism. The open side of the upper portion 1 is at or near the rear face of the shin when it is part of an assembled artificial leg, and allows, for example, a swing control mechanism or knee lock to be positioned between the rear of the knee chassis and a pivot point just above the transition section 2. The lower portion 3 is shaped for attachment to a foot and ankle assembly.
The shin component is moulded in a resin impre- gnated carbon fibre composite material. The properties of this material are well-known, and its strength is such that a relatively thin wall thickness can be used so that the element is relatively light in weight. From Figure 1 it will be apparent that there are two main changes in cross section from one end of the shin component to the other, that the portion 3 is of closed hollow cross section, and that the longitudinal axes of the portions 1 and 3 are at an angle relative to each other. The shin component is consequently of a relatively complex shape for a moulded fibre reinforcement component and requires a more sophisticated moulding technique than is used for example when moulding a simple bar-shaped component.
The preferred method of making the shin component comprises, firstly, moulding a hollow, inflatably expandable, silicone rubber internal mandrel 4to the shape shown in Figure 2. This shape corresponds approximately to the required inner shape of the shin component 1. The mandrel 4 is expanded by GB 2 085 351 A 2 supplying air under pressure by way of a pipe 5 fixed in the end 5A of the mandrel by a pipe clip 5B. It will be seen from Figure 2 that the mandrel 4 has a portion 4A of generally square cross-section and a portion 413 of circular cross-section, these portions being joined by a transition portion 4C. Further the longitudinal axes of the portions 4A and 4B are at an angle to each other, corresponding to the angle between the axes of the portions 1 and 3 of the shin component. The right-hand end of the mandrel is closed.
Figure 4 is an enlarged cross-section of the mandrel portion 4A and shows that the mandrel is hollow and contains a rigid core 14 over which the silicone rubber mandrel fits when not inflated, that is, in the nonexpanded state. The core 14 has a central passage 14A to receive compressed air supplied through the pipe 5. The core also has a plurality of lateral branch passages 14B to distribute the airto the interior of the mandrel when it is to be expanded.
Figure 3 shows the lower half 8 of a rigid external mould: the upper half is not shown, but would correspond in shape. The lower mould half 8 has parting surfaces 8A and the upper mould half would have like surfaces. The mould halves are made of aluminium alloy and the inner surface 9 is polished. It will be understood that the inner surface 9 has portions 9A, 9B and 9C which correspond with the portions 1, 2 and 3 respectively of the shin component and with the portions 4A, 4C and 413 respectively of the mandrel 4. The length of the mould halves is such that when the mandrel 4 is enclosed in the mould, the pipe 5, mandrel end 5A and pipe clip 513 are outside the mould halves. Each mould half is closed at one end by a plate 10.
The shin component is formed of a number of sheets or layers of impregnated carbon fibre woven cloth which are laid over the surface of the mandrel as diagrammatically shown in Figure 4. The starting material is carbon fibre cloth pre-impregnated with an epoxy resin system, hereinafter referred to as "prepreg", having fibres running at right angles to each other, as will be described below with reference to Figure 7. It is slightly tacky and its consistency is such that it will remain in position when laid up around the mandrel 4. Pieces of the prepreg sheets are cut outto a predetermined pattern, and then laid up around the mandrel 4.
The sheet patterns are shown in Figures 4 to 6. The sheet 15 (Figure 4) is shaped to fit overthe three sides of the mandrel portion 4A, eventually to form (together with other sheets of the same pattern) the shin component upper portion 1. The sheet 15 has connecting ortransition parts 15A, 15B and 15C separated by two slits 16. These parts 15A, 15B and 15C extend over and fit over the mandrel portion 4C. The sheet 17 (Figure 5) is shaped to fit round the circular mandrel portion 4B, with connecting or transition parts 17A (formed by slits 1713) extending over the parts 15A, 15B and 15C on the mandrel portion 4C. The smaller sheet 18 (Figure 6) is also placed on the mandrel portion 4C and in the final moulded component forms the part 2A of the portion 2, see Figure 1.
Successive prepreg sheets are laid up on the mandrel 4with the fibres in each sheet running at a predetermined angle to those of the previous layer. More specifically, and referring to Figure 7, a first layer 19 may be laid up with the fibres running parallel and perpendicular i.e. at 0' and 90' relative to the longitudinal axis X - X of the portion 1, 2 or 3 in question, then the next layer 20 is laid up with the fibres running at +45' and -45'to the axis. This may, be followed by another 450 layer 21, and then another 0', 90' layer 22, so thatfor example four layers of prepreg are used for all the parts of the shin component. The edge of each layer or sheet of prepreg are arranged to overlap adjacent layers or sheets, and successive layers or sheets are staggered with respect to one another to provide a relatively uniform distribution of discontinuities in the composite material.
In regions of potentially high stress, extra sheets of prepreg are provided, for example in the transition portion 2. Eight or more layers may be used at that location. In the upper portion 1, which has two longitudinal edges, extra strength is provided by folding back one or more of the inner sheets 7 as shown in Figure 4.
The laying up operation may be completed by laying an outer sheet or layer of a glass fibre reinforced composite material, which improves the resistance of the finished shin component to side impacts and enables any fractures in its structure to be more easily located. This latter advantage arises in that a fracture in a sheet of glass fibre reinforced composite material appears as a white line, whereas a like fracture would be almost invisible in the carbon fibre composite material.
The mandrel with the prepreg sheets on it is then placed in the one half 8 of the split external mould (Figure 3). The other mould half is then fitted over the mandrel 4 and then the whole assembly is placed for example in a hydraulic press which has means for heating the platens of the press.
An air line (not shown) from a compressor is connected to the pipe 5, and then the platens of the press are heated to 150OC; when the temperature of the mould reaches 7WC, an air pressure of 138kPa is applied to the inflatable, expandable mandrel 4 via the pipe 5 and passages 14A, 14B to expand the mandrel 4, and also to expand the prepreg sheets or layers on it, so that they are compressed against the surfaces of the mould and the mandrel. The sheets,. or layers of composite material are cured during a period of 2 hours at 1500C with pressure applied to the mandrel.
It will be seen that since the composite material is expanded outwards by the expansion of the mandrel 4, the diameter of the lower portion 3 increases from its diameter during the laying-up of the prepreg sheets. This largely avoids distortion of the prepreg sheets by puckering, as might occur if, for example, an alternative method were to be used, in which the prepreg sheets were compressed from the outside inwardly onto a rigid inner mandrel.
After curing, the mandrel 4 is de-pressurised and the shin component is removed from the mould.
Since the mandrel 4 is flexible, the angled relation- 3 GB 2 085 351 A 3 ship between the two portions 1 and 3 of the shin component does not prevent removal of the mandrel.
Excess flash resin is removed from the shin component, which is then ready for assembly into an artificial leg.

Claims (14)

1. A method of making a component of an artificial limb, the method comprising the steps of providing a composite material of reinforcement fibres and plastics material, placing the composite material between an expandable internal mandrel and a rigid external mould, and expanding the mandrel to compress the composite material between the mandrel and the mould.
2. A method according to claim 1 wherein the composite material is placed on the expandabie mandrel so that when the mandrel is expanded the composite material is expanded and compressed between the mandrel and the mould.
3. A method according to claim 1 or claim 2 wherein the mandrel is an inflatable hollow moulded element.
4. A method according to claim 3 wherein the moulded element is of silicone rubber.
5. A method according to any preceding claim wherein the reinforcement fibres are carbon fibres.
6. A method according to any preceding claim wherein the composite material comprises a plural ity of woven prepreg sheets each having reinforce ment fibres woven in a sheet of plastics material.
7. A method according to claim 6 for making an elongate component having a length direction, wherein the said plurality of sheets includes at least two sheets each of which two sheets has reinforcement fibres disposed at right angles in the sheet.
8. A method according to claim 7 wherein fibres of one of the said two sheets are disposed parallel to the said length direction and fibres of the other of the said two sheets are disposed diagonally to the said length direction.
9. A method according to claim 6 wherein the composite material includes a sheet of glass fibre reinforced plastics material as an outer layer.
10. A mould apparatus for making an artificial limb component, comprising a rigid two-part external mould and an expandable internal mandrel, the inner surface of the external mould and the outer surfaces of the internal mandrel being shaped to co-operate in forming the component when a composite material of reinforcement fibres and resin is compressed between the mould and the mandrel by expansion of the mandrel.
11. A mould apparatus according to claim 10 wherein the internal mandrel is an inflatable hollow moulded element of silicone rubber.
12. A component of an artificial limb whenever produced by a method according to any one of claims 1 to 9.
13. A method of making a component of an artificial limb substantially as herein described with reference to the drawings.
14. A mould apparatus for carrying out a method according to any of claims 1 to 9, the mould apparatus being constructed and arranged substantially as herein described and shown in the drawings.
Printed for Her Majesty's Stationery Office, by Croydon Printing Company limited, Croydon, Surrey, 1982. Published byThe Patent Office, 25 Southampton Buildings, London, WC2A lAY, from which copies may be obtained.
GB8126954A 1980-09-26 1981-09-07 A method of making an artificial limb component Expired GB2085351B (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
GB8126954A GB2085351B (en) 1980-09-26 1981-09-07 A method of making an artificial limb component
US06/303,860 US4397048A (en) 1980-09-26 1981-09-21 Reinforced plastics artificial limb component and method for making same
DE19813137652 DE3137652A1 (en) 1980-09-26 1981-09-22 COMPONENT FOR ARTIFICIAL LINKS AND METHOD AND DEVICE FOR ITS PRODUCTION
FR818117992A FR2490951B1 (en) 1980-09-26 1981-09-24 PROCESS AND APPARATUS FOR MANUFACTURING AN ARTIFICIAL MEMBER ELEMENT AND ELEMENT OBTAINED
SE8106035A SE445515B (en) 1980-09-26 1981-10-12 TOMBLE COMPONENT FOR AN ARTIFICIAL BANDLE AND PROCEDURE FOR ITS MANUFACTURING

Applications Claiming Priority (3)

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GB8031119 1980-09-26
GB8126954A GB2085351B (en) 1980-09-26 1981-09-07 A method of making an artificial limb component
SE8106035A SE445515B (en) 1980-09-26 1981-10-12 TOMBLE COMPONENT FOR AN ARTIFICIAL BANDLE AND PROCEDURE FOR ITS MANUFACTURING

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GB2085351A true GB2085351A (en) 1982-04-28
GB2085351B GB2085351B (en) 1985-02-20

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GB2250466A (en) * 1990-12-05 1992-06-10 Taylor Made Golf Co Moulding a hollow golf club shaft from composite fibre/resin material
FR2670155A1 (en) * 1990-12-05 1992-06-12 Salomon Sa Method of manufacturing tubular objects made of composite materials
WO1993006795A1 (en) * 1991-09-30 1993-04-15 Phillips L Van Energy-storing prosthetic leg pylon
WO1996008216A1 (en) * 1994-09-16 1996-03-21 M+Ind (Model & Instrument Development Corporation) Prosthetic pylon having uniform flexure characteristics
GB2301532A (en) * 1995-06-02 1996-12-11 Byrne Michael O Knee frame for lower leg amputees
US5814268A (en) * 1990-12-05 1998-09-29 Taylor Made Golf Company, Inc. Process of making a golf club shaft
WO1999026563A1 (en) * 1997-11-21 1999-06-03 Chas A. Blatchford & Sons Limited A foot and shin component for a lower limb prosthesis
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GB2129365A (en) * 1982-09-07 1984-05-16 Fischer Gmbh Hollow tubular members and a method of making such members
US4693140A (en) * 1982-09-07 1987-09-15 Fischer Gesellschaft M.B.H. Hollow tubular members and a method of making such members
FR2602458A1 (en) * 1986-08-08 1988-02-12 Aerazur Efa Method for producing a composite tube and tube thus obtained
GB2250466B (en) * 1990-12-05 1995-03-08 Taylor Made Golf Co Method for the manufacture of golf club shafts
FR2670155A1 (en) * 1990-12-05 1992-06-12 Salomon Sa Method of manufacturing tubular objects made of composite materials
GB2250466A (en) * 1990-12-05 1992-06-10 Taylor Made Golf Co Moulding a hollow golf club shaft from composite fibre/resin material
US5814268A (en) * 1990-12-05 1998-09-29 Taylor Made Golf Company, Inc. Process of making a golf club shaft
US6030574A (en) * 1990-12-05 2000-02-29 Taylor Made Golf Company, Inc. Process of manufacturing a golf club shaft
WO1993006795A1 (en) * 1991-09-30 1993-04-15 Phillips L Van Energy-storing prosthetic leg pylon
WO1996008216A1 (en) * 1994-09-16 1996-03-21 M+Ind (Model & Instrument Development Corporation) Prosthetic pylon having uniform flexure characteristics
US5571207A (en) * 1994-09-16 1996-11-05 Model & Instrument Development Corporation Prosthetic pylon having uniform flexure characteristics
GB2301532A (en) * 1995-06-02 1996-12-11 Byrne Michael O Knee frame for lower leg amputees
WO1999026563A1 (en) * 1997-11-21 1999-06-03 Chas A. Blatchford & Sons Limited A foot and shin component for a lower limb prosthesis
US6083265A (en) * 1997-11-21 2000-07-04 Chas. A. Blatchford & Sons Limited Foot and shin component for a lower limb prosthesis
WO2016164388A1 (en) * 2015-04-10 2016-10-13 Dow Global Technologies Llc Processing for producing flexible container with fitment using expandable mandrel

Also Published As

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DE3137652A1 (en) 1982-07-15
FR2490951B1 (en) 1990-07-13
SE8106035L (en) 1983-04-13
SE445515B (en) 1986-06-30
FR2490951A1 (en) 1982-04-02
US4397048A (en) 1983-08-09
GB2085351B (en) 1985-02-20

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