Method for creating a mold for a knee brace and a knee brace

Details Method for creating a mold for a knee brace and a knee brace Method for creating a mold for a knee brace and a knee brace

2007-12-25

2007-12-25

Kuhns, Allan R. (Department: 1732)

Plastic and nonmetallic article shaping or treating: processes

With step of making mold or mold shaping, per se

C029S458000, C264S101000, C264S222000, C264S313000, C264S320000, C264S500000

Reexamination Certificate

active

10603477

ABSTRACT:
Disclosed is a method for producing a three-dimensional composite structure and a method for producing the mold for the three-dimensional composite structure. The mold is formed of at least one rigid die member and a second thermoplastic die member. The second thermoplastic die member is formed by coupling a rubber flexible pattern to a surface of the first die member. Vacuum or pressure is applied to a heated thermoplastic sheet to cause the heated thermoplastic sheet to deform about the flexible pattern, thereby forming the second die. Strips of reinforced polymer thermoset pre-preg material are then positioned within the cavities formed by the flexible pattern and are allowed to cure. Optionally, heat, pressure, and vacuum may be applied to the mold construction to facilitate the curing of the thermoset materials.

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