Abstract:
An apparatus is provided for mounting to a support for modifying an ankle-foot orthosis. The apparatus comprises a tooling device having a plurality of holes spaced over an outer surface of the tooling device. The tooling device includes a first portion having a longitudinal axis, and a second portion integral with the first portion and having a longitudinal axis substantially perpendicular to the longitudinal axis of the first portion. The second portion of the tooling device defines an opening for receiving the support. A peg is configured to be inserted into one of more holes of the tooling device. The peg comprises a body portion and a post depending from the body portion and configured to be received in the holes in the outer surface of the tooling device. In one embodiment, the body portion of the peg has a convex outer surface.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    The present application claims priority to U.S. Provisional Application No. 61/504,906 filed on Jul. 6, 2011, the contents of the application is hereby incorporated by reference herein for all purposes. 
     
    
     BACKGROUND 
       [0002]    An orthosis modification tool is described, and more particularly an orthosis modification tool used to create a depression or relief in an orthosis, or to reshape the inside surface of the orthosis. 
         [0003]    An orthopedic brace is often referred to as an orthosis. An ankle-foot orthosis is worn on the lower leg and foot to support and align the ankle and foot. The object of the ankle-foot orthosis is to achieve a more natural and dynamic gait. 
         [0004]    An ankle-foot orthosis comprises a shell of thin flexible, relatively rigid material. The shell at least partially extends around the periphery of the lower leg and includes a foot plate engaging the sole of the foot of the patient, thereby providing support for stabilizing and controlling motion of the ankle and foot. Fastening elements, such as straps, are provided and configured to wrap around the leg of a patient to secure the shell and foot plate to the leg and foot, respectively. The straps typically include hook-and-loop type fasteners mounted on overlapping portions of the fastening elements and the shell for an adjustable fit. 
         [0005]    An ankle-foot orthosis is commonly formed from plastic materials, particularly thermoplastics such as polyethylene, polyurethane, polypropylene and the like. The flexibility of the material allows the orthosis to accommodate some fluctuation or change in the volume of the leg or foot by tightening or loosening the straps. The plastic orthosis may also be modified by trimming, sanding, grinding, buffing and shaping using a number of different types of tools. Some orthoses can even be cut by an ordinary pair of scissors for adjusting the height of the orthosis and the width of the foot-plate to, for example, accommodate the foot plate inside a shoe. The plastic material can also be heated and molded for further modification and a custom fit. 
         [0006]    In use, the ankle-foot orthosis is in close contact with the lower leg, including sensitive areas such as the Achilles tendon, the heel and malleoli. Moreover, the width of the ankle and the size of the heel bone vary over a wide range as seen for a normal healthy population. Skin or tissue irritation is created by rubbing of the orthosis during movement or simply the static pressure on the tissue. Redness, swelling or blistering may develop in the irritated area. 
         [0007]    Irritation from rubbing or pressure can be addressed by applying a soft padding on the inside of the orthosis. The orthosis can also be modified. Modification is typically accomplished by heating the orthosis for softening the plastic in the problem area. A tool is then used to create a depression in the hot plastic of the orthosis for creating space between inside surface of the orthosis and the location of the irritation of the patient. The ball end of a ball peen hammer is often used, as well as the end of a rivet bar, or any other tool that will create a depression. Unfortunately, this method is only crudely effective. 
         [0008]    For the foregoing reasons, there is a need for an orthosis modification tool. 
       SUMMARY 
       [0009]    An apparatus is provided for mounting to a support for modifying an ankle-foot orthosis. The apparatus comprises a tooling device having a plurality of holes spaced over an outer surface of the tooling device. The tooling device includes a first portion having a longitudinal axis, and a second portion integral with the first portion and having a longitudinal axis substantially perpendicular to the longitudinal axis of the first portion. The second portion of the tooling device defines an opening for receiving the support. A peg is configured to be inserted into one of more holes of the tooling device. The peg comprises a body portion and a post depending from the body portion and configured to be received in the holes in the outer surface of the tooling device. In one embodiment, the body portion of the peg has a convex outer surface. 
         [0010]    A system is provided for modifying an ankle-foot orthosis. The orthosis modification system comprises a support and a tooling device having a plurality of holes spaced over an outer surface of the tooling device. The tooling device includes a first portion having a longitudinal axis, and a second portion integral with the first portion and having a longitudinal axis substantially perpendicular to the longitudinal axis of the first portion. The second portion of the tooling device defines an opening for receiving the support. A peg is configured to be inserted into one of more holes of the tooling device. In one embodiment, the opening in the second portion of the tooling device is configured to non-rotatably receive the support. In another embodiment, the opening in the second portion of the tooling device is configured to non-rotatably receive the support in a plurality of positions of the tooling device relative to the support. 
         [0011]    A method of modifying an ankle-foot orthosis is also provided. The orthosis modification method comprises the steps of providing a tooling device having a plurality of holes spaced over an outer surface of the tooling device. The tooling device includes a first portion having a longitudinal axis, and a second portion integral with the first portion and having a longitudinal axis substantially perpendicular to the longitudinal axis of the first portion. The second portion of the tooling device defines an opening for receiving a support. Further steps of the method include sliding the tooling device onto the support, inserting a peg into a selected one or more of the holes in the outer surface of the tooling device, heating an area on a surface of the orthosis, and positioning the orthosis over the tooling device such that the heated area of the orthosis engages the peg for creating a depression or otherwise reshaping the inside surface of the heated area of the orthosis. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    For a more complete understanding of the present invention, reference should now be had to the embodiments shown in the accompanying drawings and described below. In the drawings: 
           [0013]      FIG. 1  is a perspective view of a tool for modifying an ankle-foot orthosis. 
           [0014]      FIG. 2  is an exploded perspective view of the modification tool shown in  FIG. 1  and a modification peg. 
           [0015]      FIG. 3  is an exploded perspective view of an ankle-foot orthosis and the modification tool shown in  FIG. 1  and in position for insertion of an end of a rivet bar. 
           [0016]      FIG. 4  is a transverse cross-section view of the modification tool in position on the rivet bar as shown in  FIG. 2  with the modification tool in a first position relative to the rivet bar. 
           [0017]      FIG. 5  is a transverse cross-section view of the modification tool in position on the rivet bar as shown in  FIG. 4  with the modification tool in a second position relative to the rivet bar. 
           [0018]      FIG. 6  is a transverse cross-section view of the modification tool in position on the rivet bar as shown in  FIG. 4  with the modification tool in a third position relative to the rivet bar. 
           [0019]      FIG. 7  is a transverse cross-section view of the modification tool in position on the rivet bar as shown in  FIG. 4  with the modification tool in a fourth position relative to the rivet bar. 
           [0020]      FIG. 8  is a perspective view of another embodiment of a tool for modifying an ankle-foot orthosis. 
           [0021]      FIG. 9  is a transverse cross-section view of the modification tool in position on the rivet bar as shown in  FIG. 8  with the modification tool in a first position relative to the rivet bar. 
           [0022]      FIG. 10  is a transverse cross-section view of the modification tool in position on the rivet bar as shown in  FIG. 9  with the modification tool in a second position relative to the rivet bar. 
           [0023]      FIG. 11  is a transverse cross-section view of the modification tool in position on the rivet bar as shown in  FIG. 9  with the modification tool in a third position relative to the rivet bar. 
           [0024]      FIG. 12  is a perspective view of the modification tool in position on the rivet bar as shown in  FIG. 3  with the rivet bar in a bench vice and a second position of the modification tool shown in phantom. 
           [0025]      FIG. 13  is an elevational end view of a tool having an opening for receiving an anvil end of a rivet bar as shown in  FIG. 3 . 
       
    
    
     DESCRIPTION 
       [0026]    Certain terminology is used herein for convenience only and is not to be taken as a limitation on the invention. For example, words such as “upper,” “lower,” “left,” “right,” “horizontal,” “vertical,” “upward,” and “downward” merely describe the configuration shown in the FIGs. Indeed, the components may be oriented in any direction and the terminology, therefore, should be understood as encompassing such variations unless specified otherwise. 
         [0027]    Referring now to the drawings, wherein like reference numerals designate corresponding or similar elements throughout the several views, an embodiment of a tool for modification of an orthosis is shown in  FIG. 1  and generally designated at  20 . The tool  20  is a rigid member formed in the shape of a lower leg  22  and foot  24  of suitable size, including a heel portion  26  and a toe portion  28  of the foot  24 . The tool  20  is preferably comprised of a strong and stable metal alloy, such as stainless steel. Other suitable materials are those that are stable, strong and capable of withstanding significant multi-directional pressures and impact without fracture or distortion, including but not limited to urethanes, epoxies, plastics, composites, metal, metal alloys and the like. Nevertheless, the tool  20  can be constructed using a wide variety of materials. It is understood that the scope of the invention is not intended to be limited by the materials listed herein, but may be carried out using any materials that allow the construction and use of the described tool  20 . 
         [0028]    The tool  20  has an outer surface  30  and an inner region  32 . The outer surface  30  of the tool  20  has a plurality of holes  34  spaced along the outer surface  30  for receiving a peg  36 . In the embodiment shown, the peg  36  comprises a truncated hemispherical, or otherwise shaped, surface  38  that will allow the support or distribution of force needed to accomplish the desired modification. The peg  36  includes a post  40  extending from the flat surface of the peg  36 . The holes  34  in the outer surface of the tool  20  are configured to receive the post  40  for securing the peg  36  on the tool  20 . 
         [0029]    The inner region  32  of the tool  20  defines a longitudinal generally rectilinear bore  42  therein. The bore  42  has a pair of spaced notches extending radially outwardly from the corners  44 ,  46  of one side edge  48  and another pair of spaced notches extending radially outwardly from the corners  50 ,  52  of a front edge  54  of the bore  42 . Each of the notches  44 ,  46 ,  50 ,  52  along with at least a portion of the bore defines an opening for removably engaging a support, the combination thus forming a plurality of identically shaped support-engaging openings through the inner region of the tool  20 , as will be described below. Each of the support-engaging openings extend nearly the full width of the tool  20  and are generally arcuate in shape with a slight outwardly radiused curvature. Each of the support-engaging openings for receiving the support includes one of the notches  44 ,  46 ,  50 ,  52 , which generally corresponds to the shape and size of the edge of the support for preventing rotation of the tool  20  relative to the support. It is understood that although the FIGs. show four support engaging openings, a greater or lesser number of support-engaging openings could be used in other embodiments of the tool  20 . 
         [0030]    Referring now to  FIG. 3 , the tool  20  is shown with an anvil end  56  of a rivet bar  58  and an ankle-foot orthosis  60 . Each of the plurality of support-engaging openings of the bore  42  in the leg portion  22  of the tool  20  is shaped to receive the anvil end  56  of the rivet bar  58 . As shown in  FIGS. 4-7 , the notches  44 ,  46 ,  50 ,  52  of each of the four openings in the bore  42  facilitate sliding the tool  20  onto the bar  58  in four different positions: toe portion facing downwardly ( FIG. 4 ), toe portion facing to the right ( FIG. 5 ), toe portion facing to the left ( FIG. 6 ), and toe portion facing upwardly ( FIG. 7 ). The tool  20  is installed onto the bar  58  in a selected position by placing the leg portion  22  of the tool  20  adjacent the bar such that one of the support-engaging openings of the bore  42  is aligned with the anvil end  56  of the bar. The tool  20  is then pushed onto the bar  58  such that the anvil end  56  enters the support-engaging opening for securely holding the tool  20  on the bar. 
         [0031]    Another embodiment of a tool for modification of an orthosis is shown in  FIG. 8  and generally designated at  70 . Three support-engaging openings are provided in this embodiment of the tool  70 . Specifically, the bore  42  has a single notch  72  extending radially outwardly from a corner of one side edge  74  and a pair of spaced notches extending radially outwardly from the corners  76 ,  78  of a front edge  80  of the bore  42 . Each of the notches  72 ,  76 ,  78  along with at least a portion of the bore  42  defines an opening for removably receiving the anvil end  56  of the rivet bar  58 . As shown in  FIGS. 9-11 , the notches  72 ,  76 ,  78  of each of the three openings in the bore  42  facilitate sliding the tool  20  onto the rivet bar  58  in three different positions: toe portion facing to the left ( FIG. 9 ), toe portion facing downwardly ( FIG. 10 ), and toe portion facing to the right ( FIG. 11 ). 
         [0032]    The tool  20  may be secured relative to the rivet bar  58  in any of the above-described positions of the tool  20 . For example, the lower leg  22  of the tool  20  may define a threaded opening for receiving a set screw (not shown) that is selectively tightened against the rivet bar  58  when the tool  20  is a selected position on the rivet bar. 
         [0033]    In use, the rivet bar  58  is secured in a machinist vice  62  so that the rounded surface of the anvil end  56  faces upward. The tool  20 ,  70  is slipped onto the anvil end  56  as described above. Two possible positions of the tool  20  relative to the rivet bar  58  are shown in  FIG. 12 , a position where the toe portion is directed downwardly and a position where the toe portion is directed to one side as shown in phantom. The peg  36 , or pegs, is then inserted into one or more of the holes  34  in the outer surface  30  of the tool  20 ,  70  in the area, or areas, in need of reshaping in order to increase comfort or decrease undue pressure areas for the wearer. Once the peg  36  is in a preferred position, a surface of the orthosis  60  in the area of the irritation is heated for softening the plastic. The orthosis  60  is then placed over the tool  20 ,  70  in the same manner as a wearer would secure the orthosis  60  to the leg and foot. The hemispherical portion  38  of each peg  36  in the tool  20 ,  70  will thus engage the hot plastic of the orthosis  60  for pushing the inside surface outwardly or inwardly for creating a depression or reshaping. When cool and rigid, the orthosis will retain the depression or desired new shape, creating a better fit or space between the inside surface of the orthosis  60  and the location of the irritation of the wearer. Because the tool  20 ,  70  has a plurality of holes  34  spaced over the outer surface  30 , any selected portions of the orthosis  60  may be modified as desired, depending on the areas of irritation affecting a wearer. 
         [0034]    It is understood that, although the orthosis modification tool is described in detail herein with reference to exemplary embodiments of the tool  20 ,  70 , the features of the tool  20 ,  70  may be applied to, and find utility in, other support-engaging tools. This aspect of the tool  20 ,  70  is shown in  FIG. 13  as a sleeve  90  having an opening  92  configured to receive the anvil end  56  of the rivet bar  58 . When used as described above, the supporting-engaging sleeve  90  may be combined with a tool in a wide variety of applications involving working or modifying a workpiece. Specifically, the sleeve  90  may be mounted to the tool, such as by insertion in an opening of the tool or otherwise securely fixing the sleeve  90  to the tool. The tool may then affixed to the rivet bar  58  or other corresponding structure by sliding the sleeve  90  and associated tool onto the rivet bar  58  as described hereinabove. Further, although the support-engaging feature is described in detail herein as embodied in an orthosis modification tool supported on a rivet bar, it is not intended to be so limited. The support-engaging feature may be used in other applications. Thus, the support-engaging structure has general applicability to any device wherein improvements in support and handling are desired. 
         [0035]    Although the present invention has been shown and described in considerable detail with respect to only a few exemplary embodiments thereof, it should be understood by those skilled in the art that I do not intend to limit the invention to the embodiments since various modifications, omissions and additions may be made to the disclosed embodiments without materially departing from the novel teachings and advantages of the invention, particularly in light of the foregoing teachings. For example, although the modification tool is shown only with an ankle-foot orthosis, it is understood that the tool could be used with a knee-ankle-foot orthosis, a hip-knee-ankle-foot orthosis, ankle supports, foot orthotics or any other of a range of orthoses, supports, guards, and the like. Moreover, although the openings of the tool are illustrated as generally arcuate in shape, it is understood that the openings may be any shape necessary to accommodate a particular support member. Accordingly, I intend to cover all such modifications, omissions, additions and equivalents as may be included within the spirit and scope of the invention.