Breast Prosthesis with Air Layer

A prosthetic breast form, comprising:

• (a) a plurality of films, including:
• a first polyurethane film, a second polyurethane film, a third polyurethane film and a fourth polyurethane film;
• (b) an interior weld that seals the second polyurethane film, the third polyurethane film and the fourth polyurethane film so as to define an interior chamber between a portion of the second polyurethane film and a portion of the third polyurethane film and a back chamber between a portion of the third polyurethane film and a portion of the fourth polyurethane film, the interior chamber being filled with air, the back chamber being filled with a resilient material;
• and
• (c) a peripheral weld having a shape of a breast form footprint that seals the first polyurethane film, the second polyurethane film, the third polyurethane film and the fourth polyurethane film, the peripheral weld spaced apart from and outside of the interior weld, so as to define a main chamber between the first polyurethane film and the second polyurethane film, the main chamber being filled with a resilient material.

A method of making a breast prosthesis, comprising the steps of:

• (a) welding a second film to a third film along an interior weld so that the interior weld defines an interior chamber that is accessible by a first sprue;
• (b) placing a first film adjacent to and above the second film, placing a fourth film adjacent to and below the third film;
• (c) welding the first film, the second film, the third film and the fourth film along a peripheral weld that has a shape of a breast form footprint and that is spaced apart from and outside of the interior weld, so as to define a first chamber between the first film and the second film that is accessible by a second sprue, and so as to define a second chamber between the third film and the fourth film that is accessible by a third sprue;
• (d) filling the first chamber with a first material through the second sprue and then sealing the second sprue;
• (e) filling the second chamber with a second material through the third sprue, thereby generating an uncured unit and then sealing the third sprue;
• placing the uncured unit in a mold having the shape of a breast;
• (g) injecting a predetermined amount of a gas into the interior chamber through the first sprue and then sealing the first sprue;
• and
• (h) placing the mold into a curing environment and curing at least one of the first material and the second material.

A method of making a breast prosthesis, comprising the steps of:

• (a) welding a second film, a third film and a fourth film along an interior weld so that the interior weld defines an interior chamber defined between the second film and the third film that is accessible by a first sprue and so that the interior weld also defines a back chamber between the third film and the fourth film that is accessible by a third sprue;
• (b) placing a first film adjacent to and above the second film;
• (c) welding the first film, the second film, the third film and the fourth film along a peripheral weld that has a shape of a breast form footprint and that is spaced apart from and outside of the interior weld, so as to define a main chamber between the first film and the second film that is accessible by a second sprue;
• (d) filling the main chamber with a first material through the second sprue and then sealing the second sprue;
• (e) filling the back chamber with a second material through the third sprue, thereby generating an uncured unit and then sealing the third sprue;
• (f) placing the uncured unit in a mold having the shape of a breast;
• (g) injecting a predetermined amount of a gas into the interior chamber through the first sprue and then sealing the first sprue;
• and
• (h) placing the mold into a curing environment and curing at least one of the first material and the second material.