JP2017515641A - 優れた変形性と剛性とを有する熱可塑性ギプスおよびその製造方法 - Google Patents
優れた変形性と剛性とを有する熱可塑性ギプスおよびその製造方法 Download PDFInfo
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Abstract
Description
この工程では、ネット形状の網状体の形態のコア材料は、射出成形またはプレス加工により、一定のサイズと形状を有する開口を規則的に形成することによって成形される。この点で、コア材料10を形成する材料は、合成樹脂エラストマー(例えば、PU、PE、軟質PVCおよびPPコポリマー)で形成される。そのエラストマーは、構造体20を形成するポリカプロラクトン複合材料の融点よりも高い融点を有する。これは、コア材料10が室温でさえ、最初に成形された形状を維持することができる。こうして、後述されるコア材料取付工程において、コア材料10は、構造体製造用金型2の内部に容易に設置される。したがって、大量生産が可能になる。
この工程では、コア材料10は、構造体製造用金型2の内部に取り付けられる。その結果、構造体20は、構造体成形工程S300によってコア材料10の外周面に成形され、取り付けられる。この目的のため、本発明は、図5aおよび図5bに示すように、ネット形状を有しながら、上部に傾斜部または湾曲部を有するガイドキャップ2Bを含む。そのガイドキャップ2Bは、構造体製造用金型2の上方に位置されている。また、本発明は、構造体製造用金型2にコア材料10を押し出すように働く押圧部材2Cを含む。このような構成により、まず、コア材料10がガイドキャップ2B上に置かれ、その後、押圧部材2Cが構造体製造用金型2に向けて下方に移動すると、ガイドキャップ2B上に置かれたコア材料10は、ガイドキャップ2Bの傾斜部または湾曲部に沿ってスライドしながら下方に移動する。そして、構造体製造用金型2の内側に容易に取り付けられる。したがって、構造体20は、コア材料10の外側に均一に取り付けられる。それにより、大量生産が可能になる。
この工程において、コア材料10がコア材料取付工程S200によって構造体製造用金型2内に取り付けられた後、ポリカプロラクトン複合材料で形成された構造体20は、コア材料10をカバーするために、コア材料10の外周面に成形される。前の工程において、コア材料10は、構造体製造用金型2の溝2Aの中央に位置するように取り付けられているが、主材料としてポリカプロラクトンを含むポリカプロラクトン複合材料は、コア材料10の外側と、構造体製造用金型2の溝2Aとの間の空間に注入される(インサート注入される)。したがって、ポリカプロラクトン複合材料の構造体20は、コア材料10の外周面を囲むように成形される。
この工程において、外側カバー30は、構造体20の外側に成形される。この工程は、必要に応じて、選択的に実行される。
2:構造体製造用金型
3:外側カバー製造用金型
2A:溝
2B:ガイドキャップ
2C:押圧部材
2D:スペーサ
2E:突起
3A:成形溝
3B:可動挿入スペーサ
3C:可動支持スペーサ
3D、3E、3Fおよび3G:可動支持スペーサ
10:コア材料
20:構造体
21:溝
30:外側カバー
F:固定部材
Claims (15)
- 骨折部のような患者の身体をカバーし、固定する熱可塑性ギプスであって、
射出成形またはプレス加工によるネット形状の合成樹脂エラストマーの成形による、前記ネット形状を有するコア材料(10)と、
ポリカプロラクトン複合材料で形成され、インサート射出で前記コア材料(10)の外周面を囲むように成形された構造体(20)と、を含むことを特徴とする熱可塑性ギプス。 - ゴム材料で形成された外側カバー(30)は、前記インサート射出によって前記構造体(20)の外側に成形され、取り付けられている請求項1に記載の熱可塑性ギプス。
- 繊維強化ガラス繊維、炭素繊維またはポリエチレンテレフタレート繊維は、前記構造体(20)を形成する前記ポリカプロラクトン複合材料に加えられる請求項1に記載の熱可塑性ギプス。
- ポリエチレン(PE)、ポリウレタン(PU)またはポリブテン(PB)は、前記構造体(20)を形成する前記ポリカプロラクトン複合材料に加えられる請求項1に記載の熱可塑性ギプス。
- 核形成剤として、タルク、ソルビトールおよび安息香酸ナトリウムのいずれか一つは、前記構造体(20)を形成する前記ポリカプロラクトン複合材料に加えられる請求項3に記載の熱可塑性ギプス。
- 内側に凹没した溝(21)は、前記構造体(20)が相互に互いに交差する部分に形成される請求項1に記載の熱可塑性ギプス。
- 骨折部のような患者の身体をカバーし、固定する熱可塑性ギプスの製造方法であって、
前記熱可塑性ギプスは、ネット形状を有し、合成樹脂エラストマーで形成されたコア材料(10)と、前記コア材料(10)の外周面を囲むように、ポリカプロラクトン複合材料で形成された構造体(20)とを含み、
射出成形またはプレス加工により前記ネット形状に合成樹脂を成形することによって、ネット状網状体を形成するコア材料成形工程(S100)で前記コア材料(10)を製造し、
構造体製造用金型(2)内に前記コア材料(10)を取り付けるコア材料取付工程(S200)と、前記構造体製造用金型(2)内に取り付けられた前記コア材料(10)の前記外周面に前記ポリカプロラクトン複合材料を注入することにより、前記構造体(20)を成形する構造体成形工程(S300)とによって、前記構造体(20)を製造することを特徴とする熱可塑性ギプスの製造方法。 - 前記コア材料取付工程(S200)において、ガイドキャップ(2B)は、前記構造体製造用金型(2)の上に設置され、前記コア材料(10)は、前記コア材料(10)が前記ガイドキャップ(2B)上に置かれている間、押圧部材(2C)を下方に移動させることにより、前記構造体製造用金型(2)内に取り付けられる請求項7に記載の製造方法。
- 前記構造体成形工程(S300)の後にインサート射出により、前記構造体(20)の外側にゴム材料で形成された外側カバー(30)を成形し、取り付ける外側カバー成形工程(S400)をさらに含む請求項7に記載の製造方法。
- 前記外側カバー成形工程(S400)において、傾斜面を有する1つ以上の溝(21)は、前記構造体(20)の下面の一部に形成され、
可動挿入スペーサ(3B)は、前記外側カバー(30)を成形する前記外側カバー製造用金型(3)に設けられ、
前記可動挿入スペーサ(3B)は、前記1つ以上の溝(21)に挿入され、前記傾斜面を有する前記溝(21)に相当する形状に形成されている請求項9に記載の製造方法。 - 可動支持スペーサ(3C)は、前記可動挿入スペーサ(3B)とは反対方向の前記外側カバー製造用金型(3)に設けられている請求項10に記載の製造方法。
- 前記外側カバー成形工程(S400)において、可動支持スペーサ(3D、3E、3Fおよび3G)は、前記外側カバー製造用金型(3)に設けられ、前記構造体(20)は、前記外側カバー製造用金型(3)の中心に位置され、前記外側カバー(30)は、所定の厚さを有するように成形される請求項7ないし11のいずれかに記載の製造方法。
- 繊維強化ガラス繊維、炭素繊維またはポリエチレンテレフタレート繊維は、前記ポリカプロラクトン複合材料に加えられる請求項7に記載の製造方法。
- ポリエチレン(PE)、ポリウレタン(PU)またはポリブテン(PB)は、前記ポリカプロラクトン複合体に加えられる請求項7に記載の製造方法。
- 核形成剤として、タルク、ソルビトールおよび安息香酸ナトリウムのいずれか一つは、前記ポリカプロラクトン複合材料に加えられる請求項7に記載の製造方法。
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