Source: http://www.google.com/patents/US7611543?dq=6272333
Timestamp: 2016-05-03 13:58:17
Document Index: 751668637

Matched Legal Cases: ['art 2', 'art 1', 'Application No. 2', 'Application No. 02', 'Application No. 02', 'Application No. 2006138484']

Patent US7611543 - Prosthetic foot with tunable performance - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inPatentsA prosthetic foot (124) incorporates a foot keel (165) and a calf shank (126) connected to the foot keel to form an ankle joint area of the prosthetic foot. The foot keel has forefoot and hindfoot portions and an upwardly arched midfoot portion extending between the forefoot and midfoot portions. The...http://www.google.com/patents/US7611543?utm_source=gb-gplus-sharePatent US7611543 - Prosthetic foot with tunable performanceAdvanced Patent SearchPublication numberUS7611543 B2Publication typeGrantApplication numberUS 10/814,260Publication dateNov 3, 2009Priority dateMar 30, 2001Fee statusLapsedAlso published asCA2560885A1, CN1937973A, CN1946357A, CN1972650A, EP1729696A2, EP1729696A4, US7735501, US20040186590, US20050016572, WO2005097008A2, WO2005097008A3, WO2005097008B1Publication number10814260, 814260, US 7611543 B2, US 7611543B2, US-B2-7611543, US7611543 B2, US7611543B2InventorsBarry W. Townsend, Byron K. ClaudinoOriginal AssigneeBioquest Prosthetics, LlcExport CitationBiBTeX, EndNote, RefManPatent Citations (99), Non-Patent Citations (48), Referenced by (8), Classifications (53), Legal Events (4) External Links: USPTO, USPTO Assignment, EspacenetProsthetic foot with tunable performance
US 7611543 B2Abstract
A prosthetic foot (124) incorporates a foot keel (165) and a calf shank (126) connected to the foot keel to form an ankle joint area of the prosthetic foot. The foot keel has forefoot and hindfoot portions and an upwardly arched midfoot portion extending between the forefoot and midfoot portions. The calf shank includes an anterior facing convexly curved lower portion which is adjustably attached at a portion thereof to the foot keel by way of a releasable fastener arrangement. The upper end of the calf shank is movable longitudinally of the foot keel in response to force loading and unloading the calf shank during use of the prosthetic foot. A device (125) connected between the upper end of the calf shank and the lower portion of the prosthesis can be used to assist posterior movement of the upper end of the calf shank and control anterior movement of the upper end of the calf shank during use of the prosthesis. The device (125) has springs which store energy during force loading with anterior motion of the upper end of the calf shank in gait and which, during force unloading, return the stored energy as kinetic power for adding to the propulsive force on the user's body generated by the prosthesis in gait.
1. A method of generating kinetic power for propulsive force in a lower extremity prosthesis including a longitudinally extending foot keel, an ankle and an elongated, upstanding shank above the ankle for connection with a lower extremity prosthetic socket on a person's leg stump, the method comprising:
providing an upstanding monolithically formed resilient member which forms the ankle and the shank in the prosthesis with a lower end of the resilient member terminating posteriorly and connected to the foot keel, the lower end of the resilient member anteriorly extending upwardly by way of an anterior facing convexly curved surface to form the ankle, the resilient member extending upwardly in a substantially curvilinear manner substantially above human ankle joint height and the ankle to form the shank and defining a lower prosthetic part of a leg, wherein the resilient member is curved longitudinally over at least substantially the entire height of the member above the foot, and wherein the shank has an upper end which during use of the lower extremity prosthesis is moved longitudinally with respect to the foot keel during force loading and unloading of the lower extremity prosthesis; and
changing the ankle torque ratio of the lower extremity prosthesis in gait by using a posterior calf device on the lower extremity prosthesis to effect a change in the sagittal plane flexure characteristic for longitudinal movement of the upper end of the resilient member in response to force loading and unloading during a person's use of the lower extremity prosthesis, the ankle torque ratio being defined as the quotient of the peak dorsiflexion ankle torque in the late terminal stance phase of gait divided by the plantar flexion ankle torque created in the lower extremity prosthesis in the initial foot flat loading response after heel strike in gait, wherein said posterior calf device assists posterior movement of the upper end of the resilient member and controls anterior movement of the upper end of the resilient member during use of the prosthesis, and wherein the posterior calf device is located posterior of the resilient member and includes at least one strap connecting the upper end of the resilient member and the lower portion of the lower extremity prosthesis, and at least one spring which is resiliently biased by the at least one strap in response to anterior movement of the upper end of the resilient member for storing energy.
2. The method according to claim 1, wherein said assisting posterior movement includes resiliently biasing the upper end of the resilient member for posterior movement using the device provided on the prosthesis.
3. The method according to claim 1, wherein said controlling anterior movement limits the range of anterior movement of the upper end of the resilient member using the device provided on the prosthesis.
4. The method according to claim 1, wherein said controlling the anterior movement includes resisting the anterior movement of the upper end of the resilient member using the device provided on the prosthesis.
5. The method according to claim 1, wherein said controlling the anterior movement includes resiliently biasing the at least one spring of the device on the prosthesis during anterior movement of the upper end of the resilient member to store energy in the device with force loading of the prosthesis in gait, the device returning the stored energy during force unloading of the prosthesis adding to the propulsion of the person's body in gait.
6. The method according to claim 1, wherein said assisting and said controlling increase the ankle torque ratio of the prosthesis in gait.
7. The method according to claim 6, including increasing the ankle torque ratio to mimic the ankle toque ratio which occurs in a human foot in gait.
8. The method according to claim 6, including increasing the ankle torque ratio so that said peak dorsiflexion ankle torque is an order of magnitude greater than said plantar flexion ankle torque.
9. The method according to claim 6, including increasing the ankle torque ratio to a value of about 11 to 1.
10. The method according to claim 1, including providing the foot with a high low dynamic response capability.
11. The method according to claim 10, including providing said foot keel with high low dynamic response capability including forming a midfoot portion of the foot keel with a longitudinal arch with a medial aspect larger in radius and with a relatively higher dynamic response capability than a lateral aspect of the arch.
12. A method of generating power for propulsive force in a prosthetic foot comprising:
providing a prosthetic foot having a longitudinally extending foot keel and a monolithically formed resilient calf shank forming an ankle and an elongated, upstanding shank above the ankle for connection with a lower extremity prosthetic socket on a person's leg stump, the calf shank having a lower end terminating posteriorly and connected to the foot keel, the lower end of the calf shank anteriorly extending upwardly by way of an anterior facing convexly curved surface to form the ankle, the resilient calf shank extending upwardly in a substantially curvilinear manner substantially above human ankle joint height and the ankle to form the lower prosthetic part of a leg, wherein the resilient calf shank is curved longitudinally over at least substantially the entire height of the calf shank above the foot keel and has an upper end which during use of the prosthetic foot is moved longitudinally with respect to the foot keel during force loading and unloading of the prosthetic foot; and
changing the ankle torque ratio of the prosthetic foot in gait by using a posterior calf device located on the prosthetic foot posterior of the calf shank and connecting the upper end of the calf shank and a lower portion of the prosthetic foot to effect a change in the sagittal plane flexure characteristic for longitudinal movement of the upper end of the calf shank in at least the anterior direction in response to force loading and unloading during a person's use of the prosthetic foot, the ankle torque ratio being defined as the quotient of the peak dorsiflexion ankle torque in the late terminal stance phase of gait divided by the plantar flexion ankle torque created in the prosthetic foot in the initial foot flat loading response after heel strike in gait.
13. The method according to claim 12, wherein the ankle torque ratio is changed to mimic that of a human foot.
14. A method according to claim 12, wherein the ankle torque ratio is changed so that the peak dorsiflexion ankle torque that occurs in the late terminal stance of gait is at least an order of magnitude greater than the plantar flexion ankle torque created in the initial foot flat loading response after heel strike in gait.
15. The method according to claim 12, wherein the ankle torque ratio is changed to about 11 to 1.
16. The method according to claim 12, wherein the ankle torque ratio is changed by using the posterior calf device to at least one of assist the posterior movement of the upper end of the calf shank and limit the anterior movement of the upper end of the calf shank.
17. The method according to claim 16, wherein the posterior calf device assists the posterior movement of the upper end of the calf shank by resiliently biasing the upper end for posterior movement.
18. The method according to claim 16, wherein the posterior calf device limits the anterior movement of the upper end of the calf shank by resiliently biasing at least one member of the posterior calf device during anterior movement of the upper end of the calf shank with force loading of the prosthetic foot to store energy for return during force unloading of the prosthetic foot.
19. The method according to claim 12, including monolithically forming the foot keel, calf shank and posterior calf device.
20. The method according to claim 12, including providing the foot keel with a resilient longitudinal arch which can be expanded in gait during force loading of the prosthetic foot for storing energy that is returned during force unloading.
21. The method according to claim 20, including forming the medial aspect of the longitudinal arch with a larger radius than the lateral aspect.
This application is a continuation in part of application Ser. No. 10/473,682, now U.S. Pat. No. 7,507,259 which is the U.S. national designated filing under 35 U.S.C. �371 of international application PCT/US02/09589 filed Mar. 29, 2002, which is a continuation in part of U.S. application Ser. No. 09/820,895, filed Mar. 30, 2001 and now U.S. Pat. No. 6,562,075 issued May 13, 2003, the priority of which is claimed. This application is also a continuation in part of application Ser. No. 10/263,795 filed Oct. 4, 2002, now U.S. Pat. No. 7,226,485, which is a continuation of U.S. application Ser. No. 09/820,895, filed Mar. 30, 2001 and now U.S. Pat. No. 6,562,075 issued May 13, 2003, the priority of which is claimed.
The forefoot, midfoot and hindfoot portions of the foot keel 2 are formed of a single piece of resilient material in the example embodiment. For example, a solid piece of material, plastic in nature, having shape-retaining characteristics when deflected by the ground reaction forces can be employed. More particularly, the foot keel and also the calf shank can be formed of laminated composite material having reinforcing fiber laminated with polymer matrix material. In particular, a high strength graphite, laminated with epoxy thermosetting resins, or extruded plastic utilized under the tradename of Delran, or degassed polyurethane copolymers, may be used to form the foot keel and also the calf shank. The functional qualities associated with these materials afford high strength with low weight and minimal creep. The thermosetting epoxy resins are laminated under vacuum utilizing prosthetic industry standards. The polyurethane copolymers can be poured into negative molds and the extruded plastic can be machined. Each material of use has its advantages and disadvantages. It has been found that the laminated composite material for the foot keel and the calf shank can also advantageously be a thermo-formed (prepreg) laminated composite material manufactured per industry standards, with reinforcing fiber and a thermoplastic polymer matrix material for superior mechanical expansion qualities. A suitable commercially available composite material of this kind is CYLON� made by Cytec Fiberite Inc. of Havre de Grace, Md. The calf shank and foot keel could also be resilient metal members formed, for example, of spring steel, stainless steel, titanium alloy, or other metal alloy.
The interrelationship between the medial to lateral radii size of the longitudinal arch concavity of the midfoot portion 5 is further defined as the anterior posterior plantar surface weight bearing surface areas of the foot keel 2. The line T1-T2 on the anterior section of 5 in FIG. 8 represents the anterior plantar surface weight bearing area. Line P1-P2 represents the posterior plantar weight-bearing surface of 5. The plantar weight bearing surfaces on the lateral side of the foot would be represented by the distance between T1-P1. The plantar weight bearing surfaces on the medial side of the foot 2 are represented by the distance between P2-T2. The distances represented by T1-P1 and P2-T2 determine the radii size, and as a result the high low dynamic response interrelationship is determined and can be influenced by converging or diverging these two lines T1-T2 to P1-P2. As a result, high low dynamic response can be determined in structural design. The T1-T2 forefoot plantar weight bearing surface can be deviated as little as 5� from the normal to the longitudinal axis A-A of the foot keel to create this high low dynamic response, FIG. 8.
Improved biplanar motion capability of the prosthetic foot is created by medial and lateral expansion joint holes 21 and 22 extending through the forefoot portion 3 between dorsal and plantar surfaces thereof. Expansion joints 23 and 24 extend forward from respective ones of the holes to the anterior edge of the forefoot portion to form medial, middle and lateral expansion struts 25-27 which create improved biplanar motion capability of the forefoot portion of the foot keel. The expansion joint holes 21 and 22 are located along a line, B-B in FIG. 5, in the transverse plane which extends at an angle α of 35� to the longitudinal axis A-A of the foot keel with the medial expansion joint hole 21 more anterior than the lateral expansion joint hole 22.
The angle α of line B-B to longitudinal axis A-A in FIG. 5 can be as small as 5� and still derive a high low dynamic response. As this angle α changes, so should the angle Z of the line T1-T2 in FIG. 8. The expansion joint holes 21 and 22 as projected on a sagittal plane are inclined at an angle of 45� to the transverse plane with the dorsal aspect of the holes being more anterior than the plantar aspect. With this arrangement, the distance from the releasable fastener 8 to the lateral expansion joint hole 22 is shorter than the distance from the releasable fastener to the medial expansion joint hole 21 such that the lateral portion of the prosthetic foot 1 has a shorter toe lever than the medial for enabling midfoot high and low dynamic response. In addition, the distance from the releasable fastener 8 to the lateral plantar weight bearing surface as represented by T1, line is shorter than the distance from the releasable fastener to the medial plantar surface weight bearing surface as represented by the line T2—such that the lateral portion of the prosthetic foot 1 has a shorter toe lever than the medial for enabling midfoot high low dynamic response.
A dorsal aspect of the midfoot portion 5 and the forefoot portion 3 of the foot keel 2 form the upwardly facing concavity, 32 in FIG. 3, so that it mimics in function the fifth ray axis of motion of a human foot. That is, the concavity 32 has a longitudinal axis C-C which is oriented at an angle β of 5� to 35� to the longitudinal axis A-A of the foot keel with the medial being more anterior than the lateral to encourage fifth ray motion in gait as in the oblique low gear axis of rotation of the second to fifth metatarsals in the human foot.
Another foot keel 33 of the invention, especially for sprinting, may be used in the prosthetic foot of the invention, see FIGS. 6 and 7. The body's center of gravity in a sprint becomes almost exclusively sagittal plane oriented. The prosthetic foot does not need to have a low dynamic response characteristic. As a consequence, the 5� to 35� external rotation orientation of the longitudinal axis of the forefoot, midfoot concavity as in foot keel 2 is not needed. Rather, the concavity's longitudinal axis D-D orientation should become parallel to the frontal plane as depicted in FIGS. 6 and 7. This makes the sprint foot respond in a sagittal direction only. Further, the orientation of the expansion joint holes 34 and 35 in the forefoot and midfoot portions, along line E-E, is parallel to the frontal plane, i.e., the lateral hole 35 is moved anteriorly and in line with the medial hole 34 and parallel to the frontal plane. The anterior terminal end 36 of the foot keel 33 is also made parallel to the frontal plane. The posterior terminal heel area 37 of the foot keel is also parallel to the frontal plane. These modifications effect in a negative way the multi-use capabilities of the prosthetic foot. However, its performance characteristics become task specific. Another variation in the sprint foot keel 33 is in the toe, ray region of the forefoot portion of the foot where 15� of dorsiflexion in the foot keel 2 are increased to 25-40� of dorsiflexion in foot keel 33.
The ground forces cause calf shanks 44, 45, 46, 47, 50 and 51 to compress with the proximal end moving posterior. With calf shanks 48, 49 the distal � of the calf shank would compress depending on the distal concavities orientation. If the distal concavity compressed in response to the GRF's the proximal concavity would expand and the entire calf shank unit would move posteriorally. The ground forces cause the calf shank to compress with the proximal end moving posteriorly. The calf shank lower tight radius compresses simulating human ankle joint plantar flexion and the forefoot is lowered by compression to the ground. At the same time to the posterior aspect of keel, as represented by hindfoot 4, depicted by 17 compresses upward through compression. Both of these compressive forces act as shock absorbers. This shock absorption is further enhanced by the offset posterior lateral heel 18 which causes the foot to evert, which also acts as a shock absorber, once the calf shank has stopped moving into plantar flexion and with the ground pushing posteriorly on the foot.
The long arch of the foot keel and the calf shank resist expansion of their respective structures. As a consequence, the calf shank anterior progression is arrested and the foot starts to pivot off the anterior plantar surface weight-bearing area. The expansion of the midfoot portion of the foot keel has as high and low response capability in the case of the foot keels in the example embodiments of FIGS. 3-5 and 8, FIGS. 11 and 12, FIG. 13 and FIG. 14. Since the midfoot forefoot transitional area of these foot keels is deviated 15� to 35� externally from the long axis of the foot, the medial long arch is longer than the lateral long arch. This is important because in the normal foot, during acceleration or deceleration, the medial aspect of the foot is used.
In the later stages of heel rise, toe off walking and running activities, the ray region of the forefoot portion is dorsiflexed 15�-35�. This upwardly extending arc allows the anteriorly directed ground forces to compress this region of the foot. This compression is less resisted than expansion and a smooth transition occurs to the swing phase of gait and running with the prosthetic foot. In later stages of stance phase of gait, the expanded calf shank and the expanded midfoot long arch release their stored energy adding to the forward and upward propulsion of the trailing limb and amputee's body center of gravity.
The prosthetic foot 70 shown in FIGS. 28-32 is similar to those in FIGS. 3-5, 8, 23 and 24 and FIGS. 25-27, but further includes a calf shank range of motion limiter and dampener device 71 on the foot to limit the extent of the motion of the upper end of the calf shank with force loading and unloading of the calf shank during use of the foot by the amputee. This feature is especially useful in a prosthetic foot having a relatively long calf shank where the wearer is to engage in activities such as running and jumping that generate forces in the calf shank many times the wearer's body weight, e.g., with running 5-7 times body weight and jumping 11-13 times body weight. In contrast, the forces generated in walking are only 1-1� times body weight.
The distal end of the calf shank 90 is more sharply curved, e.g., has a smaller radius of curvature, than the calf shank 72 in FIGS. 28-32, and extends upwardly and anteriorly in a shorter longitudinal distance. This calf shank shape is more cosmetically friendly. That is, its distal end is located more in the ankle region, where the medial and lateral malleoli of a human foot shaped outer covering of the prosthetic foot would normally be located. The calf shank tucks in the outer prosthetic foot covering better. Its functional characteristics are that it responds quicker to initial contact ground reaction forces, although with less dynamic response capability than a calf shank with a wider parabola, e g., longer radii of curvature as noted above. Thus, those active persons who run and jump with a prosthetic foot would benefit from using a wider parabola or radius of curvature which affords a greater horizontal velocity.
The foot keel 110 in FIGS. 37 and 38 and the foot keel 120 of FIGS. 39 and 40 are further example embodiments foot keels which can be used in the prosthetic foot of the invention. The foot keels are for the right foot and have similar constructions except in the hindfoot portion. The medial and lateral sides of the two foot keels are the same shape. Foot keel 110 is sagittally cut in the hindfoot area with identical lateral and medial expansion struts 111 and 112 separated by a longitudinally extending expansion joint or slot 113. The posterior terminal heel area 114 of the foot keel 110 is parallel to the frontal plane, e.g., perpendicular to the longitudinal axis A-A of the foot keel. Similarly, the hindfoot dorsal concavity 115 of the foot keel has its longitudinal axis F-F parallel to the frontal plane, e.g., at right angles to the longitudinal axis A-A, i.e., angle Δ is 90�.
Foot keel 120, in contrast to foot keel 110, is not sagittally cut in the hindfoot area but has its hindfoot dorsal concavity 121 cut such that the longitudinal axis F′-F′ of the concavity is skewed transverse to the frontal plane, e.g., makes an obtuse angle Δ′ with the longitudinal axis A-A of preferably 110-125� with the lateral side further anterior than the medial side. This orientation of the dorsal concavity makes the lateral expansion strut 122 thinner over a greater length than the medial expansion strut 123, and thereby effectively longer and more flexible than strut 123. This increase in flexibility predisposes the hindfoot to respond to initial contact ground reaction forces by everting—which is a shock absorption mechanism. This aids in efficiently transferring the forces of the body's center of gravity through the hindfoot of the foot keel in gait for achieving a more normal gait pattern.
When the strap 128 is shortened to initially preload the strap in tension prior to use of the prosthetic foot, the strap tension serves to assist posterior movement of the upper end of the resilient member as well as control anterior movement of the calf shank during use of the prosthesis. Assisting the posterior movement can be helpful in attaining a rapid foot flat response of the prosthetic foot at heel strike in the initial stance phase of gait akin to that which occurs in a human foot and ankle in gait at heel strike where plantar flexion of the foot occurs.
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ChristensenProsthetic foot with energy transfer medium including variable viscosity fluidUS20020040249Sep 20, 2001Apr 4, 2002Phillips Van L.Prosthesis with resilient ankle blockUS20020077706Aug 30, 2001Jun 20, 2002Phillips Van L.Energy storing foot prosthesis with improved plantar flexionUS20020087216Feb 25, 2002Jul 4, 2002Atkinson Stewart L.Prosthetic walking systemUS20020116072Feb 9, 2001Aug 22, 2002Rubie Eric W.Lower leg prosthesisUS20020133237May 3, 2002Sep 19, 2002Christesen Roland J.Prosthetic foot with energy transfer medium including variable viscosity fluidUS20020143408Apr 25, 2002Oct 3, 2002Townsend Barry W.Prosthetic foot with tunable performanceUS20030009238Jul 3, 2002Jan 9, 2003Whayne James G.Artificial limbs incorporating superelastic supportsUS20030028256Oct 4, 2002Feb 6, 2003Townsend Barry W.Prosthetic foot with tunable performanceUS20030045944Aug 8, 2001Mar 6, 2003Luder MoslerFoot insert for an artificial footUS20030093158Dec 17, 2002May 15, 2003Phillips Van L.Foot prosthesis having cushioned ankleUS20030120354Jan 29, 2003Jun 26, 2003Ohio Willow Wood CompanyProsthetic foot having shock absorptionNon-Patent CitationsReference12003 Ossur Product Catalog; TALUX(TM); pp. 179-181.2Atkinson et al.; Publication No. US 2002/0087216A1.3Ayyapa, E., Normal Human Locomotion, Part 2: Motion, Ground-Reaction Force and Muscle Activity, Journal of Prosthetics and Orthotics, Spring 1997, vol. 9, No. 2, pp. 49-57.4Ayyappa, E., Normal Human Locomotion, Part 1 : Basic Concepts and Terminology, Journal of Prosthetics and Orthotics, Winter 1997, vol. 9, No. 1, pp. 10-17.5Barth, D.G., Schumacher, L. and Thomas, S.S., Gait Analysis and Energy Cost of Below-Knee Amputees Wearing Six Different Prosthetic Feet, JPO: Journal of Prosthetics and Orthotics, 1992, vol. 4, No. 2, pp. 626-638.6Bateni, H., et al.., Kinematic and Kinetic Variations of Below-Knee Amputee Gait, Prosthetic and Orthotic Science, 2002, vol. 14, No. 1, pp. 2-10.7Bojsen-Moller, F., Calcaneocuboid Joint and Stability of the Longitudinal Arch of the Foot at High and Low Gear Push Off, Journal of Anatomy, Aug.-Dec. 1979, vol. 129, pp. 165-176.8Brunnstrom, S. 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