Method and apparatus for decreasing build height of prosthetic products

An adapter assembly allows mechanical coupling of prosthetic components such that a distal end of a socket adapter (160) extends below a top surface of a prosthetic (100). The adapter assembly may include sets of external threads (314, 324) to operatively engage internally threaded surfaces (170, 110) of the prosthetic and the socket adapter.

BACKGROUND

Embodiments of the invention relate to prosthetic products, and more particularly to systems and methods for decreasing build height of prosthetic products.

2. Description of the Related Art

Millions of individuals worldwide rely on prosthetic and/or orthotic devices to compensate for disabilities, such as amputation or debilitation, and to assist in the rehabilitation of injured limbs. Orthotic devices include external apparatuses used to support, align, prevent, protect, correct deformities of, or improve the function of movable parts of the body. Prosthetic devices include apparatuses used as artificial substitutes for a missing body part, such as an arm or leg.

SUMMARY

Embodiments of the present invention include, but are not limited to, adapters for connecting parts, systems incorporating the adapters, and/or methods for assembling the systems. The adapters may be used to attach prosthetic products, but can have other uses as well, such as with orthotic products.

In certain embodiments, a system for mechanically coupling prosthetic components comprises a prosthetic, a socket adapter, and an adapter assembly. The prosthetic includes a top surface. The socket adapter includes a distal end. The adapter assembly is in fixed mechanical communication with the prosthetic and the socket adapter. The distal end of the socket adapter extends below the top surface of the prosthetic. A method of mechanically coupling the prosthetic components includes engaging the prosthetic and the socket adapter such that the distal end of the socket adapter is fixed below the top surface of the prosthetic.

In certain embodiments, a system for mechanically coupling prosthetic components comprises a prosthetic, a socket adapter, and an adapter assembly. The prosthetic includes a top surface and an internally threaded surface recessed within the top surface. The socket adapter includes an internally threaded surface at a distal end. The adapter assembly has a top end and a bottom end. The adapter assembly comprises a first externally threaded surface configured to operatively engage the internally threaded surface of the prosthetic and a second externally threaded surface configured to operatively engage the internally threaded surface at the distal end of the socket adapter. The second externally threaded surface extends below the top surface of the prosthetic when the adapter assembly is coupled to the prosthetic. A method of mechanically coupling the prosthetic components includes engaging the first externally threaded surface to the internally threaded surface of the prosthetic and engaging the second externally threaded surface to the internally threaded surface of the socket adapter.

In certain embodiments, a system for mechanically coupling prosthetic components comprises a prosthetic, a socket adapter, and an adapter assembly. The prosthetic includes a top surface and an internally threaded surface recessed within the top surface. The socket adapter includes an internally threaded surface at a distal end. The adapter assembly has a top end and a bottom end. The adapter assembly comprises a first externally threaded surface configured to operatively engage the internally threaded surface of the prosthetic and a second externally threaded surface configured to operatively engage the internally threaded surface at the distal end of the socket adapter. The distal end of the socket adapter extends below the top surface of the prosthetic when the system is assembled. A method of mechanically coupling the prosthetic components includes engaging the first externally threaded surface to the internally threaded surface of the prosthetic and engaging the second externally threaded surface to the internally threaded surface of the socket adapter.

In certain embodiments, a system for mechanically coupling prosthetic components comprises a prosthetic, a socket adapter, and an adapter assembly. The prosthetic includes a top surface and an internally threaded surface recessed within the top surface. The socket adapter includes an internally threaded surface at a distal end. The adapter assembly comprises a female element and a male element. The female element includes exterior threads to operatively engage the internally threaded surface at the distal end of the socket adapter. The male element includes exterior threads to operatively engage the internally threaded surface of the prosthetic. The male element further includes a lip adapted to compress the female element against the top surface of the prosthetic. A method of mechanically coupling the prosthetic components includes extending the male element through the female element and into the recessed surface of the prosthetic, engaging the exterior threads of the male element to the internally threaded surface of the prosthetic, and engaging the exterior threads of the female element to the internally threaded surface of the socket adapter.

In certain embodiments, a system for mechanically coupling prosthetic components comprises a prosthetic, a socket adapter, and an adapter assembly. The prosthetic includes a top surface and an internally threaded surface recessed within the top surface. The socket adapter includes an internally threaded surface at a distal end. The internally threaded surface of the socket adapter defines a socket adapter cavity. The adapter assembly comprises a female element and a male element. The female element includes exterior threads to operatively engage the internally threaded surface at the distal end of the socket adapter. The male element includes exterior threads to operatively engage the internally threaded surface of the prosthetic. The male element is substantially inside the socket adapter cavity when the adapter assembly is coupled to the prosthetic. A method of mechanically coupling the prosthetic components includes extending the male element through the female element and into the recessed surface of the prosthetic, engaging the exterior threads of the male element to the internally threaded surface of the prosthetic, and engaging the exterior threads of the female element to the internally threaded surface of the socket adapter.

In certain embodiments, a system for mechanically coupling prosthetic components comprises a prosthetic, a socket adapter, and an adapter assembly. The prosthetic includes a top surface and an internally threaded surface recessed within the top surface. The socket adapter includes an internally threaded surface at a distal end and a plurality of generally longitudinally extending prongs. The adapter assembly comprises a female element and a male element. The female element includes exterior threads to operatively engage the internally threaded surface at the distal end of the socket adapter. The male element includes exterior threads to operatively engage the internally threaded surface of the prosthetic. The plurality of prongs extend below a top of the male element. A method of mechanically coupling the prosthetic components includes extending the male element through the female element and into the recessed surface of the prosthetic, engaging the exterior threads of the male element to the internally threaded surface of the prosthetic, and engaging the exterior threads of the female element to the internally threaded surface of the socket adapter.

In certain embodiments, a system for mechanically coupling prosthetic components comprises a prosthetic, a socket adapter, and an adapter assembly. The prosthetic includes a top surface and an internally threaded surface recessed within the top surface. The socket adapter includes an internally threaded surface at a distal end. The internally threaded surface of the socket adapter has a larger diameter than the internally threaded surface of the prosthetic. The adapter assembly comprises a female element and a male element. The female element is generally hollow and generally cylindrical. The female element includes an outer surface having exterior threads to operatively engage the internally threaded surface at the distal end of the socket adapter, an upper portion including a lip projecting inwardly from an interior surface, and a lower portion including a concave surface to conformally engage the rounded top surface of the prosthetic. The male element is generally cylindrical. The male element includes an outer surface having exterior threads to operatively engage the internally threaded surface of the prosthetic, a substantially flat upper portion including a lip projecting outwardly from the outer surface and adapted to engage the lip of the female element and to compress the lower portion of the female element against the rounded top surface of the prosthetic. The exterior threads of the male element fit through the lip of the female element. A method of mechanically coupling the prosthetic components includes extending the male element through the female element and into the recessed surface of the prosthetic, engaging the exterior threads of the male element to the internally threaded surface of the prosthetic, and engaging the exterior threads of the female element to the internally threaded surface of the socket adapter.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Although certain preferred embodiments and examples are disclosed below, it will be understood by those in the art that the invention extends beyond the specifically disclosed embodiments and/or uses of the invention and obvious modifications and equivalents thereof Thus, it is intended that the scope of the invention herein disclosed should not be limited by the particular disclosed embodiments described below.

Some preferred embodiments of the invention described herein relate generally to prosthetic and orthotic systems and, in particular, to prosthetic and orthotic devices having a low build height. While the description sets forth various embodiment-specific details, it will be appreciated that the description is illustrative only and should not be construed in any way as limiting the invention. Furthermore, various applications of the invention, and modifications thereto, which may occur to those who are skilled in the art, are also encompassed by the general concepts described herein.

The terms “prosthetic” and “prosthesis” as used herein are broad terms and are used in their ordinary sense and refer to, without limitation, any system, device, or apparatus that may be used as an artificial substitute or support for a body part.

The term “socket” as used herein is a broad term and is used in its ordinary sense and refers to, without limitation, any system, device, or apparatus that may be used to couple a body part to a device or apparatus, and in one embodiment, the part of the prosthesis that fits around the residual limb.

The term “adapter” as used herein is a broad term and is used in its ordinary sense and refers to, without limitation, any system, device, or apparatus that may be used to couple a prosthetic or orthotic directly or indirectly to a socket.

FIGS. 1A and 1Billustrate examples of prosthetics and sockets that may to be mechanically coupled to form a replacement limb.FIG. 1Ais a top perspective view of an example embodiment of a prosthetic100comprising a recessed portion having interior threads110and a top surface120. In certain embodiments, the top surface120of the prosthetic100has a domed top surface120.FIG. 1Billustrates a bottom perspective view of an example embodiment of a socket150configured to be coupled to the prosthetic100. The socket150includes a cylindrical body having a closed end adapted to receive an amputee's limb, such as the stump of an amputated leg. Available sockets include Iceross® and Icex® from Össur hf of Reykjavik, Iceland. Sockets from other manufacturers are also possible.

The socket150may comprise a socket adapter160, for example a “three-prong” or a “four-prong” adapter described below, which may be fused or otherwise attached to the main body of the socket150at its distal end and which includes interior threads170. Coupling of the prosthetic100and the socket150in some embodiments thus requires an adapter in order to couple the interior threads110of the prosthetic100to the interior threads170of the socket150. The prosthetic100forms part of a prosthetic knee (for trans-femoral users); however, the systems, adapters, and methods described herein may also be applied to other prosthetics or other devices, such as prosthetic ankles (trans-tibial users), prosthetic feet, elbows (trans-ulnal users), shoulders, and the like (seeFIG. 10A). It will also be appreciated that other embodiments may include different connection mechanisms other than the interior threads110of the prosthetic100and the interior threads170of the socket adapter160, for example, exterior threads, clamps, snap-fitting, mechanical interlocks, adhesives, press-fit, etc.

FIG. 2Adepicts perspective views of a plurality of adapters that may be used to mechanically couple the prosthetic100and the socket150. As described above, the socket150may include a socket adapter160having interior threads170. InFIG. 2A, two possibilities for the adapter160ofFIG. 1Bare depicted: the adapter162is a “three-prong” adapter and the adapter164is a “four-prong” adapter. The “prongs” comprise elements that extend generally longitudinally from the threaded base of the adapter160. It will be appreciated that any suitable number of prongs may be used, as well as any shape (e.g., hemispherical) that can suitably engage the main body of the socket150.

An adapter system for mechanically coupling the prosthetic100to the socket150inFIG. 2Acomprises an adapter assembly200including two adapters, a male pyramid220and a female pyramid210. The male pyramid220comprises a frusto-pyramidal portion222that is inverted with respect to a main body having at least a portion comprising exterior threads224, which, for example, are configured to engage the interior threads110of the prosthetic100.FIG. 2Billustrates the adapter220mechanically coupled (e.g., screwed into) the prosthetic100.

Although the adapter220inFIG. 2Bis slightly different than the adapter220illustrated inFIG. 2A, it will be appreciated that any suitable adapter with an inverted frusto-pyramidal portion222and exterior threads224may be used, depending on the configuration of the prosthetic100. For example, if the recessed portion of the prosthetic100has a large diameter, the adapter220may have a top surface between the inverted frusto-pyramidal portion222and the exterior threads224(e.g., as depicted by the adapted220inFIG. 2A). For another example, if the recessed portion of the prosthetic100has a small diameter, the adapter220may have no top surface between the inverted frusto-pyramidal portion222and the exterior threads224(e.g., as depicted by the adapted220inFIG. 2B).

The female pyramid210may be coupled to the male pyramid220. The female pyramid210comprises an aperture configured to engage the frusto-pyramidal portion222of the adapter220. Preferably, the portion212of the adapter210is shaped as an inverse inverted frusto-pyramid in order to optimally engage the inverted frusto-pyramidal portion222of the adapter220. A plurality of fasteners216(e.g., screws) may then be applied so as to secure the male pyramid220to the female pyramid210. The adapter210further comprises an exteriorly threaded portion214, for example configured to engage the interiorly threaded portion170of the socket adapter160.

The socket adapter160may be screwed onto the threads214of the adapter210. Once properly oriented, a fastener, for example a screw through a hole166in the adapter162or through hole168in the adapter164, may be applied to secure the adapter160, and thus the socket150, to the adapter210.FIG. 2Cillustrates an assembled version of the adapter system ofFIG. 2A. The prosthetic100is mechanically coupled to the adapter220. The adapter210is mechanically coupled to the adapter220and fastened by screws216. The socket adapter160, which is preferably laminated within a socket150(not shown) is mechanically coupled to the adapter210and tightened with a screw (not shown) through the hole166. Additional stability may be provided by gluing the pieces in place (e.g., using epoxy) during or after assembly. It will be appreciated that the mechanical coupling methods described herein may be performed in a different order (e.g., the reverse order) or by adding, deleting, or substituting steps.

Some doctors are very hesitant to amputate far away from certain joints (e.g., knee, ankle), which results in long stumps on users and little space left for connecting mechanical connection units to prosthetic joints, for example connecting the residual limb of a user to an artificial knee or ankle. This can result in incorrect positioning of the center of the prosthetic joint, for example further away from the true knee center, which can cause incorrect gait and user discomfort, such as when the user is sitting down, because the prosthetic knee is further away from the body than the healthy knee. Certain embodiments of the present invention can advantageously reduce the build height of the prosthetic joint, thereby allowing amputation close to certain joints.

FIG. 3Adepicts perspective views of an embodiment of a system including a plurality of adapters that may be used to mechanically couple the prosthetic100and the socket150with reduced build height. As described above with reference toFIG. 2A, the socket adapter160may comprise a three-prong adapter162, a four-prong adapter164, or any suitable adapter.

The system includes a prosthetic100, a socket adapter160, and an adapter assembly300. The prosthetic100includes a top surface120and an internally threaded surface110recessed within the top surface120. The socket adapter160includes an internally threaded surface170at a distal end. The adapter assembly300has a top end and a bottom end. The adapter assembly300comprises a first externally threaded surface314configured to operatively engage the internally threaded surface110of the prosthetic100and a second externally threaded surface324configured to operatively engage the internally threaded surface170at the distal end of the socket adapter160. Although illustrated as comprising two pieces, the adapter assembly300may also be a single piece or have additional components.

In certain embodiments, an adapter assembly300is configured such that the socket adapter160extends below the top surface120of the prosthetic100. The adapter assembly300may include external threads324. Other configurations are also possible.

In certain embodiments, the adapter assembly300has a height measured between the top and bottom ends is between no more than about 14 and 27.3 mm, preferably between no more than about 14 mm and 22 mm, more preferably between no more than about 14 mm and 18 mm, or even more preferably between no more than about 14 mm and 16 mm. Other heights are also possible. In certain embodiments, a height measured between the top surface120of the prosthetic100and top end of the adapter assembly300is between no more than about 6 and 19.3 mm, preferably between no more than about 6 mm and 16 mm, more preferably between no more than about 6 mm and 12 mm, or even more preferably between no more than about 6 mm and 8 mm. Other heights are also possible.

In certain embodiments, the second externally threaded surface324extends below the top surface120of the prosthetic100when the adapter assembly300is coupled to the prosthetic100(seeFIG. 3C). In certain embodiments, the distal end of the socket adapter160extends below the top surface120when the system is assembled (seeFIGS. 4A and 4B).

The adapter system300for mechanically coupling the prosthetic100to the socket150illustrated inFIG. 3Acomprises two pieces. The first piece, herein referred to as a “male” adapter or element310, comprises a generally cylindrical main body having a surface including external threads314, a lip312that laterally overlaps the external threads314and defines a horizontal lower surface, and a fastening device316such as a hexagonal recess. The threaded exterior314of the adapter310is configured to operatively engage the threaded interior110of the prosthetic100. The second piece, herein referred to as a “female” adapter or element320, is a generally hollow cylindrical body comprising a surface including exterior threads324, and may include an internal lip322defining a horizontal upper surface. The exterior threads324are configured to operatively engage the threaded interior170of the adapter160. The male adapter310and female adapter320are described in more detail below.

To assemble the system depicted inFIG. 3A, the female adapter320is placed on the top120of the prosthetic100. The female adapter320has a lower concave surface326that preferably matingly engages the domed top surface120of the prosthetic100(seeFIG. 4B). The male adapter310is then placed into the female adapter320to secure both pieces to the prosthetic100. Accordingly, the main body of the male adapter310is preferably sized to have approximately the same, and slightly smaller, diameter DM2(seeFIG. 5E) than the interior diameter DF2(seeFIG. 6D) of the female adapter as defined by the internal lip322. The external threads314of the male adapter310engage the internal threads110of the prosthetic100, thereby forcing the male adapter310towards the prosthetic100.FIG. 3Billustrates the partially screwed in male adapter310surrounded by the female adapter320as placed on the prosthetic100.

When the male adapter310reaches a certain depth in the recessed portion of the prosthetic100, the lip312of the male adapter310engages the female adapter320(e.g., the lip322of the female adapter320), thereby applying pressure to the female adapter320and engaging it with the top surface120of the prosthetic100.FIG. 3Cillustrates a fully screwed in male adapter310engaged with the female adapter320and the prosthetic100, wherein the top surface of the male adapter310is preferably flush with the top surface of the female adapter320. As illustrated, the outer diameter DM1(seeFIG. 5D) defined by the lip312of the male adapter310is preferably approximately the same, and slightly smaller, than the diameter DF1(seeFIG. 6D) of the cylindrical inner wall extending from the top surface of the female adapter320. Although not depicted, the socket adapter160, which may or may not be laminated within a socket150, may then be screwed onto the external threads324of the female adapter320, thereby mechanically coupling the socket150to the prosthetic100. The socket adapter160may be secured by inserting a fastener (e.g., screw) through the hole166,168.

The internal threads170of the socket adapter160define a socket adapter cavity. In certain embodiments, the male element310(or at least the portion of the male adapter extending above the prosthetic100) is substantially inside the socket adapter cavity when the adapter assembly is coupled to the prosthetic when the system is assembled. In certain embodiments, a substantial portion of the top of the male element310engages a top of the socket adapter cavity when the system is assembled. In certain embodiments, the prongs of the socket adapter160extend below the top of the male element310when the system is assembled.

FIG. 4Ashows a side-by-side comparison of the assembled adapter systems described above with respect toFIGS. 2A-2Cand3A-3C. Due to the shape and configuration of the adapters210,220compared to the shape and configuration of the adapters310,320, the bottom surface161of the socket adapter162on the left side is higher from the prosthetic100by a distance d than the bottom surface161of the socket adapter162on the right side.FIG. 4Bis a cut-away view of the assemblies ofFIG. 4A. On the left side, the male pyramid220extends above the top surface120of the prosthetic100, where it is engaged by the female pyramid210, which then engages the adapter162. On the right side, the male adapter310is inserted into the prosthetic100, and the female adapter320, which operatively engages the adapter162, extends below the top surface120of the prosthetic100. Likewise, the bottom surface of the socket adapter162extends below the top surface of the prosthetic100. As such, a decreased height of distance d may be achieved. The female adapter320preferably extends below the top surface120of the prosthetic100, but it will be appreciated that other embodiments wherein the female adapter320does not extend below the top surface120of the prosthetic100may also allow the bottom surface161of the adapter162to extend below the top surface120of the prosthetic100. In certain embodiments, the bottom surface161of the adapter162does not extend below the top surface120of the prosthetic100, yet the build height is still less than the build height of the adapter system on the left side. Additional stability may be provided by gluing the pieces in place (e.g., using epoxy) during or after assembly. It will be appreciated that the mechanical coupling methods described herein may be performed in a different order or by adding, deleting, or substituting steps.

FIGS. 5A through 5Fillustrate the male adapter310in more detail. The male adapter310may comprise aluminum, stainless steel, brass, plastic, or any material or combination of materials that can withstand the force applied by a particular user. In some embodiments, the surfaces of the male adapter310are coated so as to inhibit corrosion when a metallic male adapter310is coupled to adapters comprising different metals.

FIG. 5Ais a top perspective top view of the male adapter310. The male adapter310is generally cylindrical in shape, although any shape that can engage the female adapter310and the prosthetic100may be used. The adapter310comprises a surface including an outer surface having external threads314, a substantially flat upper portion including a lip312projecting outwardly from the outer surface, and a fastening device316. The exterior threads314are adapted to operatively engage the internal threads110of the prosthetic100. As depicted, the lip312is a disc-shaped, but the lip312may be any suitable shape (e.g., comprising one or more protrusions projecting outwardly from the outer surface) that can compress female adapter320into the top surface120of the prosthetic100. The fastening device316is configured such that a substantially transverse force applied to the fastening device316causes rotation of the male adapter310. As depicted, the fastening device316is a hexagonal nut, but the fastening device316may be any suitable fastening mechanism that can allow the user to screw the male adapter310into the prosthetic100(e.g., star nut, four-sided nut, fold-down butterfly nut, Phillips head cross-slot, flat head slot, etc.). Preferably, the fastening device316does not extend above the upper surface such that the upper portion is substantially flat.FIG. 5Bis a top schematic perspective view of the male adapter310.

FIG. 5Cis a bottom perspective view of the male adapter310. As illustrated, the fastening device316extends all the way through the adapter310, although the fastening device316may extend only partially through the adapter310. The threads314as illustrated extend substantially close to the lip312, although it will be appreciated that the threads may only extend as far as necessary for secure fastening of the adapter310to the prosthetic100.

FIG. 5Dis a top plan view of the adapter310showing a possible embodiment of a hexagonal nut316in more detail. In certain embodiments, the hexagonal nut316is sized relative to the size of the male adapter310(e.g., the top surface of the male adapter310). For example, the illustrated hexagonal nut316has a width of about 10 mm and the top surface of the male adapter310has a diameter DM1(seeFIG. 5F) of about 28 mm.

FIG. 5Eis a side schematic view of the adapter310, which illustrates further example measurements of particular components of certain embodiments. For example, the threads314may be M22×1.0−4 h type. Other threads types are also possible depending on the specific manufacture of the prosthetic100(e.g., having a wider pitch). For another example, the lip312may extend beyond the external threads314by about 3.5 mm on each side. For yet another example, the adapter310ofFIG. 5Chas an approximately 4 mm “neck” between the external threads314and the lip312. Other dimensions may be suitable for various prosthetics100and female adapters320.

FIG. 5Fis a cross-sectional view of the adapter310taken along line5F-5F ofFIG. 5B. The interior of the male adapter310may comprise a wide variety of shapes. For example, as illustrated inFIG. 5F, the male adapter has a hollowed interior lower portion with rounded walls of radius 4 mm. A wide variety of modifications can be made, for example, to engage or avoid certain components within the recessed portion of the prosthetic100, as long as the male adapter310is able to operatively engage the threads110of the prosthetic100and to engage the female adapter320.

FIGS. 6A through 6Fillustrate the female adapter320in more detail. The female adapter320may comprise aluminum, stainless steel, brass, plastic, or any material or combination of materials that can withstand the force applied by a particular user. In some embodiments, the surfaces of the female adapter320are coated so as to inhibit corrosion when a metallic female adapter320is coupled to adapters comprising different metals.

FIG. 6Ais a top perspective top view of the female adapter320. The female adapter320is generally hollow and generally cylindrical, although any shape that can engage the male adapter320and the socket adapter160may be used. The adapter320comprises an outer surface having exterior threads324, an upper portion including a lip322projecting inwardly from an interior surface, and a lower portion including a rounded surface326(seeFIG. 6B). The exterior threads324are adapted to operatively engage the internal threads170of the socket adapter160. In the embodiment illustrated inFIG. 6A, the adapter320comprises a ring-shaped lip322extending laterally inward from the external threads324. In embodiments including a lip322, the lip322may be any suitable shape (e.g., comprising one or more protrusions extending laterally inward from the threaded portion324) that can engage the lip312of the male adapter310such that the female adapter320is compressed into the top surface120of the prosthetic100when the male adapter310is screwed into the prosthetic100. In embodiments not including a lip322, the lip312of the male adapter310may apply pressure to the top surface of the female adapter320. For example, seeFIG. 9A. The threads324as illustrated extend substantially across the exterior surface of the female adapter320, although it will be appreciated that the threads may only extend as far as necessary for secure fastening of the adapter160to the adapter320.FIG. 6Bis a top schematic perspective view of the female adapter320.

FIG. 6Cis a bottom perspective view of the female adapter320. In the illustrated embodiment, the adapter320has a bottom portion326that is concavely shaped so as to conformally engage a domed top surface120of a prosthetic100. Such shaping may help to prevent scratching of the top surface120of the prosthetic100and to provide increased surface area to engage the prosthetic100. In some embodiments, the bottom portion326of the adapter320is shaped so as to engage the top surface120of the prosthetic100at a plurality of points or to avoid contacting the prosthetic100.

FIG. 6Dis a top schematic view of the female adapter320. The adapter320has an interior diameter DF1that is larger than the outer diameter DM1of the male adapter310illustrated inFIG. 5Dsuch that adapters310,320form a flat surface when joined, as illustrated inFIG. 3C. The adapter320has an interior diameter DF2that is larger than the outer diameter DM2of the male adapter310illustrated inFIG. 5Esuch that adapter310may extend through the adapter320.

FIG. 6Eis a side schematic view of the adapter320, which illustrates example measurements of particular components of certain embodiments. For example, the threads324may be M36×1.5−6 g type. Other threads types are also possible depending on the manufacture of the socket adapter160(e.g., having a wider pitch). Other dimensions may be suitable for various prosthetics100and female adapters320.

FIG. 6Fis a cross-sectional view of the adapter320taken along line6F-6F ofFIG. 6B, which illustrates further example measurements of particular components of certain embodiments. For example, the interior diameter DF1may be about 28.2 mm when the outer diameter DM1is about 28 mm. A wide variety of modifications can be made as long as the female adapter320is able to operatively engage the threads170of the adapter160and operatively engage the male adapter310.

FIG. 7Ais a bottom perspective view of the adapters310and320coupled together. Looking at the joined adapters310,320from the bottom, the bottom rounded surface326of the female adapter320, and the threaded portions314,324are exposed.FIG. 7Billustrates a top perspective view of the adapters310and320coupled together. Looking at the joined adapters310,320from the top, the connector316and the flat top surfaces of the adapters310,320are exposed.

As described above, the threaded portions314,324on the surfaces of the adapters310,320may extend for only a portion of their respective external surfaces.FIG. 8Aillustrates an embodiment in which the threads324of the adapter320extend substantially the entire height of the outer surface of the adapter320. The exterior threads312of the adapter310extend for a length that is similar to the depth of the recess of the prosthetic100. Given the shapes of the particular adapters310,320, in this embodiment, the threads324overlap the threads312by a distance o when the adapters310,320are coupled.FIG. 8Billustrates an embodiment in which the threads324of the adapter320extend only partially across the exterior surface of the adapter320and in which the threads312of the adapter310extend only for a portion of the depth of the recess of the prosthetic100. In such an embodiment, the threads are separated by a distance s when the adapters310,320are coupled.FIG. 8Cillustrates another embodiment in which the threads324of the adapter320extend substantially the entire height of the outer surface of the adapter320and in which the threads312of the adapter310extend only for a portion of the depth of the recess of the prosthetic100. In such an embodiment, the threads are separated by a distance s when the adapters310,320are coupled. A wide variety of threading configurations are possible, as long as the male adapter310can securely engage the prosthetic100and as long as the female adapter320can securely engage the adapter160.

FIGS. 9A through 9Dillustrate alternative embodiments of adapter systems that may be used to couple the prosthetic100to the adapter160.FIG. 9Aillustrates an embodiment in which a female adapter320does not have a recessed portion or a lip322. In the illustrated embodiment, the male adapter310has a lip312that extends over the top surface328of the adapter320(e.g., substantially to the outer surface of the adapter320). Thus, when the male adapter310is screwed into the prosthetic100, the lip312compresses the top surface328of the female adapter320to the top surface120of the prosthetic100. In such an embodiment, the build height of the adapter system may be similar to the adapter system illustrated inFIG. 3Aby decreasing the height of the female adapter320. If the height of the adapter320is not sufficient to engage the adapter160, adjustments can be made, for example, by adding threading similar to the threads324the exterior of the lip312.

The preferred embodiment of a reduced build height adapter system comprises two pieces because independent pieces allows, for example, one piece (e.g., a female adapter320) to balance abnormal stresses applied by the another piece (e.g., a male adapter310), to align to the top surface120of the prosthetic100, to decrease scratching of the top surface120of the prosthetic100, and to maintain strength due to increased surface contact with the top surface120of the prosthetic100. However, embodiments comprising one piece are also possible.FIG. 9Billustrates an embodiment in which the male adapter310and female adapter320are formed as a single adapter330. The adapter330looks substantially like the joined male and female adapters illustrated inFIGS. 7A and 7B. The single adapter330has exterior threads332, exterior threads334, and a surface to engage the top surface120of the prosthetic100.

FIG. 9Cillustrates an embodiment of a one piece adapter340that is shaped so as to not contact the top surface120of the prosthetic100. The adapter340comprises external threads342and external threads344. Such an embodiment may advantageously prevent scratching of the top surface of the prosthetic100, although an appropriate material should be selected such that the strength and structural integrity of the adapter system is maintained. For example, in some embodiments, the external threads342extend the same height as the external threads332ofFIG. 9Bor the external threads324ofFIG. 8Ain order to provide a large surface for engagement of the threads170of the adapter160.

FIG. 9Dillustrates an embodiment in which a female adapter360includes an inverted frusto-pyramid and in which a male adapter350includes a male frusto-pyramid. The male adapter350is screwed into the prosthetic100. The female adapter360is then secured to the male adapter350by applying a plurality of fasteners370(e.g., screws), which also couples the bottom surface of the female adapter360to the top surface120of the prosthetic100. The socket adapter160may then be screwed onto the external threads362of the female adapter360. In such an embodiment, the build height of the adapter system may be similar to the adapter system illustrated inFIG. 3Aby decreasing the height of the female adapter320as compared to the female pyramid210. Unlike the female pyramid210, in which the fasteners216extend through a portion that is spaced from the externally threaded surface214, the fasteners370extend through a portion of adapter360that is externally threaded. Preferably, four fasteners370are engaged for a four-sided frusto-pyramid, which leaves enough surface area for the adapter160to operatively engage the external threads362of the adapter360.

FIG. 10Aillustrates a variety of prosthetics that may be coupled to sockets. The prosthetic1010is a Flex-Foot® Axia™, available from Össur. The prosthetic1020is a Proprio Foot™, also available from Össur. The prosthetic1030is a Rheo Knee™, also available from Össur. Prosthetics from other manufacturers are also possible. In preferred embodiments, the prosthetic100has a domed top surface120, such as illustrated by each of the prosthetics1010,1020,1030. Although the prosthetics1010,1020,1030have an inverted pyramid insert, each prosthetic1010,1020,1030also has a recess comprising interior threads110similar to the prosthetic100(not shown). Thus, it will be appreciated that the methods and apparatuses described herein may also be suitable for a wide variety of prosthetics having a recess including internal threads.

FIG. 10Billustrates a variety of adapters that the adapter systems described herein may be used in conjunction with or instead of. The adapter1041is a male pyramid insert (e.g., similar to the adapter220described above). The adapter1042is a female pyramid insert (e.g., similar to the adapter210described above). The adapter1043is a socket attachment block. The adapter1044is a 4-hole male pyramid. The adapter1045is a 4-hole female pyramid. The adapter1046is a male pyramid tube clamp. The adapter1047is a female pyramid tube clamp. The adapter1048is a 4-hole tube clamp. The adapter1049is a male single adapter, short. The adapter1051is a male single adapter, long. The adapter1052is a female single adapter. The adapter1053is a 4-hole single adapter. The adapter1054is a 32 mm female double adapter. The adapter1055is a 45 mm double female adapter. The adapter1056is a 60 mm female double adapter. Other double female adapter lengths are also possible (e.g., 75 mm). The adapter1057is a male double adapter. The adapter1058is a sach foot adapter. The adapter1059is a slide adapter euro 4-hole with male pyramid. The adapter1061is a slide adapter euro 4-hole. The adapter1062is a male pyramid slide adapter M36×1.5−6 g thread. It will be appreciated that the embodiments described herein may also be used instead of or in addition to other types of adapters for prosthetics.

FIGS. 11A-11Cillustrate an example embodiment of an adapter1100compatible with the adapter systems described herein:FIG. 11Ais a top perspective view;FIG. 11Bis a bottom perspective view; andFIG. 11Cis a top plan view. The adapter1100comprises a tube having a bore therethrough. The tube includes a slot1102, which allows the tube to have a reduced interior volume when laterally compressed, for example by a fastener inserted through the fastener bore1104. As illustrated inFIG. 11B, the adapter1100includes a bottom surface1106adapted to engage the top surface120of a prosthetic100. In the illustrated embodiment, the adapter1100has a bottom surface1106that is concavely shaped so as to conformally engage a domed top surface120of a prosthetic100. Such shaping may help to prevent scratching of the top surface120of the prosthetic100and to provide increased surface area to engage the prosthetic100. In some embodiments, the bottom surface1106of the adapter1100is shaped so as to engage the top surface120of the prosthetic100at a plurality of points or to avoid contacting the prosthetic100. As illustrated inFIG. 11C, the adapter1100includes a shoulder1108adapted to engage the lip312of a male adapter310. In the embodiment illustrated inFIG. 11C, the adapter1100comprises a ring-shaped shoulder1108extending laterally inward from the tube. In some embodiments, the shoulder is shaped to allow a tube connector or “pylon” (e.g., the adapter1051illustrated inFIG. 10B) inserted into the tube to extend below the shoulder1108(e.g., around the shoulder1108and a male adapter310). In embodiments including a shoulder1108, the shoulder1108may be any suitable shape (e.g., comprising one or more protrusions extending laterally inward from the threaded portion324) that can engage the lip312of the male adapter310such that the adapter1100is compressed into the top surface120of the prosthetic100when the male adapter310is screwed into the prosthetic100. Accordingly, the adapter1100may be considered a “female” adapter or element. In certain embodiments, the shoulder1108is disposed proximate to and on an opposite side of the bottom surface1106such that the shoulder1108resides at a low position within the tube, thereby allowing for a low build height. As the position of the shoulder1108within the tube increases, the minimum build height of a system comprising the adapter1100increases.

FIG. 11Dschematically illustrates an example adapter system that may be used to mechanically couple the prosthetic100to a tube connector (e.g., the adapter1051illustrated inFIG. 10B). To assemble the system depicted inFIG. 11D, the adapter1100is placed on the top120of the prosthetic100. The adapter1100has a lower concave surface1106that preferably matingly engages the domed top surface120of the prosthetic100. The male adapter310is then placed into the adapter1100to secure both pieces to the prosthetic100. Accordingly, the main body of the male adapter310is preferably sized to have approximately the same, and slightly smaller, diameter DM2than the interior diameter of the adapter1100. The external threads314of the male adapter310engage the internal threads110of the prosthetic100, thereby forcing the male adapter310towards the prosthetic100. When the male adapter310reaches a certain depth in the recessed portion of the prosthetic100, the lip312of the male adapter310engages the adapter1100(e.g., the shoulder1108of the adapter1100), thereby applying pressure to the adapter1100and engaging it with the top surface120of the prosthetic100. When assembled, the adapter1100extends below the top surface120of the prosthetic100, and a pylon (e.g., the adapter1051) may project further towards the prosthetic100(e.g., until contact with the adapter310) than in systems in which the adapter does not extend below the top surface120of the prosthetic100, thereby providing a lower build height of the adapter assembly.

FIGS. 12A and 12Billustrate another example embodiment of an adapter1200compatible with the adapter systems described herein:FIG. 12Ais a top perspective view andFIG. 12Bis a bottom perspective view. The adapter1200comprises a plate having a bore1204therethrough. The plate includes a plurality of fastener bores1202, which allow the plate to be secured to an adapter (e.g., one of the adapters1045,1048,1059,1061illustrated inFIG. 10B). As illustrated inFIG. 12A, the adapter1200includes a shoulder1208adapted to engage the lip312of a male adapter310. In the embodiment illustrated inFIG. 12A, the adapter1200comprises a ring-shaped shoulder1208extending laterally inward from the tube. In embodiments including a shoulder1208, the shoulder1208may be any suitable shape (e.g., comprising one or more protrusions extending laterally inward from the threaded portion324) that can engage the lip312of the male adapter310such that the adapter1200is compressed into the top surface120of the prosthetic100when the male adapter310is screwed into the prosthetic100. As illustrated inFIG. 12B, the adapter1200includes a bottom surface1206adapted to engage the top surface120of a prosthetic100. In the illustrated embodiment, the adapter1200has a bottom surface1206that is concavely shaped so as to conformally engage a domed top surface120of a prosthetic100. Such shaping may help to prevent scratching of the top surface120of the prosthetic100and to provide increased surface area to engage the prosthetic100. In some embodiments, the bottom surface1206of the adapter1200is shaped so as to engage the top surface120of the prosthetic100at a plurality of points or to avoid contacting the prosthetic100. Accordingly, the adapter1200may be considered a “female” adapter or element.

FIG. 12Cschematically illustrates an example adapter system that may be used to mechanically couple the prosthetic100to an adapter (e.g., one of the adapters1044,1045,1048,1053,1059,1061illustrated inFIG. 10B). To assemble the system depicted inFIG. 12C, the adapter1200is placed on the top120of the prosthetic100. The adapter1200has a lower concave surface1206that preferably matingly engages the domed top surface120of the prosthetic100. The male adapter310is then placed into the adapter1200to secure both pieces to the prosthetic100. The external threads314of the male adapter310engage the internal threads110of the prosthetic100, thereby forcing the male adapter310towards the prosthetic100. When the male adapter310reaches a certain depth in the recessed portion of the prosthetic100, the lip312of the male adapter310engages the adapter1200(e.g., the shoulder1208of the adapter1200), thereby applying pressure to the adapter1200and engaging it with the top surface120of the prosthetic100.

FIGS. 13A and 13Billustrate yet another example embodiment of an adapter1300compatible with the adapter systems described herein:FIG. 13Ais a top perspective view andFIG. 13Bis a bottom perspective view. The adapter1300comprises a plate having a bore1304therethrough. The bore1304is shifted from the center of the plate (e.g., by about 9 mm). The plate includes a plurality of fastener bores1302, which allow the plate to be secured to an adapter (e.g., one of the adapters1044,1045,1048,1053,1059,1061illustrated inFIG. 10B). As illustrated inFIG. 13A, the adapter1300includes a shoulder1308adapted to engage the lip312of a male adapter310. In the embodiment illustrated inFIG. 13A, the adapter1300comprises a ring-shaped shoulder1308extending laterally inward from the tube. In embodiments including a shoulder1308, the shoulder1308may be any suitable shape (e.g., comprising one or more protrusions extending laterally inward from the threaded portion324) that can engage the lip312of the male adapter310such that the adapter1300is compressed into the top surface120of the prosthetic100when the male adapter310is screwed into the prosthetic100. As illustrated inFIG. 13B, the adapter1300includes a bottom surface1306adapted to engage the top surface120of a prosthetic100. In the illustrated embodiment, the adapter1300has a bottom surface1306that is concavely shaped so as to conformally engage a domed top surface120of a prosthetic100. Such shaping may help to prevent scratching of the top surface120of the prosthetic100and to provide increased surface area to engage the prosthetic100. In some embodiments, the bottom surface1306of the adapter1300is shaped so as to engage the top surface120of the prosthetic100at a plurality of points or to avoid contacting the prosthetic100. Accordingly, the adapter1300may be considered a “female” adapter or element.

FIG. 13Cschematically illustrates an example adapter system that may be used to mechanically couple the prosthetic100to an adapter (e.g., one of the adapters1045,1048,1059,1061illustrated inFIG. 10B). To assemble the system depicted inFIG. 13C, the adapter1300is placed on the top120of the prosthetic100. The adapter1300has a lower concave surface1306that preferably matingly engages the domed top surface120of the prosthetic100. The male adapter310is then placed into the adapter1300to secure both pieces to the prosthetic100. The external threads314of the male adapter310engage the internal threads110of the prosthetic100, thereby forcing the male adapter310towards the prosthetic100. When the male adapter310reaches a certain depth in the recessed portion of the prosthetic100, the lip312of the male adapter310engages the adapter1300(e.g., the shoulder1308of the adapter1300), thereby applying pressure to the adapter1300and engaging it with the top surface120of the prosthetic100.

The embodiments described above explain screwing the adapter160onto the adapters320et al. by rotation such that the socket150is fixed in the sagittal plane and the coronal plane but can be rotated in the transverse plane. In alternative embodiments, the adapter160and the adapters320et al. may be modified so as to not limit the rotation in the transverse plane but to enable angular alignment (e.g., a few degrees of angular alignment) in both the sagittal plane and the coronal plane.

Certain embodiments of the present invention can lower the build height by approximately 13.4 mm, thus allowing the possibility to move the center of the prosthetic joint closer to the true anatomical center of the joint than with previous systems. Certain embodiments of the present invention may also minimize the minimum distance from the center of the prosthetic joint to a user's residual limb, thus making it possible for users with long residual limbs and residual limbs which have been amputated too close to the joint to use prosthetic joints (e.g., Rheo Knee™, Proprio Foot™) with domed tops and making it possible to have the prosthetic joint center close to true anatomical joint center.

While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms. For example, the foregoing may be applied to the motion-control of joints other than the knee, such as an ankle or a shoulder. Furthermore, various omissions, substitutions and changes in the form of the methods and systems described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions.