Immersion Curing Process

Abstract

A system and method for manufacture of prosthesis shells using a hot liquid bath to cure the shells is described. The shell is formed on a mold or mandrel, and is then immersed in a hot liquid bath to cure the shell material. Multiple layers of material, such a silicone, may be formed by immersing the layer into a hot liquid bath, cooling the cured layer, applying another layer of uncured material to the cured layer, and then curing the uncured layer in a hot liquid bath. A textured surface may be imparted to the shell by incorporating a texture component into the last layer formed, such that immersing the uncured layer incorporating the texture component in the hot liquid bath cures the last layer formed and dissolves the texture component.

I Claim: 
     
         1 . A method for manufacturing a thin sheet of prosthetic material, comprising:
 applying a solution of uncured prosthetic material to a mold; and   curing the applied uncured prosthetic material by immersing the mold and applied uncured prosthetic material in a hot liquid bath.   
     
     
         2 . The method of  claim 1 , wherein the uncured prosthetic material is silicone. 
     
     
         3 . The method of  claim 1 , wherein the mold is a mandrel. 
     
     
         4 . The method of  claim 1 , wherein the liquid in the hot liquid bath is water having a temperature greater than 50 degrees centigrade. 
     
     
         5 . The method of  claim 1 , wherein the liquid in the hot liquid bath is a liquid having a low solubility in uncured silicone. 
     
     
         6 . The method of  claim 1 , wherein the liquid has a temperature in the range of 120 to 150 degrees centigrade. 
     
     
         7 . The method of  claim 6 , wherein the temperature is 130 degrees centigrade. 
     
     
         8 . The method of  claim 5 , wherein the liquid has a temperature in the range of 120 to 150 degrees centigrade. 
     
     
         9 . The method of  claim 8 , wherein the temperature is 110 to 140 degrees centigrade. 
     
     
         10 . The method of  claim 5 , wherein the liquid is a non-toxic liquid. 
     
     
         11 . The method of  claim 10 , wherein the non-toxic liquid is selected from the group consisting of propylene glycol, polyethylene glycol, esterified polyethylene glycol and fatty acid esters. 
     
     
         12 . The method of  claim 1 , wherein the liquid is a eutectic salt having a melting point of less than 200 degrees centigrade. 
     
     
         13 . The method of  claim 1 , wherein the liquid is a eutectic metal having a melting point of less than 200 degrees centigrade. 
     
     
         14 . The method of  claim 1 , wherein applying the solution of uncured prosthetic material forms an uncured breast implant shell. 
     
     
         15 . The method of  claim 1 , wherein applying the solution of uncured prosthetic material includes dipping the mold into the solution of uncured prosthetic material. 
     
     
         16 . The method of  claim 15 , wherein dipping the mold into the solution of uncured prosthetic material forms a layer of uncured prosthetic material on the mold having a thickness of less than 1 millimeter. 
     
     
         17 . The method of  claim 1 , wherein applying the solution of uncured prosthetic material includes spraying the solution of uncured prosthetic material onto the mold. 
     
     
         18 . The method of  claim 1 , further comprising:
 applying a second layer of uncured prosthetic material to the mold; and   curing the second layer of uncured prosthetic material by immersing the mold and uncured second layer of uncured prosthetic material in a hot liquid bath.   
     
     
         19 . The method of  claim 18 , wherein the second layer of uncured prosthetic material includes texture components. 
     
     
         20 . The method of  claim 19 , wherein curing the second layer of uncured prosthetic material by immersing the mold and uncured second layer into the hot liquid bath also dissolves the texturing components from the uncured second layer such that the cured second layer has a textured outer surface. 
     
     
         21 . The method of  claim 1 , further comprising:
 mechanically applying a texture to a top surface of the applied uncured prosthetic material before immersing the applied uncured prosthetic material and mold into the hot liquid bath.