Patent ID: 6852269
Filing Date: 2005-02-08
Classification: A61F,B29C,B29L

Abstract:
1. A process for forming a final molded article in the form of a cushion layer of a preselected thickness on an inside of a prosthetic liner body, the process comprising the steps of: providing an apparatus including a mold having a cavity formed therein and a mandrel that is positionable between a retracted position and an extended position, wherein in the extended position, at least a portion of the mandrel is received within the cavity, wherein the distance between a first point alone an inner surface of the mold cavity and a second point along an outer surface of the mandrel when it is disposed therein represents a thickness of the final molded article, wherein the distance is measured along an axis that extends only across an empty space formed between the inner and outer surfaces; disposing the prosthetic liner body into the mold cavity; disposing a quantity of cushioning material, in its liquid state, into the inside of the prosthetic liner such that the cushioning material pools at a distal end of the prosthetic liner, the quantity being a sufficient quantity to form the cushion layer of the preselected thickness, wherein the cushioning material comprises a thermoplastic elastomer that forms the final molded article and is selected so that the cooled resulting final molded article can be freely rolled off the mandrel; directing the mandrel into the inside of the prosthetic liner until the mandrel is positioned in the extended position, the driving action of the mandrel causing the cushioning material to be dispersed between the mandrel and the prosthetic liner, thereby forming the cushioning layer of the preselected thickness; cooling the cushioning material to form a cushioned prosthetic liner; and withdrawing the mandrel from the mold cavity such that the final molded article can be removed therefrom.