WO2003043793A1

WO2003043793A1 - Molding material and patterning method using the molding material

Info

Publication number: WO2003043793A1
Application number: PCT/JP2002/012072
Authority: WO
Inventors: Masao Inoue; Masanori Shimizu; Shigeomi Nishimiya
Original assignee: Mac Inc.
Priority date: 2001-11-19
Filing date: 2002-11-19
Publication date: 2003-05-30
Also published as: JP2003144484A

Abstract

A molding material and a patterning method using the molding material without using gypsum, the method comprising the steps of stacking, in sandwich shape, a thermoplastic material (12) such as a thermoplastic resin on expandable base materials (11) and (13) such as cloth, stamping the thermoplastic material (12) in fluidized state on a patterned object through the base material (11), and cooling the thermoplastic material (12); the molding material capable of being used as a molding material for free molding by using the same formation of the base material and the thermoplastic material.

Description

Description Molding material and molding method using it

The present invention also includes a casting technique that can be used in various fields, such as a casting method when creating a prosthetic limb such as a prosthesis or an artificial hand, a casting method when creating a prosthetic device used in orthopedic surgery, and a casting technique. Therefore, it relates to a molding technology that can easily form a desired three-dimensional shape.In particular, in the molding technology, it is shorter than the conventional molding technology performed using gypsum or a plaster bandage. This is a technology that can be used simply and finely in a dry process. Background art

2. Description of the Related Art Conventionally, in various fields such as a medical field such as orthopedic surgery and an art modeling field, a human body and other types of molding, that is, molding are performed. In the field of medicine, in orthopedic surgery, casting is performed in the production of so-called prostheses, including prostheses such as prostheses and prostheses, and orthoses that are worn for fixing or correcting obstacles in the body. Have been done. In particular, when making such a prosthetic device, it is often worn over a long period of time for the purpose of assisting an obstruction, and a sophisticated casting technique is required so that there is no trouble in mounting. ing.

In the field of medicine, so-called gypsum bandages in which gypsum is adhered to gauze bandages are mainly used for casting. Gypsum bandage, which has been cut to an appropriate width in advance according to the type to be cast, is temporarily immersed in water or lukewarm water, and immediately wound around the affected area such as a stump to be cast while the gypsum does not dry. Have done the type.

For example, when creating a prosthesis used to assist a lower limb lost due to amputation, a tricot soaked in water is placed over the stump of the patient and secured with a string. Mark prominent irregularities such as the epiphysis on the tricot with a copy pencil.

In this state, the gypsum bandage, which has been softened by immersing it in water or lukewarm water as described above, is quickly wound onto the tricot with a certain winding force so that the unevenness of the affected part is reproduced. It must be wound before the plaster does not solidify. This When the plaster bandage thus set solidifies, the plaster bandage is removed from the affected area to form a so-called female type (also called a negative model). On the inner surface of the female mold, the portion previously marked on the tricot is transcribed.

Then, plaster is poured in a state where a mandrel such as an iron bar is set up at the center of the female mold, and then solidified to form a male mold (also referred to as a positive model). The male part is used to form the prosthetic limb and the prosthetic device for the affected area. The quality of the initial female mold casting will determine the quality of the final fit of the prosthetic device to the affected area.

On the other hand, gypsum is used where gypsum bandages cannot be used. For example, the surface of the sole and the like can not be skillfully cast with gypsum bandage, and the method of shaping is performed by pressing the sole against gypsum mud in a softened state to some extent. In cases where the time required for molding cannot be sufficiently ensured, a method called sketch measuring is also used.

Casting is actively used in fields other than medicine. For example, in the field of plastic arts, elaborate reproductions of natural objects, including human bodies, are sometimes performed. For such reproduction, casting using gypsum is indispensable. When duplicating an elaborate human face, it is necessary to press the face against the softened gypsum surface, hold the breath for a while in that state, etc., to keep the face still, and then relax and remove the face from the gypsum surface Have been done.

As described above, a casting technique using gypsum has been used in various fields. However, most of the methods use gypsum in a wet state, that is, in a state of gypsum mud.

However, the casting technique using gypsum or plaster bandage as described above has the following problems.

The plaster bandage must be wrapped neatly while the plaster is not dry, with a moderate amount of wrapping force while the plaster is softening without excessively pressing the soft tissue of the affected area. It usually takes about 5 minutes to complete the task. Therefore, considerable skill is required to perform good casting.

In the actual medical practice, with this in mind, a qualified prosthetist and orthodontist must be engaged in such casting under the prescription of a doctor. However, at present, it cannot be said that there are enough prosthetics and orthotics, and precision casting is not enough to meet the demand. Do not fit.

As described above, since it generally takes a considerable amount of time before the casting, it is not possible to quickly provide a prosthetic device to the patient. Therefore, there is a strong demand on the site for a technique that enables sophisticated casting without requiring special skill.

In addition, the skill of winding gypsum bandages depends on the skill of the prosthetist as described above, and individual differences are likely to occur. For this reason, it is difficult to control the quality of casting by using gypsum bandages.

In addition, since the gypsum is easy to dry in the casting by gypsum bandage wrapping, it is practically difficult to correct the wrapping even if you try to go back a little and fix the wrapping during the wrapping work. .

It has also been pointed out that there are problems with the secondary treatment before and after the work, including the work of winding the plaster bandage. For example, gypsum dressings need to be soaked in water or lukewarm water before use, so that the gypsum powder contains water. It is necessary to drain water appropriately so that the formed muddy gypsum mud does not run off from bandages such as gauze. Normally, a long plaster bandage is wound into a roll and dipped in water for an appropriate period of time, and the end of the roll is drained by gripping the roll end. The degree of drainage differs from the outside of the roll, which may affect the casting operation. However, it is practically impossible to perform powerful drainage evenly.

Further, in the molding method using a plaster bandage, since the molding is performed in a so-called wet state as described above, the affected area to be molded is stained with gypsum mud. The affected area is required to be as dirty as possible, which is a major problem. If dry casting can be performed, the problem of power will be solved. At the same time, there is a tendency for individual differences in the method of attaching a marker that marks the specific position on the affected area and the removal of gypsum dressing after solidification, and sufficient attention is required.

Also, in conventional gypsum casting, the gypsum itself after solidification is extremely fragile and requires careful handling. If the plaster mold is damaged, it is difficult to repair it and must be remolded. Casting must be performed by a prosthetic orthotist for a considerable amount of time, which makes it difficult to provide patients with orthotics. Furthermore, for the patient, the wet gypsum solidifies while generating heat while in contact with the skin, so if the wound state is maintained for a certain period of time, in the case of people with weak skin, Irritation due to gypsum may occur. In particular, at the stump, the affected area is often different from the outer skin on the body surface side, and is more sensitive to stimuli.

In addition, even if gypsum bandages are not used, if it is necessary to take a gypsum mold, wet casting will be performed using gypsum mud, so gypsum will inevitably adhere to the side to be cast and gypsum adhered after casting Must be washed off. As described above, since the post-processing of the conventional casting using gypsum is troublesome, there is a strong demand for the development of a technology that does not require such post-processing.

Furthermore, once a prosthetic device is cast, it does not have to be done for many years without having to do it for a long time. In particular, children, etc., should appropriately cast their prosthetic devices so as to match the growth rate according to their age. It is necessary to ensure the proper mounting state of the prosthesis, and there is a need for a technology that can easily and quickly perform the molding, instead of the complicated molding method of the conventional molding described above. In recent years, many people have been injured by land mines in conflict areas around the world, and many prostheses have been required on site. However, in the case of a prosthesis, more elaborate casting is required, and since the preparation of the plaster mold at present requires an experienced person, it is hardly expected that smooth casting will be performed on site.

The inventor of the present invention has thought that it is possible to help save the present situation by developing a technology that allows even an amateur to easily perform casting in such a painful situation. In other words, by making the casting technique easy and without any special knowledge, the casting of many disabled persons can be done quickly at the local site, and the prosthetic limb can be brought back to a country free from war damage. It is thought that the creation of this system will facilitate the supply of prostheses and support the rehabilitation of many people.

An object of the present invention is to provide a simple casting technique that does not use gypsum. Disclosure of the invention

The molding material of the present invention has a stretchable base material and a thermoplastic material such as a thermoplastic resin laminated on the base material, and the thermoplastic material has a desired shape in a fluidized state. Transformed into It is characterized in that it can be shaped by being made.

The molding material is formed as a molding material used for molding the shape by pressing the molding material in a state where the thermoplastic material is fluidized. The base material is a cloth. The molding material is formed in any one of a sheet shape, a bag shape, and a tubular shape.

Further, the present invention provides a method of molding a shape by pressing a molding material against a molding object, wherein the molding material is obtained by laminating a thermoplastic material such as a thermoplastic resin on a stretchable base material. And forming a female mold by fluidizing the thermoplastic material, pressing the substrate side of the molding material against the molding target, molding, curing, and molding. . The molding object is a mounting portion on the human body side when a prosthetic device is mounted on the human body for the purpose of reducing or eliminating a functional disorder, for example, by fluidizing the thermoplastic material of the molding material. A female mold forming step in which the base material side of the molding material is applied to the mounting portion to mold and cure to form a female mold; and the inner surface of the female mold has the same configuration as the molding material. And a male molding step of fluidizing thermoplastic material of another molding material, pressing the base material side to form a mold, and curing to form a male mold.

Pressing the molding material against the inner surface of the female mold is performed by injecting a fluid into an inflating member such as a balloon contained in a bag-shaped molding material contained in the female mold and inflating the same, and expanding the base material of the molding material. The side is pressed against the inner surface of the female mold.

The present invention is a molding method for molding a male mold by pressing a molding material against a female mold, wherein the molding material is formed by laminating a thermoplastic material such as a thermoplastic resin on a stretchable base material. In the male mold, the fluid is inflated by injecting a fluid into an inflating member such as a balloon contained in a bag-shaped molding material contained in the female mold, and the base material side of the molding material is set to the inner surface of the female mold. By taking the inside of the female mold.

The term “thermoplastic” used in this specification does not mean a “plasticizer” that is added to impart plasticity to a resin or the like, but refers to a material having thermoplasticity. For example, synthetic rubber and thermoplastic resin. BRIEF DESCRIPTION OF THE FIGURES FIGS. 1A and 1B are views showing a molding material formed in a sheet shape according to an embodiment of the present invention, wherein FIG. 1A is a perspective view and FIG. 1B is a sectional view thereof.

2A and 2B are views showing a molding material, (A) is a perspective view of a molding material formed in a bag shape, (B) is a perspective view of a molding material formed in a cylindrical shape, and (C) is a line in a cylinder direction. FIG. 4 is a perspective view of a cylindrical molding material provided with a portion.

FIG. 3 is a cross-sectional view showing a case where a base material and a thermoplastic resin are configured in a multilayer.

Fig. 4 is a diagram showing a molding material and a core used for the same. (A) is a perspective view of a bag-shaped molding material used for making a prosthesis, (B) is a cross-sectional view thereof, and (C) () Is a perspective view showing a core used for producing the molding material shown in (A).

FIG. 5 is a process chart showing the temperature and the required time in each step in producing a bag-shaped molding material.

FIG. 6 is a view showing a sample, (A) is a partial cross-sectional view showing a configuration of the sample used in the sensory temperature test, and (B) is a view showing a state where the sample is placed in a high-temperature bath.

FIGS. 7A and 7B are flow charts showing the mold making process. FIG. 7A is a flow chart for making a female mold, and FIG. 7B is a flow chart for making a male mold.

FIGS. 8 (A) to 8 (F) are explanatory diagrams showing each operation procedure of female mold making.

FIGS. 9 (A) to 9 (F) are explanatory diagrams showing the working procedures of male mold creation and artificial leg creation. FIGS. 10A and 10B are cross-sectional views showing a modification of lamination of a base material and a thermoplastic material. BEST MODE FOR CARRYING OUT THE INVENTION

(Embodiment 1)

In the present embodiment, a case will be described in which the shaped material of the present invention is configured as a molding material. FIG. 1 (A) is a perspective view of a molding material formed in a sheet shape, and FIG. 1 (B) is a cross-sectional view of the molding material shown in FIG. FIG. 2 (A) is a perspective view of a bag-shaped molding material, and FIGS. 2 (B) and 2 (C) are perspective views of a cylindrical molding material. In the case shown in FIG. 1A, the molding material 10 is formed in a substantially rectangular sheet shape. As shown in FIG. 1 (B), such a molding material 10 is formed by sequentially laminating an elastic substrate 11, a thermoplastic material 12, and an elastic substrate 13 to form a single composite sheet. Is formed. The sheet shape of the molding material 10 may be a shape other than the rectangular shape shown in FIG. For example, a circular shape, a triangular shape, or an indefinite shape may be used according to a molding object, and any shape may be used as needed.

For example, a stretchable cloth can be used as the base material 11. As such a cloth, for example, a stretchable yarn obtained by weaving yarns of various fibers, such as a woven fabric made of spandex and a knit (including a wooly yarn), can be used. Spandex unidirectional or woven fabric with elasticity in the vertical and horizontal directions, one direction using spandex or wooly, or a piece of fabric with elasticity in the vertical and horizontal directions can be used.

The molding material 10 according to the present invention is obtained by heating the thermoplastic material 12 to a degree sufficient to spread it along, for example, the fine uneven surface of the molding object and fluidizing it. Material 1 Perform molding by pressing against the 1 side. For this reason, the base material 11 is required to have sufficient elasticity to cope with the expansion and contraction of the thermoplastic material 12 that undergoes various deformations in accordance with the molding target.

In addition, as the base material 11, an elastic nonwoven fabric may be used in addition to the woven fabric. Further, a thin film such as a rubber-based film may be used. It is also acceptable to use a stretchy woven or non-woven fabric thinly rubberized. That is, the base material 11 can be used as long as it has elasticity enough to follow the deformation of the thermoplastic material 12 at the time of molding.

When used for molding to make a prosthetic device to be attached to the affected part or stump of the human body, it is heated and fluidized to a temperature where the required fluidity is obtained, such as the softening point or melting point. A cloth having a relatively small thermal conductivity, which has an effect of relieving the temperature of the thermoplastic material in the state, is preferable. It is more preferable that the cloth has a soft texture that does not give a strong sense of incongruity even when directly touching the skin.

As the thermoplastic material, for example, a thermoplastic resin or a synthetic rubber can be used. As the thermoplastic resin, use of an olefin resin, an ethylene-propylene resin, a butyl resin, a urethane resin, or the like can be considered.

For example, examples of the olefin resin include polyethylene, polypropylene, and ethylene vinyl acetate copolymer resin (EVA). As synthetic rubbers, styrene-butadiene-styrene (SBS), styrene-isoprene-styrene (SBS) IS), styrene-ethylene-butylene-styrene (SEBS), styrene-ethylene-propylene-styrene (SEPS), and the like.

Further, a crosslinked thermoplastic resin may be used. For example, a cross-linked polystyrene resin, a polyolefin resin, a polyurethane resin, an acrylic resin, a polyester resin, a polyamide resin, or the like, or a silane cross-linked synthetic rubber can be considered. Examples of the crosslinking method include a chemical reaction type, a thermosetting type, a UV irradiation type, an electron beam irradiation type, and a high frequency irradiation type.

These thermoplastic resins may optionally be mixed with tackifying resins, waxes, process oils, fillers, antioxidants, and the like, if necessary.

From the viewpoint of ease of use, those having a pour point higher than room temperature are preferable. This is because at the time of molding, the material is heated to a temperature higher than room temperature to fluidize it, pressed against the object to be molded before cooling, and allowed to cool naturally by allowing it to cool to form the mold. In particular, when performing the casting necessary for making a prosthesis to be attached to the affected part or stump of the human body, the heat of the fluidized thermoplastic material 12 can not withstand the affected part through the base material 11. It is preferable to select a material having a pour point that does not make the user feel the heat. For example, when a cotton cloth is used as the base material 11, the pour point of the thermoplastic material 12 can be used at least up to about 80 ° C. at least by the experiment of the present inventor for use in molding to a human body. confirmed.

If the temperature of 80 ° C is transmitted directly to the human body, for example, the affected area, the heat conduction becomes unbearably hot. Then, it can be used. Use of a thermoplastic material 12 with a higher fluidization temperature by taking measures to prevent heat conduction, such as by making the base material 11 small in thermal conductivity or thickening the base material 11 Becomes possible.

When a thermoplastic material such as a thermoplastic resin is directly applied to a diseased part for molding, the temperature of the softened state of the thermoplastic material is directly transmitted to the diseased part and the like, and it may be impossible to withstand the heat. However, by using a thermoplastic material covered with a base material as in the case of the casting material of the present invention, heat transmission to the subject is hindered. It allows the use of thermoplastics that soften and flow at higher temperatures. In addition, if the object to be sampled is not a person or animal, but an object that is not expected to cause any particular damage due to heat, the pour point of the thermoplastic material 12 should be such that it can be easily used. The pour point of high temperature may be used if necessary.

Furthermore, in the molding material of the present invention, by adjusting the fluidity of the thermoplastic material 12 at the time of fluidization, it is prevented from flowing out or dripping from the surface of the base material 11 during molding. ing. It is preferable for the molding to have fluidity that can be extended to the extent that it can be extended and spread well along the fine irregularities of the molding target without flowing down.

The inventor has set the viscosity in the range of 0.5 to 1000 Pa * S (pass force in seconds) as the fluidity. If the viscosity is less than 0.5 Pa · S, the fluidity is too large and the thermoplastic material 12 flows out at the time of molding, making it difficult to handle at the time of molding. However, if the viscosity exceeds 1000 Pa · S, the fluidity is poor and precise molding cannot be performed sufficiently along the molding object having delicate irregularities. More preferably, it is in the range of 2 to 200 Pa · S.

In the above measurement, a Brookfield viscometer Thermozel system rotor No. 2820 rZm was used.

The lamination of the thermoplastic material 12 and the substrate 11 may be performed by applying the fluidized thermoplastic material 12 to the surface of the substrate 11. Alternatively, a sheet-shaped cured thermoplastic material 12 is placed on one surface of the base material 11, and the thermoplastic material 12 is heated to a temperature at which an adhesive force is generated in this state, and the base material 11 and the thermoplastic material are heated. You can make the material 1 and 2 heat-coated. Alternatively, it is also possible to adopt a dipping method in which the base material 11 is immersed in a liquid thermoplastic material 12 and taken out.

In using the molding material 10 of the present invention thus formed, it is necessary to heat the thermoplastic material 12 to soften it. For such heating, an oven range, an electric oven, A method of applying hot air from a heat dryer may be considered. In addition, if the pour point is low, portable heating agents such as Hokalon® may be used.

When heating the thermoplastic material, it may be fluidized to a moldable state. Heating may be performed until appropriate fluidity is obtained according to the fineness of the mold object, such as unevenness. When there are relatively few undulations and no fine uneven surface, the heating temperature is reduced and the fluidity is reduced, that is, the viscosity is relatively low, compared to a molding object that has many fine undulations and large unevenness. It may be set to be larger. As described above, by appropriately changing the heating conditions, it is only necessary to obtain the fluidity suitable for the target for molding.

Although the above description shown in FIG. 1 shows a case where the molding material 10 is formed in a substantially rectangular sheet shape, it may be formed in a bag shape as shown in FIG. 2 (A). The shape of the bag can also be, for example, a sock-shaped bag that allows easy insertion of feet when taking a last, a hat-shaped bag when taking a head, a palm or a finger. Various types of bags can be considered according to the type of object to be collected, such as gloves when the palm is worn while the hands are being cast.

As shown in Fig. 2 (B), when the arm is formed in a cylindrical shape, when the arm is cast, the ankle or the ankle or the like has a length and a diameter corresponding to the average arm length and the arm thickness. For the molding of the legs, the legs may be formed in a cylindrical shape having a length and a diameter corresponding to each. Further, in the case shown in FIG. 2 (B), the case where it is formed in a straight cylindrical shape is shown, but a shape in which one end or both ends are open to the skirt, or conversely, a shape in which the shape is constricted is opened. Various shapes can be employed as needed.

Furthermore, in the case of forming a cylinder, as shown in Fig. 2 (C), by providing a disconnection portion 13a in the length direction of the cylinder, the mold after this molding can be removed. It can be easier. That is, the disconnecting portion 13a may be detached while slightly distorting.

As shown in FIG. 2 (C), the disconnection portion 13a (indicated by a broken line in the figure) is formed, for example, in the longitudinal direction of the cylinder with a predetermined width, while leaving the outer base material and the inner heat source. What is necessary is just to form in a state where only the plastic material and the inner base material are omitted. Alternatively, a completely separated portion may be formed at predetermined intervals in the length direction of the cylinder, and may be formed in a substantially C-shaped cross section.

In any case, unlike the gypsum, the thermoplastic material 12 has a certain degree of elasticity even in a hardened state. Can be performed easily.

In the above description, the case where the molding material 10 has a configuration in which the thermoplastic material 12 is further sandwiched between the elastic substrates 11 and 13 has been described, for example, as shown in FIG. The thermoplastic materials 14a, 14b and the base materials 15a, 15b, 15c may be alternately laminated in multiple layers. In such a case, the plurality of substrates 15a, 15b, and 15c may be the same material or different materials. Similarly, for the plurality of thermoplastics 14a and 14b, the same thermoplastic may be used, or different types of thermoplastics may be used.

Unlike the conventional molding technique, the molding material of the present invention does not use gypsum or a gypsum bandage, so that there is no risk of soiling the molding target with gypsum mud or the like. Therefore, it can be said that the material is extremely suitable for molding in the production of assistive devices that need to avoid contamination of the stump.

Among the prostheses, when creating prostheses such as prostheses and prostheses, the quality of the mounting condition at the mounting part of the stump of the prosthesis is one of the important problems when mounting. Unlike gypsum, because of the use of a thermoplastic, shrinkage during curing is not as large as that of gypsum, and more precise molding can be performed. For this reason, the mounting state of the assisting device obtained by molding using the molding material according to the present invention is much better than that obtained by the conventional molding method.

However, since the molding material of the present invention is brought into contact with the patient's stump through a base material such as cloth in a state where the thermoplastic material is fluidized, the body temperature at the stump at the time of molding is measured. The degree of the degree is an important issue. The present inventor has confirmed the safety of such a point through experiments.

In the experiment, a specimen was formed in a bag shape in the following manner in order to use it at the stump. The bag-shaped sample is formed in the shape shown in Fig. 4 (A). As shown in FIG. 4 (B), the molding material 10 is made of two elastic cloths 16 a and 16 b formed in a bag shape as a base material 16 and a thermoplastic resin 1. 7a is sandwiched in a sandwich shape as a thermoplastic material 17.

The two fabrics 16a and 16b are made in a round mesh slat sock. The linking 18 at the tip is similar to that of socks. Of the two cloths 16a and 16b, the inner cloth 16a is in contact with the thermoplastic resin 17a so that the cotton thread comes on the side that comes into contact with the stump when the cutting material is mounted. The woven side is woven with spandex yarn.

On the other hand, the cloth 16b constituting the outer side of the molding material is woven using a spandette yarn on the side in contact with the resin, and a polyester yarn or a Nyarn yarn on the side constituting the outer surface of the molding material. .

The reason for using cotton yarn on the side that comes into contact with the stump is that the cotton yarn has low thermal conductivity. This is because by selectively using a yarn having low thermal conductivity, the transmission of the temperature of the thermoplastic resin 17a in the fluidized state to the stump can be suppressed as much as possible. The polyester or nylon yarn used for the outer surface of the casting material had a melting point of 255 ° C or higher.

The two fabrics woven in this manner are surface-attached with a thermoplastic resin interposed therebetween, and as shown in FIG. They are locked together like a piece of cloth.

More specifically, examples of the component composition of the thermoplastic resin 17a used in such a composition include the following.

25 parts by weight of ethylene vinyl acetate copolymer resin

(Evaflex 220: manufactured by DuPont Mitsui Polychemicals)

Adhesive resin (Alcon P 100: Arakawa Chemical Co., Ltd.) 15 parts by weight Wax (HNP-9: Nippon Seisakusho) 35 parts by weight Talc (average particle size: 1.75 / zm) 25 parts by weight Polyester fiber ( (Thickness 0.5D, length 3mm) 0.2 weight ^ The thermoplastic resin of such a composition has a melt viscosity of 420 OmPas / 180 ° C (Bunolex Field viscometer Samosel system rotor No.27 At 20 r / m), the softening point (R & B method) was 81 ° C.

In use, heating until a viscosity of 0.5 to 100 OPaS is obtained will result in softness that can be sufficiently molded, and after hardening, sufficient hardness will be obtained. It can sufficiently withstand use as a molding die. This hardness is the It was harder than plaster.

In the thermoplastic resin 17a having the above composition, the wax is used for adjusting the viscosity of the thermoplastic resin 17a when flowing, the talc is used for adjusting the flow of the thermoplastic resin 17a, and the polyester fiber is used in the cured state. It is individually formulated for hardness and elasticity enhancement.

In order to form a composite by laminating with the base material 16 using the thermoplastic resin 17a having such a configuration, first, the same flat plate-like shape shown in FIG. The core 21 is inserted to adjust the shape, and then dipped in the liquefied thermoplastic resin 17a. The dive was made up to the dotted line near the welt 19 shown in FIG. After the curing of the thermoplastic resin 17a, the outer cloth 16b was put thereon, and then exposed to a high-temperature bath in that state, so that the outer cloth 16b was attached to the thermoplastic resin 17a. The 19 part of Uenolet was locked by lock stitching. The bag-shaped molding material 10 formed in this manner is, for example, a shape as shown in FIG. 4 (A), having an outer shape with a width of 10 to 15:11 and a thickness of about 1 cm. At the time of molding, the perimeter could be extended up to about 50 to 60 cm.

In order to perform molding using such a bag-shaped molding material, the cured bag-shaped molding material 10 is appropriately fluidized in, for example, a thermoplastic resin 17a portion in a high-temperature bath. And cover the stump in that state. The thermoplastic resin 17a cures in a few minutes when covered. If it is desired to accelerate the hardening of a necessary part particularly, the part may be cooled quickly with a sponge or the like containing water.

Also, since the curing is too fast, even if the molding work is left in a necessary part, the part can be partially softened or fluidized by applying a heat dryer to the part. Such a work such as partially correcting the molding is not possible with the technology using the plaster and the plaster bandage of the conventional configuration, and can be performed only with the molding material 10 of the present invention.

Regarding the above procedure of the molding material 10 of the present invention, FIG. 5 shows the required temperature in each operation and the required man-hour in each operation. When the thermoplastic resin 17a having the above composition is used, the diving is performed at about 160 ° C., and the curing of the thermoplastic resin 17a adhered to the surface of the base material 16 by the diving is performed at 5 to 5 ° C. It takes 10 minutes. Further It took 10 minutes at 120 ° C. for the high temperature bath and 5 to 10 minutes for hardening when the outer cloth 16b was applied to the outside. In this way, the bag-shaped molding material 10 can be produced. When using the bag-shaped sample material 10 formed in this way, it is heated at 90 ° C. for about 20 minutes in a high-temperature bath such as a microwave oven. Thereafter, the mold material 10 in a heated state is attached to the stump to perform molding. It is only necessary to wait about 5 minutes for the molded sample material 10 to harden. Even if it does not cool completely, it cures sufficiently to prevent it from losing its shape.

The time required for the high-temperature bath shown in Fig. 5 is the time required to raise the temperature of the thermoplastic resin 17a of the molding material from the normal temperature state to the temperature, and the thermoplastic resin 1 of the molding material 10 7a is the time required for fluidization to the extent that casting can be performed evenly during casting.

In order to shorten the molding time, a hot box in which the temperature of the molding material 10 of the present invention is maintained at 60 to 70 ° C in advance is prepared and stored in the hot box. By preheating, the time required to reach the required temperature shown in FIG. 5 can be shortened.

In addition, the present inventor conducted a test using a thermoplastic resin 17a having the above composition to determine the force at which the temperature transmitted from the molding material 10 to the molding object side during molding, that is, the body temperature test. The procedure was as follows.

In the test, as shown in FIG. 6, a sheet-shaped sample material 10 of B5 size was constructed and used as a sample. The sample is composed by laminating the thermoplastic resin 17a of the above configuration by sandwiching it between an outer cloth 16b and an inner cloth 16a as shown in Fig. 6 (A). did. Three kinds of samples were formed as shown in Table 1. As shown in Table 1, two of them used pile netting fabric for No. 1 and No. 2, and flat netting fabric for No. 3.

At the time of the test, apply Beech paste paper 22 to the surface of the inner cloth 16a on the side directly in contact with the stump, etc., place it on a wire mesh as shown in Fig. 6 (B), and place it in a high-temperature Heating was performed at 90 for 20 minutes with the DF-41) manufactured by Kagaku Co., Ltd. being placed at the approximate center of the space in the tank. After the completion of the heating, the temperature state was measured 3 to 5 seconds later. The measurement was performed using a digital thermometer (made by SATO, Delta MC20T), and as a bodily sensation test The sheet surface of the molding material 10 was applied to the palm surface of the arm, and the body was observed as to how it felt. The results are shown in Table 1.

In the above test, the heating with the cardboard applied was carried out because, in actual use of the bag-shaped molding material according to the present invention, when the thermoplastic material was heated until it was fluidized, the bag was heated. This is because heating is performed with the cardboard inserted in the bag so that the mouth can be easily opened, and the test is performed in a state in which such actual conditions are satisfied.

Measurement result

Sheet fabric

Material

No.1 pile knitting small loop small loop polyester 100% orchid twine / spandex yarn

No.2 pile knitting small loop small loop 100% cotton No. 0 single yarn / spandex yarn

No.3 Flat knitting Flat knitting Flat knitting Polyester 100% fine twin yarn In the case of N0.1 shown in Table 1, the temperature of the inner cloth 16a is 49 and the temperature of the outer cloth 16b is At 53 ° C, neither felt physically hot. In the case of No. 2, the temperature of the inner and outer cloths 16a and 16b is 50 ° C and 52 ° C, respectively, and the heat is not felt physically as above. Was. In the case of No. 3, the temperature of the inner and outer cloths 16a and 16b was 55 ° C and 63 ° C, respectively. However, on the outside, it was hot and I could barely endure for about 10 seconds.

No. 1 is the case where the cloth 16 b used as the outer base material 16 was used as described above, and in the case of N 0.2, the cloth 16 a used as the inner base material 16 was used. This is the case when used. From the comparison of No. 1 and No. 2, although No. 2 was hotter than No. 1, it was a situation where heat was not felt physically. That is, the effectiveness of using cotton yarn as the inner base material can be confirmed.

From the comparison of Nos. 1 and 3, both cases use the cloth 16b used as the outer base material.However, No. 3 does not use a bandex yarn and has a temperature of N 0.1. Is higher than in the case. The inner cloth 16a has the function of suppressing heat conduction and preventing the body temperature from becoming hot, but the outer cloth 16b also minimizes the heat of the thermoplastic resin 17a to the outside. That is, it has the role of maintaining the fluidized state during molding as much as possible so that hardening does not start within the molding time. From the point of power, it can be said that the use of spandex yarn has an effect of suppressing the release of heat of the thermoplastic resin 17a to the outside. From these results, it was confirmed that the use of the spandex yarn for the outer cloth 16b was effective. At the same time, it was confirmed that when the molding material 10 of the present invention was used on the stump, it could be safely used by both the molding worker and the subject, without feeling the heat of burning. Was done.

Furthermore, it was confirmed that the mold formed by using the molding material of the present invention had sufficiently higher strength than the conventional gypsum mold. The results are shown in Table 2.

Test piece bending so-called limit load MPa Bending maximum load MPa Summary Inventive product ① 2.66 6,02

② 3.21 6.58 ① ～ ③ Average bending load 1943 ③ 2.96 6.83 ① ～ ③ Average bending maximum load 6.477 Conventional products ① 1.36 1,80 ① 、 1, Average bending proportional limit load 1.835

(2) 2.31 2.76 (1), (2) Average value of maximum bending load (2) For the test, a fabric consisting of 100% polyester, 100D twin yarn knitted with a circular knitting machine with a gauge of 176 flat knits was used as the base material and only one side of the base material A sample was obtained by laminating the thermoplastic resin having the above configuration. On the other hand, as a comparative sample, a gypsum bandage, which has been conventionally used mainly in the medical field, was cast in the state of gypsum mud and then solidified to form a comparative sample. Both samples were formed into strips of 25 mm width.

The strength was expressed as bending stress by bending proportional limit load (MPa) and bending maximum load (MPa). The test method was performed using an autograph (Ag-500B universal tester, manufactured by Shimadzu Corporation) in accordance with the test standard of JIS K 7171 (ISO 198: 1993). Test speed: 5 mm / min, distance between supports: 80 mm, support radius: 2 mm, test room temperature: 23 ± 2 ° C, humidity: 50 ± 5%.

From Table 2, it can be seen that the mold formed using the molding material of the present invention (designated as the product in the table) is formed from the gypsum bandage (designated as the conventional product in the table) at the bending proportional limit load. It was confirmed that it could withstand a load about 1.6 times that of the model that did. Similarly, it can be seen that the product of the present invention is 2.8 times larger than the conventional product also in the maximum bending load. In other words, it was confirmed that the product of the present invention was stronger in strength than the conventional product, did not have the brittleness that was likely to be of a gypsum type, and was not easily damaged under normal use conditions. The molding material 10 of the present invention having the above configuration is considered to be used in various fields as follows. It is. In other words, it can be used as a molding material 10 in other fields such as arts, crafts, decoration, stages and events, plastic models, and daily works.

Currently, except for examples such as die-casting, the method of applying gypsum or alginic acid directly onto the object to be duplicated or pouring it into the object to be duplicated is adopted for the reproduction. 10 can be used instead. By using the molding material 10 of the present invention, the work is easier than when using gypsum or alginic acid, and the required pure outer shape is easily duplicated without soiling the duplication target and the worker with plaster etc. can do.

In addition, compared to the case of using gypsum, there is no shrinkage at the time of hardening, and a more sophisticated copy can be made. Furthermore, the storage of the mold is less brittle than gypsum, has no hygroscopicity, and is easy to store.

The plaster bandage or urethane bandage mentioned above is used for medical orthopedic surgery, but when using a powerful bandage, it is necessary to add water and so on. Although it is necessary to make a three-dimensional shape by spirally winding the material, when using the molding material 10 of the present invention, it is not necessary to wrap the material like a bandage, and press the sheet surface against the molding object. If you can do it.

In addition, the molding material 10 can be used for the purpose of fixing a fixed shape such as fixing to a fractured part or the like, that is, as a fixing tunic material. The fixing of the foot can be easily achieved without applying any pressure or work to the object at the time of molding with the plaster bandage. By forming the molding material 10 into a sheet or various shapes, and by using a material having different properties such as the pour point or elasticity of the thermoplastic resin 17a, the fracture can be prevented. It is possible to create ones corresponding to various fixed states such as.

It can also be used for sheaths such as shoes used for persons with foot disorders. Conventionally, standard products have been applied, but from the beginning, shoes ideally fitted to the shape of each foot are ideal. This is especially true for those requiring medical correction and prosthesis. In rehabilitation, it is premised that the rehabilitation be performed using the right shoes, but at the moment, I am patient with ready-made products that are the closest shape to my feet. By utilizing the molding material 10 of the present invention, Shoes can be easily created.

In the molding material 10 of the present invention, even if the thermoplastic resin 17a is in a fluidized state, the thermoplastic resin 17a does not adhere directly to the molding target, so that the thermoplastic resin 17a is fluidized. Since the temperature at that time is transmitted in a state of being alleviated by the base material 16, it is possible to prevent heat damage to the molding object. Therefore, unlike the case where the thermoplastic resin 17a is directly contacted without the interposition of the base material 16, the thermoplastic resin 17 has a high pour point temperature such that the direct contact may cause thermal damage. a can also be used

(Embodiment 2)

In the present embodiment, a molding method of the present invention using the molding material 10 described in the first embodiment will be described. Unlike the conventional molding method, the molding method of the present invention does not use any gypsum or plaster bandage.

FIG. 7 is a flow chart showing a molding procedure using the molding material 10 of the present invention, taking a case of producing a prosthesis as an example. Figures 8 and 9 schematically show the work status in an easy-to-understand manner. The procedure for creating a prosthesis is as follows: First, a female mold at the stump is molded, a male mold is molded using the female mold, and then a portion to be attached to the stump of the prosthesis is formed according to the male mold. . Therefore, by elaborating the first female mold, the prosthetic leg can be attached to the stump of the prosthesis properly.

As shown in Fig. 7 (A), the female mold (negative model) creation flow is performed in the heating step 31 for the female mold. Heat the thermoplastic resin 17 used above the pour point of 17a. At the time of heating, the mold sample 10 is simply put into the microwave oven 23 and the microwave is heated. When the thermoplastic resin 17a is fluidized by heating in a microwave oven, the mold sample 10 is removed from the microwave oven 23. This situation is shown in FIGS. 8 (A) and (B).

The thermoplastic resin 1 Ίa fluidized and softened in the heating step 3 1 of the molding material 10 1 .The molding material 10 was removed from the bag in the molding process 3 2 as shown in the flow of Figure 7 (A). The part is put on the stump 24 and the molding is performed. This is shown in Fig. 8 (C). In such a molding process 32, a bag-shaped molding material 10 is inserted so that the stump 24 reaches the bottom of the bag as shown in FIG. 8 (D). In this state, as shown in Fig. 8 (E), The mold material 10 is pressed against the stump 24 and the periphery thereof, and the thermoplastic resin 17a is stretched so as to fit along the uneven portion such as the stump 24.

Then, as shown in the cooling step 33 of the molding material in the flow chart of FIG. 7 (A), the molding material 10 is stretched so that the unevenness of the stump 24 is sufficiently removed. Allow 0 to cool as it is, or blow it with cold air, or apply a sponge impregnated with water to cool it.

In the cooling step 33 of the molding material 10, the thermoplastic resin 17 a of the molding material 10 is cooled down from the pour point temperature and is quickly cured in that state, so that the shape at the time of molding is not lost. In this state, when the molding material 10 is pulled out from the stump 24, the extracted molding material 10 is formed as it is on the female mold 25 as shown in a completed step 24 of the flow chart of FIG. It will be. This is shown in FIG. 8 (F).

After forming the female mold 25 in this manner, the male mold 26 is molded using the female mold 25 as follows. As shown in FIG. 7 (B), the male mold 26 is made by putting a bag-shaped mold material into a female mold and expanding the mold. As shown in the flow chart of FIG. 7 (B), in the heating step 35, the sample material 10 to be inserted into the female mold 25 is heated in the microwave oven 23.

In the insertion step 36 of the molding material 10, the molding material 10 in a state where the thermoplastic resin 17 a is fluidized by heating is put into the female mold 25. The heating of the casting material 10 can be easily performed with the microwave oven 23 or the like as described above. This is shown in FIGS. 9 (A) and 9 (B).

Then, in the insertion step 37 of the expansion member 26, as shown in FIG. 9 (C), the expansion member 26 such as a balloon is inserted while the molding material 10 inserted into the female mold 25 does not cool down. . Thereafter, as shown in the expansion step 38, a fluid such as a gas or a liquid is caused to flow into the expansion member 26 to fully expand the expansion member 26. Due to the expansion of the expansion member 26, the soft molding material 10 is pressed against the inner surface of the female mold 25, and the side surface of the molding material 10 is molded along the uneven shape of the inner surface of the female mold 25. This is shown in FIGS. 9 (C) and (D).

In this state, in the cooling step 39 of FIG. 7, the casting material 10 is cooled and hardened until it does not collapse. In this state, pull out the hardened mold material 10 from the female mold 25 As shown in the male mold completion step 40 in the flow chart of FIG. 7B, the extracted mold material 10 is formed as it is in the male mold 25. This is shown in Fig. 9 (E).

The casting for creating the prosthesis is up to the process shown in Fig. 7 (A) and (B), and the casting is completed when the male mold 25 is completed as shown in Fig. 9 (E). . In the preparation of the prosthesis, it is necessary to form a mounting portion that fits the stump 24 using the formed male die 25 after the completion of the molding process. The formation of the mounting portion and the formation of the prosthesis main body 27 as shown in FIG. 9 (F) may be performed in a conventional manner.

In the above explanation, in both cases of the female mold making process and the male mold making process, the molding material 10 was formed from a bag shape from the beginning. It does not matter even if it is formed into a shape and used.

For the expansion of the expansion member 26, a method of allowing compressed air to flow and expanding the balloon can be used simply. However, the inflowing gas needs to be at a temperature that does not harden the thermoplastic resin 17a of the molding material 10 that has been fluidized by heating at an angle. Such temperature control is important even when the liquid flows in, and for example, hot water may be used as the inflow gas.

In the above description, the case where the molding material of the present invention is used in both the molding of the female mold and the male mold has been described as an example.However, for example, a female mold made of conventional gypsum is used, and A male mold making method using a mold material may be applied to the present invention. Compared to the conventional method of pouring gypsum mud into a female mold, a lightweight male mold can be easily and quickly made.

(Embodiment 3)

In the above-described embodiment, the case where the shaped material according to the present invention is used as a molding material has been described. However, usage modes other than the molding will be described.

The shaping material used in the present embodiment has a configuration including the same base material and thermoplastic material as described in the first embodiment, and may be formed in a sheet shape, for example. When used as such a molding material, for example, a cloth, a nonwoven fabric, or a rubber-based coating material used as a base material may be configured to have various colors, or a ground pattern may be applied. It does not matter. Further, the shape may be various shapes such as a circle, a ring, a triangle, and other polygons in addition to the rectangular shape.

In use, the shaped material having such a configuration is heated with an oven range or the like until the thermoplastic material is fluidized. By adjusting the heating, the fluidization state can be changed in various ways to suit the usage conditions. In this way, the fluidized state may be freely deformed and deformed into a desired shape for shaping.

For example, in art classes at schools and the like, the theme of drawing the face of a "loved person" may be given, but by using this molding material, what was previously drawn on two-dimensional drawing paper While recalling the details of the face such as eyes, nose, mouth, etc., it can be easily constructed in a three-dimensional relief shape, and expressions that cannot be obtained in two dimensions can be performed. In addition, this molding material can be used not only as a material for expression in art, but also as a simple molding material that is effective for explaining the items of reinforcement.

For example, in the subject of making clothing, the difference between the conical surface of the skirt pattern can be known by making the obese body and the standard body using the molding material of the present invention. The description that requires such a three-dimensional spatial understanding may not be easily understood by the other party using words or two-dimensional illustrations, but can be accurately and easily performed using the modeling material of the present invention.

By using the molding material of the present invention, it is also possible to simulate the creation of ancient objects, unlike the case where people understand the ideas and ideas of things at the time by explaining in words. You can know.

With the shaped material of the present invention, various uneven shapes can be formed on the surface, for example, by pinching the surface of the shaped material in a state where it is placed in a plane, or providing a groove through the surface. Therefore, various patterns including the topography such as mountains and valleys can be formed on the surface and used effectively as molding materials for relief.

In addition, parts for various types of model work are formed in advance as a set using the molding material of the present invention, and as a molding material for model work such as assembling the same, a molded object on a stage or an event, a store or a signboard. It can be used as a material in various crab fields, such as a decorative material configuration.

In addition, as a record of the growth period of infants and children, bills and footprints are collected and recorded. It can be used as a memorial art material. It can also be applied to collecting footprints of criminal in criminal operations. Unlike collecting footprints using gypsum, it is easier to cast, less bulky, less susceptible to breakage, and has better storage properties than conventional gypsum.

The present invention is not limited to the description of the above embodiment, and can be variously modified without departing from the gist of the present invention.

For example, in the above-described embodiment, the description has been made using a mold-forming material in which a thermoplastic resin is sandwiched between base materials. It doesn't matter. As shown in Fig. 10 (A), even in a configuration in which the base material 11 is provided only on one surface of the thermoplastic resin 12a, the viscosity of the thermoplastic resin 12a in the flowing state is adjusted to obtain a mayonnaise-like material. If it is configured in a flowing state so that the liquid does not drip, manual work can be performed without adhering to the hand.

Further, as shown in FIG. 10 (B), the base materials 11 and 13 sandwiching the thermoplastic resin 12 a are configured to be wider than the thermoplastic resin 12 a surface, and As shown in (2), a configuration in which the edge portions are not aligned and stopped one by one may be used. In the fluidized state, the viscosity of the thermoplastic resin 12a used in the present invention is adjusted so as not to flow down. Widely substrate

If the range setting of 1 1 and 13 is performed, the thermoplastic 1 "green resin 1 2a will not come into direct contact with the molding target.

According to the present invention, in a state where the thermoplastic resin laminated on the base material is fluidized, it is possible to perform the molding by pressing the molding material along the irregularities of the molding object, so that the gypsum or the gypsum bandage is used. Compared with the conventional molding method using, the molding target at the time of molding is not polluted with gypsum mud. Therefore, even when preparing a prosthesis including a prosthetic hand or a prosthesis, the affected part including the stump of the patient can be collected without soiling. According to the present invention, since the mold formed by molding is composed of a base material on which a thermoplastic resin is laminated, the mold has elasticity due to the thermoplastic resin, and is molded by a conventional gypsum or a gypsum bandage. Unlike gypsum molds that have been formed, It is hard to produce.

According to the present invention, since the thermoplastic resin laminated on the base material is heated and fluidized to mold the molding material along the irregularities of the molding object, the gypsum mold formed by curing once is formed. In contrast, even during or after casting, the required parts can be re-fluidized, making it easy to modify or reuse the mold.

According to the present invention, since the molding is performed along the irregularities of the molding target in a state in which the thermoplastic resin laminated on the base material is fluidized, compared to the conventional molding using gypsum or a plaster bandage. Therefore, since it is not necessary to quickly mold the gypsum before it is not dried, molding can be performed without requiring special skill.

According to the present invention, since the thermoplastic resin is laminated on the substrate, the fluidized thermoplastic resin does not directly adhere to the surface to be molded at the time of molding, so that the substrate is provided. As compared with the case where the thermoplastic resin is directly pressed against the molding target without performing the molding, heat damage to the molding target can be avoided.

According to the present invention, at the time of casting a male mold, a method of pressing a casting material into a female mold by inflating an inflating member is adopted, which is different from a conventional configuration in which gypsum is poured into a female mold. Male molds can be created easily in a short time.

Since the shaped material of the present invention can easily change its shape simply by fluidizing the thermoplastic resin laminated on the base material, unlike the conventional viscosity, gypsum, etc., it does not stain the hands, and can be easily formed. Three-dimensional free modeling can be performed. Therefore, it can be effectively used as an expression material that allows children to safely, easily, and three-dimensionally express.

Claims

The scope of the claims

1. It has a stretchable base material and a thermoplastic material such as a thermoplastic resin laminated on the base material,

A molding material characterized in that the thermoplastic material can be shaped by deforming it into a desired shape in a fluidized state.

2. The molding material according to claim 1,

The molding material is formed as a molding material used for molding the shape by pressing the molding material in a state where the thermoplastic material is fluidized.

3. The shaped material according to claim 1 or 2,

The shaping material, wherein the base material is a cloth.

4. The shaped material according to any one of claims 1 to 3,

The shaping material is formed in any one of a sheet shape, a bag shape, and a tubular shape.

5. A method of molding a shape by pressing a molding material against a molding object,

The molding material is formed by laminating a thermoplastic material such as a thermoplastic resin on a stretchable base material,

A molding method comprising: a female mold molding step of fluidizing the thermoplastic material, pressing the base material side of the molding material against the molding target, molding, curing, and molding.

6. The method of claim 5, wherein:

The casting target is a mounting part on the human body side when a prosthetic device is mounted on the human body for the purpose of reducing or eliminating a functional disorder. A female mold molding step of fluidizing the thermoplastic material of the molding material, applying the base material side of the molding material to the mounting portion, molding and curing to form a female mold,

On the inner surface of the female mold, a thermoplastic material of another molding material having the same configuration as the molding material is fluidized, the base material side is pressed and molded, and the male mold is formed by hardening to form a male mold. A molding method comprising a molding step.

7. The method of claim 6, wherein:

Pressing the molding material against the inner surface of the female mold is performed by injecting a fluid into an inflating member such as a balloon contained in a bag-shaped molding material contained in the female mold and inflating the same, and expanding the base material of the molding material. A molding method wherein the side is pressed against the inner surface of the female mold.

8. A molding method for molding a male mold by pressing a molding material against a female mold,

The male mold is formed by injecting a fluid into an inflatable member such as a balloon contained in a bag-shaped molding material contained in a female mold and inflating the same, and pressing a base material side of the molding material against an inner surface of the female mold. A method for making a mold, wherein the method is performed by taking the inside of the female mold.