Abstract: The essence of the technique is to superimpose a shaped elastic membrane/cover over a seat shell and lock the membrane to the edge of the seat shell with a channel-section trim. The uppermost edge of the cover is left temporarily unattached to the seat so an incipiently-reacting foam, mixed in a volume predetermined to be in excess of what is necessary, can be poured between the membrane and the shell. The subject is then seated and the foam expands to provide positive support for the anatomy and fill all the voids between the body's impression in the membrane and the seat shell, thereby making a full-contact mold of the body. Overflow is allowed to escape at the uppermost portion of the seat where it is captured in a bag that also serves to contain noxious chemical vapors. Foam may be of a rigid or resilient type to vary the support and cushion provided.

Abstract: Methods for making a conformable cube corner retroreflective sheeting having a plurality of discrete cube corner segments that are conformably bonded together. Each cube corner segment includes at least one cube corner retroreflective element.

Abstract: A copy of a complete or partial denture is obtained by forming an impression of the denture in a flask with distinct impressions made in plaster for a gum base and in silicone resin for a dental arch. The duplicate of the denture is formed by formation of the teeth and of the gum base using respective polymerizable materials in the same flask.

Abstract: A method for fabricating an individually adapted in-the-ear hearing aid shell with a battery compartment cast into the shell such that the door of the battery compartment is flush or slightly recessed in the portion of the shell that contacts the user's ear cavity.

Abstract: Described is an artificial mamma and a series of molds for producing the mamma, in which the mamma comprises a bag-like member which has as a skin a thick film member made of silicon rubber and interposing therein an elastic fabric as a core enclosing air internally, the thick film member being partially larger in thickness to provide a point where an air injection needle is inserted. The mold for producing the mamma can be constructed from ordinary materials and without the need for specialized technicians.

Abstract: A method is provided of forming a cervical cap in situ, i.e., within a patient's body, which cap will substantially completely conform to the shape of the patient's cervix, allowing the cap to be left in place over an extended period of time. The method includes the steps of positioning a snugly fitting rim member around the patient's exocervix, mounting a shell member, having an aperture, onto the rim member such that the rim member, shell member and exocervix define a cavity, and injecting a curable material through the aperture to substantially fill the cavity. After the curable material is allowed to harden, the entire assembly is removed from the patient and the shell removed from the cured material.

Abstract: A prosthetic casting machine receives an amputated stump while a patient is standing so that a hard socket can be made based upon the shape of the stump when it is under load. The machine includes a brim for accommodating an above-the-knee stump or a retaining disc for below-the-knee stumps. A telescoping leg enables precise adjustment of the height of the machine to accommodate patients of differing heights. The patient's stump is inserted into a liner and the liner is coated with plaster before the stump is inserted into the machine. After insertion, while the patient is standing, compressed air is introduced into a space between a transparent flexible bladder and a transparent rigid cylinder so that a uniform pressure is applied to the plaster by the bladder. The transparent parts enable a prosthetist to observe the results of the pressurization so that corrective steps may be taken if the plaster is not evenly compressed.

Abstract: A reusable die for the manufacture of molded seat cushions that includes a first device for forming a positive profile of a contoured surface, such as a seating support surface, from data obtained for defining the positive surface profile; and a second device for forming a negative profile of the contoured surface, whereby the first surface is adapted to be maintained in contact with the second surface. The first device includes a plurality of rods adapted to define the positive profile. The second device also includes a plurality of rods and a deformable member, such as a wire mesh, that coact with the rods of the first device to form the negative profile. The rods of both the first device and the second device are adapted to be locked in place. A sealing surface is vacuum formed over the negative profile, which then forms a wall of a foam mold. Liquid foam material is then injected in the mold and permitted to cure thereby forming a contoured seat cushion.

Abstract: In a method of manufacturing an in-the-ear hearing aid an auxiliary element, whose cross-section is larger than that of an auditory canal, is introduced into the auditory canal. As a result, the auditory canal is expanded. Subsequently, a hollow vent tube is inserted into the auditory canal, after which the auditory canal is filled with a viscous material. After the viscous material has solidified the mold is removed from the auditory canal. The vent tube insures that air is admitted to a space behind the mold. The mold thus formed has a cross-section larger than the cross-section of the auditory canal. Subsequently, a housing for the hearing aid is made, the mold being used as a template. Consequently, the heating aid will fit tightly in the auditory canal, which improves the wearing convenience.

Abstract: A method is provided for prefitting a stiffened member to a curved body having a geometry approximatable by a cone. Two points are initially selected on the surface of the body which also lie on two different planes passing through the body, such that the intersection of the surface and the planes defines two closed curves. A cone is approximated based on parameters relating to the curves and the selected points. A three-dimensional pattern of a stiffened member is then superimposed onto the conical surface at a modeling position corresponding to the desired placement position of the member on the body. The geometry and dimensions of the pattern are mathematically specified relative to the conical surface and the specifications provide a model for fabricating the prefitted stiffened member.

Abstract: An apparatus for immobilizing and positioning the lower or inferior portion of the human for radiographic examination or treatment. The device consists of a framework made from a base board, a plurality of siderails, a foot board and a pair of leg support blocks. A foam mixture is applied to the upper surface of the baseboard and to the leg support blocks and the entire device is placed into a large flexible container or bag. A patient's inferior or lower body portion is placed on the device in a supine position with a leg support block supporting at least one of the legs. The patient remains in a fixed position while the foam mixture expands around the patient's body and the apparatus framework. After a brief period of time, the foam sets or hardens and a mold or template is formed. This mold serves to immobilize the lower portion of the body during radiographic examinations and treatment as well as other procedures.

Abstract: Custom-profiled seating for a wheel chair or other body support seating systems includes seat and backrest members having outer covers in which a liner bag is removably accommodated and into which expandable, curable foam-in-place material is introduced to conform to that portion of a person's body which is to engage seat or backrest to attain a custom fit. The seat and backrest members are provided with access openings sufficiently large to enable the liner and resultant foam cushion member within the liner to be removed from the cavity for reshaping or replacement.

Abstract: A lid for sealing a container. The lid adheres to the container by a vacuum formed within the container. The lid is formed of a substantially circular panel having a flanged perimeter and a concave depression on an upper side of the circular panel. A pressure release hole extends through the concave depression of the circular panel and sanitary coating is disposed on a lower side of the circular panel. A first adhesive material is applied to the lower side of the lid by fusion to the sanitary coating to form a thin film over the release hole, and a second adhesive material is disposed in the concave depression on the upper side of the lid to form a removable seal. The second adhesive material has the same properties as the first adhesive material.

Abstract: In a method of manufacturing an in-the-ear hearing aid (25), a mould (23) is made of an ear canal for use as a moulding die for making a housing of the hearing aid. After the mould is made an auxiliary tool made up of a flexible tube (11) with a flange at one end is inserted into the ear canal into the proximity of the tympanic membrane of the ear. Subsequently, a curable material (19) is introduced into the ear canal. The material presses the flange against the tympanic membrane, which precludes the ingress of material between the flange and the tympanic membrane. After the material has cured the mould with the tube and the flange is removed from the ear canal. During removal of the mould the space between the tympanic membrane and the mould is in communication with the outer air via the tube, so that no partial vacuum is produced which otherwise might damage the tympanic membrane. The mould obtained is used as a moulding die for making a custom made in-the-ear hearing aid.

Abstract: A preform for use in forming orthotic devices which have a memory in the original preform shape. The preform is preferably formed into a final body shape which retains a memory of the original preform shape.

Abstract: A composite socket member for use with a prosthetic appliance for a residual limb which comprises an outer socket which defines an inner cavity generally conforming to the outer surface of a residual limb, an inner socket which defines an inner cavity and being adapted to receive the residual limb, with the inner socket conforming to the shape of the outer socket and when nested within the cavity of the outer socket defines an air space between the inner surface of the outer socket and the outer surface of the inner socket and an inflatable bladder being disposed between the inner surface of the outer socket and the outer surface of the inner socket. The inner socket contains at least one opening through its side wall at a preselected weight-bearing location whereby upon inflation of the bladder, pressure is applied by the bladder through the side wall opening against the preselected weight-bearing location of the residual limb to control the movement and rotation stability of the prosthetic appliance.

Abstract: A footwear article and the method of making the same which will allow water vapor due to perspiration to transpire through the article but will prevent liquid water from external sources from reaching the wearer's foot. One form of the footwear article of the invention comprises a sock which is of three-ply construction with the inside and outside plies being knit and the intermediate ply being made from an elastomeric polyurethane film. The three plies are uniquely bonded together using a pliant, waterproof adhesive.

Abstract: A biocompatible moldable curable polymer/monomer system capable of curing at ambient temperatures to provide an elastomer product while producing a lower exotherm than previously used systems. The system includes an alkyl acrylate or methacrylate homopolymer or copolymer; a monomer mixture of higher alkylacrylate or methacrylate combined with one or more of acrylic acid, methacrylic acid and their lower alkyl esters; and a plasticizer and optionally cross-linking agents, anti-tack agents, and activators or photoinitiators. The moldable systems is a dough used for making earmoulds and earpieces or in fabrication of prostheses.

Abstract: A process of producing a cranial plate duplicating the dimensions of an excised portion of the cranium comprising, obtaining an excised portion of the cranium of a patient, preparing a three-dimensional impression of the excised portion in an impression material, removing the excised portion of the patient's cranium from the impression material to provide a mold cavity, and thereafter filling the cavity with a sterile resinous material which sets, and thereafter removing the set resinous material to form a plate duplicating the dimensions of the excised portion of the patient's cranium, and finally surgically installing the plate in the patient's cranium to replace the excised portion of the cranium earlier removed.

Abstract: Disclosed in the present application is a method of curing a dental impression material by passing actinic light through a tray while the tray is in contact with the impression making composition, a new dental impression composition that is polymerizable by having an initiator activated by actinic light within the visible light range of 360 to 600 nanometers, a new composition of matter that is a compound having at least two terminal acrylate unsaturations and an organosilicone containing backbone and a new method of forming dental prosthetics by directly forming against the soft tissue of the oral cavity and then setting with visible light curing.

Abstract: The method of the present invention creates a hollow plastic prosthesis using the following steps. First, a mold of the prosthetic article is created and the mold is injected with room temperature vulcanizable plastic. The mold containing the RTV plastic is maintained at a fixed temperature for a sufficient period of time for the outer most portions of the RTV plastic to form a vulcanized layer in proximity to the inner surface of the mold. The RTV plastic article is then removed from the mold and the remaining unvulcanized plastic is expressed from the interior. The opening is then sealed and the entire article is allowed to completely cure. The prosthetic article thus created is a one piece seamless article conforming substantially to the shape of the mold.

Abstract: A visco-elastic polymer liner for use in donning over a residual limb and fitting within the socket of an artificial limb. The liner is shaped to have its cavity formed with a volume and shape less than a volume and shape of the residual limb for both tension and tissue configuration relief while the liner has an outer surface formed with a volume and shape greater than the volume and shape of the artificial limb socket for relief of certain tissue configurations and to create weight bearing, relief and compression areas on and in the liner to absorb and dissipate shock, shear and mechanical forces through the liner otherwise transmitted to the residual limb. The liner may have imbedded on its inner cavity side electrodes adjacent muscles that are sensitive to the muscle action potentials to generate signals to a power source to move an articulable artificial limb.

Abstract: A method of contouring bone plates or other bone fixation element is set forth comprising the steps of making a molded impression of the surface of the area to which the bone plate is to be fixed, appropriately positioning the bone plate to be contoured relative to the molded impression of the molding material to contour the bone plate to the molded impression when sufficient compressive force is applied to the bone plate, and applying sufficient compressive force to the bone plate to contour the bone plate to the shape of the molded impression, thereby contouring the bone plate to the surface of the fixation area. An apparatus for contouring bone plates with substantial accuracy is also set forth comprising a means for forming a molded impression of the surface of the area to which the bone plate is to be fixed, a compression member, and a means for applying sufficient compressive force to the compression member to contour the bone plate to the molded impression of the mold forming means.

Abstract: A game apparatus has a panel with a target area supported on a frame against which a ball is aimed and tossed. The ball covering and the target area include hook and pile fastener materials so that the ball will releasably attach to the target area upon impact. The target area employs hook material while the ball covering includes the pile material. A graphic representation of a target is formed on the target area by applying pigmented ink to selected portions of the hooks and by employing a heat sublimation process to deform selected portions of the hooks along with the pigmented ink to display a particular target representation. The frame may be placed on the ground or may be floated by using buoyant spheres or bulbs secured to the frame.

Abstract: A one-piece continuous polymeric prosthesis is disclosed and taught. The prosthesis is intended for patients with a below-knee amputation. The one-piece socket-pylon-keel allows good energy storage and release for a superior feel during physical activities. The construction and the materials makes for a much lighter weight prosthesis than conventional types.

Abstract: A method forms a helmet liner which during its formation is fitted to the head of the user, by forming an inflatable liner element of extensible sheet material approximately conforming to the shape of the interior surface of a helmet shell, providing the element with respective foam filling and vent passages, the vent passages serving to expel air from the liner as foam filling proceeds, mounting the liner element in the helmet on the head of the user, supplying foam to the foam filling passages to inflate the liner element, expel air therefrom and conform the element at an outer surface to the shape of the interior surface of the helmet shell and at an inner surface to the shape of the head of the user, allowing time for curing of the foam admitted to the liner element, and severing parts of the vent and foam filling passages projecting from the liner. The liner element can embrace a forehead portion only of the head of the user or a further element which embraces a rear part of the head can be added.

Abstract: A preform for use in forming orthotic devices which have a memory in the original preform shape. The preform is preferably formed into a final body shape which retains a memory of the original preform shape.

Abstract: A dental refractory model material comprises as powdery components 5 to 20% by weight of a soluble phosphate, 5 to 20% by weight of magnesium oxide and 10 to 50% by weight of at least one selected from the group of alumina, zirconia, fused quartz, mullite, spinel and cordierite with the balance being crystalline quartz and crystobalite. The refractory model material also includes a liquid component such as a colloidal silica dispersion.

Abstract: A method for producing a plate denture which includes heating a flask after embedding a wax denture and wax elimination to a temperature for polymerizing a heat-curable resin, the flask being an assembly including a first half shell having a plaster cast with a corresponding mucosal surface and a second half shell having a plaster cast with artificial teeth embedded therein. The method further including placing the heat-curable resin into the heated flask for polymerization while the flask is at an elevated temperature from the heating, and polymerizing the heat-curable resin in the heated flask. Wherein, during the step of heating the first half shell is heated to a higher temperature level in a range of temperature for polymerizing the heat-curable resin while the second half shell is heated to a lower temperature level in the range than the first half shell.

Abstract: The shape-dictating surfaces of the pattern are constituted by a thin self-supporting shell (4 & 5) of photocured polymer. The shell is produced by a laser controlled by a computer with reference to a design drawing. The inside of the shell is packed full of low melting-point modeling compound. The areas (6 & 7) of the pattern that do not dictate shape are demarcated by the low melting-point modeling compound.

Abstract: An insert forming apparatus and method is provided for making an insert to conformingly fit a shoe and a person's foot within the shoe. The method for practicing the invention includes using standard molding techniques to form a mold of the bottom of the last and using the mold to vacuum form a lower shell half that conforms to the bottom of the last. With the lower shell half covering the mold and having vacuum communicating holes drilled therein, the last is placed in the lower shell half and the upper shell half is drawn down over the last and lower shell half by vacuum forming. When the upper and lower shell halves have been formed, a hole is drilled in the lower shell half for injecting curable material. A sheet of fabric or leather is placed over the lover shell half, a person's foot is placed on the fabric or leather in the lower shell half, and the upper shell half is placed over the person's foot and fastened to the lower shell half.

Abstract: My invention relates to the art of making three dimensional impressions and likenesses. More specifically, my invention is an improvement of making three dimensional duplicate of a persons facial appearance and expression.

Abstract: Method and materials for making a mold that conforms to a body part, such as the stump of an amputated limb. This is formed by two, or more, layers of knit fabric substrate, one or more of which is impregnated with a water activated foaming isocyanate polymer casting resin which is placed over the body part to be molded, and allowed to cure.

Abstract: A molding material for constructing h of living models comprises a composition of alginate powder, water, and chopped polystyrene. This composition is useable in a method of making one-piece head molds or one-piece hand molds of living models by applying the composition to the head of a model, wrapping the composition-covered head in plaster bandages until the composition has cured, removing the bandages, cutting the cured mold so that the model can be freed from the mold, placing the cut edges of the mold in register, and replacing the plaster bandages.

Abstract: A method for use in preparing a dental prosthesis comprises the step of receiving an electrical signal encoding geometric specifications of a substructure of the prosthesis, the specifications including dimensions and shape of a tooth preparation at a dental site at which the prosthesis is to be affixed and the configuration of the substructure. In a subsequent step performed in response to the electrical signal, a computer is operated to automatically select a first mold component having a surface corresponding in dimensions to the tooth preparation and to automatically select a second mold component to produce, in cooperation with the first mold component, a mold cavity having dimensions and configuration corresponding to dimensions and configuration of the substructure. The first mold component and the second mold component are placed in predetermined relative positions to form the mold cavity and the mold cavity is filled with a quantity of a fluidic solidifiable dental material, i.e.

Abstract: A process for obtaining precision castings of body parts wherein the body part is first immersed in a ice and water slush, immediately removed therefrom and immersed in a melted paraffin wax-water container, immediately removed therefrom and the body part extracted from the resulting wax mold. At least the interior surface of the hollow wax mold is coated with a casting material and permitted to cure at room temperature. The cured casting is heated by immersion in the wax-water container or in a separate heated water container for a period of at least ten minutes to remove the wax mold and recover a casting of the body part. The removed wax molding material may be recycled and employed in subsequent castings and recover a casting of the body part.

Abstract: The invention provides a composition and a method for studying skin surface areas with simplified magnifying devices by making a replication of the skin surface area while minimizing irritation to the subject's skin, cracking of the replicas, surface artifacts, and air bubbles in the replicas. The method entails preparing a negative skin surface replica composition by mixing a silicone polysiloxane base and a biocompatible surface tension modifying agent. The mixture is placed in a vacuum desiccator to remove air bubbles and thereafter a curing agent is added to the mixture. An adhesive collar is placed on the subject's skin, which collar surrounds the surface area to be replicated, and thereafter the composition is applied to the skin surface area and the adhesive collar and allowed to dry. The negative skin surface casting is removed from the skin area and is then placed skin side up in a mold cup.

Abstract: A self-lubricating ocular prosthesis includes a solid rigid prosthetic eye body with a chamber in the body opening through an access passage through the posterior surface of the body closed with a releasable cap having an outside face conforming to the posterior surface of the body which abuts the orbital cavity. The cap is of a semi-rigid or flexible polymeric resin to retain a fluid in the chamber which is dispensed through bore openings from the chamber through the surface of the eye body. Liquid may be inserted directly into the cavity through the bore opening while the prosthesis is in place. The prosthesis may also include a dispensing ball or depressible button to dispense fluid from the prosthesis.

Abstract: Hand grips for the handles of devices such as motorcycles, tennis rackets, and guns can be custom-molded to fit exactly the contours of the user's hand. The grip has an inner layer that is thermoplastic and moldable at molding temperatures reached by heating with hot water or a hair dryer. An adherent outer, resilient, vibration-resistant layer is stable at these molding temperatures. The user heats the grip to molding temperature and then rapidly cools the outer surface to a comfortable temperature. The grip is then grasped by the hand while the inner layer is still at molding temperature. The hot inner layer conforms to the hand, becoming thinner under the fingers and thicker between fingers. The grip is cooled to ambient temperature and the inner layer retains its hand-conforming shape. The outer layer maintains its original thickness providing a fixed resilient cushioning layer over the custom formed inner layer.

Abstract: A method of producing a prosthetic implant for a predetermined organ site. Three-dimensional data including surface contour information of the organ site is obtained and a physical life size model of at least a part of the surface contour of the organ site is produced based on the three-dimensional data. Thereafter, an implant model is formed onto the surface of the physical organ model, and a prosthetic implant is produced from the implant model using a casting process.

Abstract: A mould for an injection moulding apparatus having two resilient mould inserts mate to form a mould cavity and which separate to permit removal of the moulded article. Each mould insert being inserted into opposed movable mould parts such that they abut to form the mould cavity before the movable mould parts abut one another. A process for forming the mould inserts by pressing bodies of mouldable material together around an article and curing the material to form the inserts.

Abstract: Disclosed in the present application is a method of curing a dental impression material by passing actinic light through a tray while the tray is in contact with the impression making composition, a new dental impression composition that is polymerizable by having an initiator activated by actinic light within the visible light range of 360 to 600 nanometers, a new composition of matter that is a compound having at least two terminal acrylate unsaturations and an organosilicone containing backbone and a new method of forming dental prosthetics by directly forming against the soft tissue of the oral cavity and then setting with visible light curing.

Abstract: A method of making a femoral rasp wherein the hip stem implant is used to make a two part mold. The mold halves are separated and the implant removed to yield left and right mold halves representing corresponding halves of the hip stem. The cavities of the mold halves are lined with wax and a plurality of blades are imbedded into the wax such that an anchor portion of each of the blades remains exposed. The mold halves are connected together and a stem of handle is inserted therein. A moldable material such as PMMA is poured into the mold and allowed to cure. When the PMMA is hard or cured, the mold halves are separated and the wax is removed from the rasp body exposing the cutting surfaces of the teeth.

Abstract: A nursing device provides a nursing or pacifier nipple for use with nursing infants, and a method for manufacturing such articles. The device comprises an exact replica of the mother's nipple incorporated onto a bottle, specialized dispenser, or pacifier. The nursing device is formed from a mold taken of the nursing mother's natural breast and nipple.

Abstract: Gloves are made in situ on human hands by applying a glove-making fluid composition completely about the entire expanse of the hands within a chamber of an enclosure. The fluid composition solidifies to form glove-like coatings upon exposure to air.

Abstract: A custom-fitted insole assembly for use in a shoe directly under a wearer's foot includes a heel-cupping and arch-supporting base component custom contoured to fit the heel and arch of the wearer's foot, a heel stabilizing component attached to an underside heel region of the base component, and a shock absorbing top sheet component sized to underlie the bottom of the wearer's foot and at its rear half to overlie and conform to the contour of the base component.

Abstract: The present serving tray is formed with an underside having a recess therein which is contoured to the shape of a human hand. When the serving tray is used, the server's hand fits comfortably and securely within this contoured recess, thereby obtaining greater control over the serving tray than is possible with serving trays currently in use. The recess of the present serving tray is preferably contoured to conform to the shape, size and preferred position of a particular server's hand.

Abstract: An acoustically sealed earmold for a hearing aid insertable into the ear of individuals with impaired hearing can be prepared in situ employing the hydrophilic composite polymer materials described herein. Such composite materials include at least one hydrophilic polymer in a powder form and one or more liquid components of which at least one is hydrophilic and which can be polymerized with said hydrophilic polymer. The resulting earmold has a shape-retaining, non-tacky flexible consistency which allows it to be shaped further and also to be modified to accommodate a receiver adapter or external receiver. The earmold can then be cured by any of the conventional curing methods to retain its shape permanently. This method enables an audiologist to fit the earmold and evaluate the hearing aid in a single office visit.

Abstract: A process for producing a breast prosthesis with a concave recess facing the human body. A synthetic resin composition curable to a gelatinous state is enclosed between two thermoplastic films and is shaped in a heated mold defined by a male die and female die. A first film which will face away from the human body is stretched over the female die and heated to permanently conform it to the contour of the die by deep drawing. The deep-drawn film is removed from the female die and an insert having a volume and a free area which correspond to the volume and free area of the concave recess facing the body is then positioned in the female die. The deep-drawn film is placed over the insert in the die and the die is filled with the synthetic resin composition up to its edge. The synthetic resin composition is covered with a second film (cover film) which is welded to the first film over these entire overlapping edges.

Abstract: A process for making a model skin surface for testing adhesion of medical adhesive as a screening test and/or as an alternative to costly and highly variable human skin substrates including casting silicone rubber on human skin to produce a mold having human skin topography and pouring a water-swellable, water-soluble proteinaceous material along with a crosslinking agent and fatty acid constituent into the mold. The proteinaceous material crosslinks while in the mold and the water content of the material is adjustable to simulate varying moisture contents in human skin.