Thermoformable medical member with heater and method of manufacturing same
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
A61F-005/00
A61F-005/058
B29C-051/42
B29K-067/00
B29L-031/00
출원번호
US-0482351
(2014-09-10)
등록번호
US-9872795
(2018-01-23)
발명자
/ 주소
Laubach, Adam
Barrio, Alberto Macias
출원인 / 주소
RECHARGEABLE BATTERY CORPORATION
대리인 / 주소
Schroeder Intellectual Property Law Group, LLC
인용정보
피인용 횟수 :
1인용 특허 :
4
초록▼
A thermoformable medical member and heater and method for manufacturing same. A thermoplastic material is converted from a relatively rigid state to a formable state over a narrow temperature range, and, which reverts back to a clinically rigid state within a relatively short period of time, and, wh
A thermoformable medical member and heater and method for manufacturing same. A thermoplastic material is converted from a relatively rigid state to a formable state over a narrow temperature range, and, which reverts back to a clinically rigid state within a relatively short period of time, and, which remains in that state even at elevated ambient temperatures.
대표청구항▼
1. A thermoformable medical member and heater comprising: a thermoplastic material having a top side and a bottom side opposite the top side, wherein the thermoplastic material comprises a flexural modulus at 73 degrees F. of at least 2.3 GPa, a heat deflection temperature less than 70 degrees C.; a
1. A thermoformable medical member and heater comprising: a thermoplastic material having a top side and a bottom side opposite the top side, wherein the thermoplastic material comprises a flexural modulus at 73 degrees F. of at least 2.3 GPa, a heat deflection temperature less than 70 degrees C.; and a thermoformable temperature in the range of 35-70 degrees C.; anda heater operatively associated with at least one of the top and bottom sides of the thermoplastic material,wherein the thermoplastic material contains a polylactic acid (PLA) polymer and the PLA polymer has an L-lactide/D-lactide ratio of 24:1 to 30:1. 2. The invention according to claim 1 wherein the thermoplastic material has a tensile modulus of at least 0.3 GPa at 23 degrees C. 3. The invention according to claim 1 wherein the PLA polymer has a flexural modulus of 2.4-4.9 GPa at 23 degrees C. 4. The invention according to claim 1 wherein the thermoplastic material further includes at least one of an organic and inorganic filler. 5. The invention according to claim 4 wherein the filler has a thermal conductivity greater than 0.12 W/(meter ° C.) at 48 degrees C. 6. The invention according to claim 1 wherein the thermoplastic material has at least a portion of at least one of the top and bottom sides has a textured surface. 7. The invention according to claim 6 wherein the textured surface is corrugated. 8. The invention according to claim 1 wherein the thermoplastic material has an internal structure, having a volume, located between the top and bottom sides, wherein 40% or less of the volume is defined by an open cell structure. 9. The invention according to claim 1 wherein the thermoformable medical member comprises a splint. 10. The invention according to claim 1 wherein the thermoformable medical member comprises an orthotic. 11. The invention according to claim 1 wherein the thermoformable medical member comprises an exoskeleton member. 12. The invention according to claim 1 wherein the heater comprises one of an oxygen activated heater and a water activated heater. 13. The invention according to claim 12 wherein the heater is integrated with the thermoformable medical member. 14. The invention according to claim 1 wherein the thermoplastic material is chemically or physically bonded to the heater. 15. The invention according to claim 1 wherein the thermoplastic material has a glass transition temperature in the range of 35-70 degrees C. 16. The invention according to claim 1 wherein the thermoplastic material contains a reinforcing fiber. 17. The invention according to claim 1 wherein the thermoformable medical member contains a thermosetting component capable of forming crosslinks in the range of 20-70 degrees C. 18. A method for achieving an effect on a thermoformable medical member from an integrated heater for use on a patient comprising the steps of: heating a thermoformable medical member fabricated from a thermoplastic material with at least one of an oxygen activated heater and a water activated heater in a range of 48-70 degrees C., wherein the thermoplastic material prior to heating is in a relatively rigid, non-thermoformable phase;converting the thermoplastic material from a non-thermoformable state to a thermoformable state within the heated range;forming the thermoplastic material to a desired shape while in its thermoformable state;converting the thermoplastic material back toward and into a relatively rigid non-thermoformable phase; andmaintaining the desired shape of the thermoplastic material at a temperature imparted to the thermoplastic material of less than 48 degrees C. 19. The method according to claim 18 wherein the step of converting the thermoplastic material from a non-thermoformable state comprises maintaining structural rigidity of the thermoplastic material until the thermoplastic material until it is heated within the range of 48-70 degrees C. 20. The method according to claim 18 wherein the step of heating comprises constructing the heater so that it ceases to generate heat to the thermoplastic material in the range of 48-70 degrees C. after the thermoplastic material has been converted to a thermoformable state. 21. The method according to claim 20 wherein the step of heating comprises generating heat to the thermoplastic material in the range of 48-70 degrees C. after the thermoplastic material has been converted to a thermoformable state for a period of approximately 1-7 minutes, and, preferably 3-5 minutes. 22. The method according to claim 18 wherein the step of converting the thermoplastic material back toward and into a relatively rigid non-thermoformable state occurs after the temperature of the thermoplastic material is less than 48 degrees C. 23. The method according to claim 22 wherein the step of converting the thermoplastic material back toward and into a relatively rigid non-thermoformable state occurs within 1-7 minutes, and, preferably 3-5 minutes. 24. A thermoformable medical member and heater comprising: a thermoplastic material having a top side and a bottom side opposite the top side, wherein the thermoplastic material comprises a flexural modulus at 73 degrees F. of at least 2.3 GPa, a heat deflection temperature less than 70 degrees C.; and a thermoformable temperature in the range of 35-70 degrees C.; anda heater operatively associated with at least one of the top and bottom sides of the thermoplastic material,wherein the thermoplastic material further includes at least one of an organic and inorganic filler. 25. The invention according to claim 24 wherein the thermoplastic material has a tensile modulus of at least 0.3 GPa at 23 degrees C. 26. The invention according to claim 24 wherein the thermoplastic material contains a polylactic acid (PLA) polymer, cellulose acetate butyrate, or polycaprolactone. 27. The invention according to claim 26 wherein the PLA polymer has a flexural modulus of 2.4-4.9 GPa at 23 degrees C. 28. The invention according to claim 24 wherein the thermoplastic material has at least a portion of at least one of the top and bottom sides has a textured surface. 29. The invention according to claim 28 wherein the textured surface is corrugated. 30. The invention according to claim 24 wherein the thermoplastic material has an internal structure, having a volume, located between the top and bottom sides, wherein 40% or less of the volume is defined by an open cell structure. 31. The invention according to claim 24 wherein the thermoformable medical member comprises a splint. 32. The invention according to claim 24 wherein the thermoformable medical member comprises an orthotic. 33. The invention according to claim 24 wherein the thermoformable medical member comprises an exoskeleton member. 34. The invention according to claim 24 wherein the heater comprises one of an oxygen activated heater and a water activated heater. 35. The invention according to claim 34 wherein the heater is integrated with the thermoformable medical member. 36. The invention according to claim 24 wherein the thermoplastic material is chemically or physically bonded to the heater. 37. The invention according to claim 24 wherein the thermoplastic material has a glass transition temperature in the range of 35-70 degrees C. 38. The invention according to claim 24 wherein the thermoplastic material contains a reinforcing fiber. 39. The invention according to claim 24 wherein the thermoformable medical member contains a thermosetting component capable of forming crosslinks in the range of 20-70 degrees C. 40. A thermoformable medical member and heater comprising: a thermoplastic material having a top side and a bottom side opposite the top side, wherein the thermoplastic material comprises a flexural modulus at 73 degrees F. of at least 2.3 GPa, a heat deflection temperature less than 70 degrees C.; and a thermoformable temperature in the range of 35-70 degrees C.; anda heater operatively associated with at least one of the top and bottom sides of the thermoplastic material,wherein the thermoplastic material further includes at least one of an organic and inorganic filler, and the filler has a thermal conductivity greater than 0.12 W/(meter ° C.) at 48 degrees C. 41. The invention according to claim 40 wherein the thermoplastic material has a tensile modulus of at least 0.3 GPa at 23 degrees C. 42. The invention according to claim 40 wherein the thermoplastic material contains a polylactic acid (PLA) polymer, cellulose acetate butyrate, or polycaprolactone. 43. The invention according to claim 42 wherein the PLA polymer has a flexural modulus of 2.4-4.9 GPa at 23 degrees C. 44. The invention according to claim 40 wherein the thermoplastic material has at least a portion of at least one of the top and bottom sides has a textured surface. 45. The invention according to claim 44 wherein the textured surface is corrugated. 46. The invention according to claim 40 wherein the thermoplastic material has an internal structure, having a volume, located between the top and bottom sides, wherein 40% or less of the volume is defined by an open cell structure. 47. The invention according to claim 40 wherein the thermoformable medical member comprises a splint. 48. The invention according to claim 40 wherein the thermoformable medical member comprises an orthotic. 49. The invention according to claim 40 wherein the thermoformable medical member comprises an exoskeleton member. 50. The invention according to claim 40 wherein the heater comprises one of an oxygen activated heater and a water activated heater. 51. The invention according to claim 50 wherein the heater is integrated with the thermoformable medical member. 52. The invention according to claim 40 wherein the thermoplastic material is chemically or physically bonded to the heater. 53. The invention according to claim 40 wherein the thermoplastic material has a glass transition temperature in the range of 35-70 degrees C. 54. The invention according to claim 40 wherein the thermoplastic material contains a reinforcing fiber. 55. The invention according to claim 40 wherein the thermoformable medical member contains a thermosetting component capable of forming crosslinks in the range of 20-70 degrees C. 56. A thermoformable medical member and heater comprising: a thermoplastic material having a top side and a bottom side opposite the top side, wherein the thermoplastic material comprises a flexural modulus at 73 degrees F. of at least 2.3 GPa, a heat deflection temperature less than 70 degrees C.; and a thermoformable temperature in the range of 35-70 degrees C.; anda heater operatively associated with at least one of the top and bottom sides of the thermoplastic material,wherein the thermoplastic material has at least a portion of at least one of the top and bottom sides has a textured surface. 57. The invention according to claim 56 wherein the thermoplastic material has a tensile modulus of at least 0.3 GPa at 23 degrees C. 58. The invention according to claim 56 wherein the thermoplastic material contains a polylactic acid (PLA) polymer, cellulose acetate butyrate, or polycaprolactone. 59. The invention according to claim 58 wherein the PLA polymer has a flexural modulus of 2.4-4.9 GPa at 23 degrees C. 60. The invention according to claim 56 wherein the thermoplastic material has an internal structure, having a volume, located between the top and bottom sides, wherein 40% or less of the volume is defined by an open cell structure. 61. The invention according to claim 56 wherein the thermoformable medical member comprises a splint. 62. The invention according to claim 56 wherein the thermoformable medical member comprises an orthotic. 63. The invention according to claim 56 wherein the thermoformable medical member comprises an exoskeleton member. 64. The invention according to claim 56 wherein the heater comprises one of an oxygen activated heater and a water activated heater. 65. The invention according to claim 64 wherein the heater is integrated with the thermoformable medical member. 66. The invention according to claim 56 wherein the thermoplastic material is chemically or physically bonded to the heater. 67. The invention according to claim 56 wherein the thermoplastic material has a glass transition temperature in the range of 35-70 degrees C. 68. The invention according to claim 56 wherein the thermoplastic material contains a reinforcing fiber. 69. The invention according to claim 56 wherein the thermoformable medical member contains a thermosetting component capable of forming crosslinks in the range of 20-70 degrees C. 70. A thermoformable medical member and heater comprising: a thermoplastic material having a top side and a bottom side opposite the top side, wherein the thermoplastic material comprises a flexural modulus at 73 degrees F. of at least 2.3 GPa, a heat deflection temperature less than 70 degrees C.; and a thermoformable temperature in the range of 35-70 degrees C.; anda heater operatively associated with at least one of the top and bottom sides of the thermoplastic material,wherein the thermoplastic material has at least a portion of at least one of the top and bottom sides has a textured surface, and the textured surface is corrugated. 71. The invention according to claim 70 wherein the thermoplastic material has a tensile modulus of at least 0.3 GPa at 23 degrees C. 72. The invention according to claim 70 wherein the thermoplastic material contains a polylactic acid (PLA) polymer, cellulose acetate butyrate, or polycaprolactone. 73. The invention according to claim 72 wherein the PLA polymer has a flexural modulus of 2.4-4.9 GPa at 23 degrees C. 74. The invention according to claim 70 wherein the thermoplastic material has an internal structure, having a volume, located between the top and bottom sides, wherein 40% or less of the volume is defined by an open cell structure. 75. The invention according to claim 70 wherein the thermoformable medical member comprises a splint. 76. The invention according to claim 70 wherein the thermoformable medical member comprises an orthotic. 77. The invention according to claim 70 wherein the thermoformable medical member comprises an exoskeleton member. 78. The invention according to claim 70 wherein the heater comprises one of an oxygen activated heater and a water activated heater. 79. The invention according to claim 78 wherein the heater is integrated with the thermoformable medical member. 80. The invention according to claim 70 wherein the thermoplastic material is chemically or physically bonded to the heater. 81. The invention according to claim 70 wherein the thermoplastic material has a glass transition temperature in the range of 35-70 degrees C. 82. The invention according to claim 70 wherein the thermoplastic material contains a reinforcing fiber. 83. The invention according to claim 70 wherein the thermoformable medical member contains a thermosetting component capable of forming crosslinks in the range of 20-70 degrees C. 84. A thermoformable medical member and heater comprising: a thermoplastic material having a top side and a bottom side opposite the top side, wherein the thermoplastic material comprises a flexural modulus at 73 degrees F. of at least 2.3 GPa, a heat deflection temperature less than 70 degrees C.; and a thermoformable temperature in the range of 35-70 degrees C.; anda heater operatively associated with at least one of the top and bottom sides of the thermoplastic material,wherein the thermoplastic material has an internal structure, having a volume, located between the top and bottom sides, wherein 40% or less of the volume is defined by an open cell structure. 85. The invention according to claim 84 wherein the thermoplastic material has a tensile modulus of at least 0.3 GPa at 23 degrees C. 86. The invention according to claim 84 wherein the thermoplastic material contains a polylactic acid (PLA) polymer, cellulose acetate butyrate, or polycaprolactone. 87. The invention according to claim 86 wherein the PLA polymer has a flexural modulus of 2.4-4.9 GPa at 23 degrees C. 88. The invention according to claim 84 wherein the thermoformable medical member comprises a splint. 89. The invention according to claim 84 wherein the thermoformable medical member comprises an orthotic. 90. The invention according to claim 84 wherein the thermoformable medical member comprises an exoskeleton member. 91. The invention according to claim 84 wherein the heater comprises one of an oxygen activated heater and a water activated heater. 92. The invention according to claim 91 wherein the heater is integrated with the thermoformable medical member. 93. The invention according to claim 84 wherein the thermoplastic material is chemically or physically bonded to the heater. 94. The invention according to claim 84 wherein the thermoplastic material has a glass transition temperature in the range of 35-70 degrees C. 95. The invention according to claim 84 wherein the thermoplastic material contains a reinforcing fiber. 96. The invention according to claim 84 wherein the thermoformable medical member contains a thermosetting component capable of forming crosslinks in the range of 20-70 degrees C. 97. A thermoformable medical member and heater comprising: a thermoplastic material having a top side and a bottom side opposite the top side, wherein the thermoplastic material comprises a flexural modulus at 73 degrees F. of at least 2.3 GPa, a heat deflection temperature less than 70 degrees C.; and a thermoformable temperature in the range of 35-70 degrees C.; anda heater operatively associated with at least one of the top and bottom sides of the thermoplastic material,wherein the heater comprises one of an oxygen activated heater and a water activated heater. 98. The invention according to claim 97 wherein the thermoplastic material has a tensile modulus of at least 0.3 GPa at 23 degrees C. 99. The invention according to claim 97 wherein the thermoplastic material contains a polylactic acid (PLA) polymer, cellulose acetate butyrate, or polycaprolactone. 100. The invention according to claim 99 wherein the PLA polymer has a flexural modulus of 2.4-4.9 GPa at 23 degrees C. 101. The invention according to claim 97 wherein the thermoformable medical member comprises a splint. 102. The invention according to claim 97 wherein the thermoformable medical member comprises an orthotic. 103. The invention according to claim 97 wherein the thermoformable medical member comprises an exoskeleton member. 104. The invention according to claim 97 wherein the thermoplastic material is chemically or physically bonded to the heater. 105. The invention according to claim 97 wherein the thermoplastic material has a glass transition temperature in the range of 35-70 degrees C. 106. The invention according to claim 97 wherein the thermoplastic material contains a reinforcing fiber. 107. The invention according to claim 97 wherein the thermoformable medical member contains a thermosetting component capable of forming crosslinks in the range of 20-70 degrees C. 108. A thermoformable medical member and heater comprising: a thermoplastic material having a top side and a bottom side opposite the top side, wherein the thermoplastic material comprises a flexural modulus at 73 degrees F. of at least 2.3 GPa, a heat deflection temperature less than 70 degrees C.; and a thermoformable temperature in the range of 35-70 degrees C.; anda heater operatively associated with at least one of the top and bottom sides of the thermoplastic material,wherein the heater comprises one of an oxygen activated heater and a water activated heater and the heater is integrated with the thermoformable medical member. 109. The invention according to claim 108 wherein the thermoplastic material has a tensile modulus of at least 0.3 GPa at 23 degrees C. 110. The invention according to claim 108 wherein the thermoplastic material contains a polylactic acid (PLA) polymer, cellulose acetate butyrate, or polycaprolactone. 111. The invention according to claim 110 wherein the PLA polymer has a flexural modulus of 2.4-4.9 GPa at 23 degrees C. 112. The invention according to claim 108 wherein the thermoformable medical member comprises a splint. 113. The invention according to claim 108 wherein the thermoformable medical member comprises an orthotic. 114. The invention according to claim 108 wherein the thermoformable medical member comprises an exoskeleton member. 115. The invention according to claim 108 wherein the thermoplastic material is chemically or physically bonded to the heater. 116. The invention according to claim 108 wherein the thermoplastic material has a glass transition temperature in the range of 35-70 degrees C. 117. The invention according to claim 108 wherein the thermoplastic material contains a reinforcing fiber. 118. The invention according to claim 108 wherein the thermoformable medical member contains a thermosetting component capable of forming crosslinks in the range of 20-70 degrees C. 119. A thermoformable medical member and heater comprising: a thermoplastic material having a top side and a bottom side opposite the top side, wherein the thermoplastic material comprises a flexural modulus at 73 degrees F. of at least 2.3 GPa, a heat deflection temperature less than 70 degrees C.; and a thermoformable temperature in the range of 35-70 degrees C.; anda heater operatively associated with at least one of the top and bottom sides of the thermoplastic material,wherein the thermoplastic material contains a reinforcing fiber. 120. The invention according to claim 119 wherein the thermoplastic material has a tensile modulus of at least 0.3 GPa at 23 degrees C. 121. The invention according to claim 119 wherein the thermoplastic material contains a polylactic acid (PLA) polymer, cellulose acetate butyrate, or polycaprolactone. 122. The invention according to claim 121 wherein the PLA polymer has a flexural modulus of 2.4-4.9 GPa at 23 degrees C. 123. The invention according to claim 119 wherein the thermoformable medical member comprises a splint. 124. The invention according to claim 119 wherein the thermoformable medical member comprises an orthotic. 125. The invention according to claim 119 wherein the thermoformable medical member comprises an exoskeleton member. 126. The invention according to claim 119 wherein the thermoplastic material is chemically or physically bonded to the heater. 127. The invention according to claim 119 wherein the thermoplastic material has a glass transition temperature in the range of 35-70 degrees C. 128. The invention according to claim 119 wherein the thermoformable medical member contains a thermosetting component capable of forming crosslinks in the range of 20-70 degrees C.
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이 특허에 인용된 특허 (4)
Friedensohn, Joshua; Murph, Nefetari Bordain; Quincy, III, Roger Bradshaw; McKenzie, Karen, Conformable thermal device.
Kocher Patrick N. ; Mudar Kimberly Ann ; Mueller Walter Berndt ; Stockley H. Walker, Laminate having a coextruded, multilayer film which delaminates and package made therefrom.
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