Patent Description:
A loss of a limb or part of a limb creates challenges for the amputee in performing simple tasks. The loss of upper limbs creates particular challenges due to the intricacy and dexterity of the human hand. Existing solutions for prosthetic digits provide limited movements. For example, existing digit prosthetics, such as prosthetic thumbs and fingers, do not provide in a natural manner the full range of motion and capabilities of a sound thumb. Improvements in this area are therefore desirable.

<CIT> which constitutes the closest prior art document, discloses an automated hand, such as a prosthetic hand, which includes a thumb rotation locking mechanism.

The following disclosure describes non-limiting examples of some embodiments. For instance, other embodiments of the disclosed systems and methods may or may not include the features described herein. Moreover, disclosed advantages and benefits can apply only to certain embodiments of the invention and should not be used to limit the disclosure. The embodiments disclosed herein each have several aspects no single one of which is solely responsible for the disclosure's desirable attributes.

According to the present invention there is provided a powered prosthetic thumb as recited in claim <NUM>.

<FIG> and <FIG> are side and front views respectively of an embodiment of an upper limb <NUM> that includes an embodiment of a powered prosthetic thumb <NUM>. As shown, the upper limb <NUM> may include an arm <NUM> attached to a hand <NUM>. The arm <NUM> may be a prosthetic arm. The hand <NUM> may be a left hand. The thumb <NUM> may also be used with a right hand. In some embodiments, the arm <NUM> may be a natural arm, i.e. a natural or sound human arm. The arm <NUM> may be a stump and/or include a fitting on a distal end thereof. The arm <NUM> may be or include one or more prosthetic sockets <NUM> and/or <NUM> (see <FIG>) mounted on the arm <NUM>, such as a residual limb, or on the hand <NUM>, such as a palm portion <NUM> (see <FIG>) on the end of the arm <NUM>. For clarity the prosthetic sockets <NUM>, <NUM> are not shown in <FIG>. The prosthetic sockets <NUM> may connect one or more finger digits <NUM> with the arm <NUM> and/or the palm <NUM>. The prosthetic socket <NUM> may connect the thumb <NUM> with the arm <NUM> and/or the palm <NUM>. The prosthetic sockets <NUM>, <NUM> may be a variety of different types of suitable prosthetic sockets. For example, the prosthetic sockets <NUM>, <NUM> may be created by a prosthetist for the appropriate anatomical spacing and location of the finger digits <NUM> and the thumb <NUM> relative to the end of the arm <NUM> or relative to the palm <NUM> of the hand <NUM>. The prosthetic sockets <NUM>, <NUM> are shown schematically in <FIG>.

The hand <NUM> may be a prosthetic hand, for example a full prosthetic hand or a partial prosthetic hand. The hand <NUM> may include one or more prosthetic finger digits <NUM>, for example the four finger digits <NUM> and the thumb <NUM>. In some embodiments, there may be fewer than four of the digits <NUM>, for example where the hand <NUM> is a partial prosthetic hand. The thumb <NUM> may be used with partial hand patients, for example that are missing a natural thumb only, and who could thus use the thumb <NUM> with a partial hand system. In some embodiments, the thumb <NUM> may be used with patients that are missing a natural thumb and/or one or more natural fingers and/or a natural palm, either partially or completely missing any of these natural anatomical body parts. In some embodiments, the digits <NUM> and/or thumb <NUM> may connect directly with the arm <NUM>. Thus the hand <NUM> may just include the digits <NUM> and/or just the thumb <NUM>. An example embodiment of a partial prosthetic hand 120A that the thumb <NUM> may be used with is shown and described with respect to <FIG> and <FIG>. There may be a structure, such as a palm structure, of the palm <NUM> attaching the digits <NUM> and/or thumb <NUM> with the arm <NUM>. In some embodiments, there may just be the thumb <NUM> attached to a partial prosthetic hand <NUM>, which is attached to a natural partial hand having one or more natural fingers, which is attached to a natural arm <NUM>.

The digits <NUM> and the thumb <NUM> may be configured to facilitate grasping an object <NUM>. As shown in <FIG>, the object <NUM> may be a cylinder, or other objects. The thumb <NUM> described herein facilitates grasping and/or manipulating this and other objects by allowing for movement in a natural manner and through large ranges of motion, for example by providing rotation about multiple axes, simultaneous rotation about multiple axes, rotation about one or more moving axes, among other advantages, as further described.

<FIG> are various perspective views of the thumb <NUM>. As shown, the thumb <NUM> may include a lower assembly <NUM>, a middle assembly <NUM> and an upper assembly <NUM>. The lower assembly <NUM> may be configured to attach to the hand <NUM>, for example a palm structure thereof, or to the arm <NUM>. In some embodiments, the lower assembly <NUM> attaches to a full prosthetic hand <NUM> or a partial prosthetic hand <NUM>. The lower assembly <NUM> may include a plate <NUM> for attaching to the hand <NUM>. The thumb <NUM> may provide rotation of the upper assembly <NUM> about a pinch axis <NUM>, about a lateral axis <NUM>, or about both the pinch axis <NUM> and the lateral axis <NUM>, as further described below. Other rotations and movements may also be performed by the thumb <NUM>. For example, the thumb <NUM> may include other joints along the upper assembly <NUM> that rotate as well. The upper assembly <NUM> or portions thereof may be considered a digit, such as a thumb digit, which performs the various rotations, as further described herein. A cover <NUM> may extend along the digit. The digit may have a top side <NUM> and an opposite underside <NUM>. The underside <NUM> may refer to a side of the digit that would be on the same side of a palm of a sound hand. The top side <NUM> may refer to a side of the digit that would be on the same side as the back of a sound hand.

The assemblies <NUM>, <NUM>, <NUM> may have rotatable connections with each other, as generally described here, and as described in further detail herein, for example with respect to <FIG>. Various geometric references may be used to describe the thumb <NUM>. As shown, a distal direction extends in a direction generally from the lower assembly <NUM> toward the upper assembly <NUM>. A proximal direction extends generally in a direction from the upper assembly <NUM> toward the lower assembly <NUM>.

The lower assembly <NUM> is rotatably connected with the middle assembly <NUM>. The middle assembly <NUM> may include a rocker <NUM> and a coupler <NUM>. Proximal ends of the rocker <NUM> and the coupler <NUM> may be rotatable connected with a mount <NUM> of the lower assembly <NUM>. The middle assembly <NUM> may include a swaying chassis <NUM> rotatably connected with a distal end of the rocker <NUM> and connected with the coupler <NUM>. The upper assembly <NUM> is rotatably connected at a proximal end thereof with the middle assembly <NUM>. The upper assembly <NUM> may include a cover <NUM> having a proximal end rotatably connecting the upper assembly <NUM> with a distal end of the swaying chassis <NUM>.

The upper assembly <NUM> is configured to rotate about a pinch axis <NUM> and/or a lateral axis <NUM>, as described in further detail herein. The pinch axis <NUM> may be defined and be fixed with respect to portions of the upper assembly <NUM>. Further, the upper assembly <NUM> may move in directions other than merely rotating about the pinch axis <NUM>. Thus, the orientation of the pinch axis <NUM> may also change, for example relative to the lower assembly <NUM> such as the mount <NUM>, due to movement of the upper assembly <NUM>. The upper assembly may rotate about the pinch axis <NUM> due to mechanical communication between various worm gears <NUM>, <NUM> and worm wheels <NUM>, <NUM>, as further described.

The lateral axis <NUM> may be defined and be fixed with respect to portions of the lower assembly <NUM>. Further, the upper assembly 500may move in directions other than merely rotating about the pinch axis <NUM>. Thus, the orientation of the pinch axis <NUM> may also change, for example relative to the lower assembly <NUM> such as the mount <NUM>, due to movement of the upper assembly <NUM>. The upper assembly <NUM> may rotate only about the pinch axis <NUM>, only about the lateral axis <NUM>, or about the pinch axis <NUM> and the lateral axis <NUM> simultaneously, as further described. The upper assembly <NUM> may rotate about the lateral axis <NUM> due to mechanical communication between a first bevel gear <NUM> and a second bevel gear <NUM>, as further described. A clutch assembly <NUM> may allow for manual rotation of the upper assembly <NUM> about the lateral axis <NUM>, for example to prevent damage in case of excessive force applied to the digit, as further described.

<FIG> are sequential perspective views of the thumb <NUM> showing sequential positions of the upper assembly <NUM> and other components before and after, respectively, lateral rotation about the lateral axis <NUM>. The upper assembly <NUM> has been rotated from the position in <FIG> to the position shown in <FIG>. Further, the orientation of the <NUM> pinch axis <NUM> in <FIG> have changed relative to the orientation in <FIG>. The change in orientation of the axis <NUM> may be described as relative to the lateral axis <NUM>, the mount <NUM> or other fixed reference portion of the thumb <NUM>. Thus the pinch axis <NUM> may rotate about the lateral axis <NUM>. The upper assembly <NUM> may rotate back from the position shown in <FIG> to the position shown in <FIG>. Under manual lateral rotation, a clutch component may rotate about the clutch axis <NUM> to allow for lateral manual rotation, as further described. These are just example positions meant to illustrate one possible rotation about the lateral axis <NUM>. In some embodiments, the thumb <NUM> may be configured such that the lateral axis <NUM> moves as the upper assembly <NUM> performs the various rotations described herein.

In some embodiments, rotation of the upper assembly <NUM> may be described with respect to a rotation vector. It is understood in the art that a rotation vector has a magnitude that is proportional to the amount or speed of rotation and a direction that is perpendicular to the plane of rotation. It is also understood in the art that a rotation vector's magnitude and direction may be described by three components corresponding to coordinates of three mutually orthogonal axes, such as a reference X-Y-Z axis system. Here, a reference axis system may be fixed with respect to a fixed portion of the thumb, such as the lower assembly <NUM>, for example the mount <NUM>. A reference axis system may instead be fixed to the upper assembly <NUM> and move with the upper assembly <NUM> as the upper assembly <NUM> moves. A rotation vector of the upper assembly <NUM> may be described with respect to such reference frames. In some embodiments, the upper assembly <NUM> may have a rotation vector that has one, two or three components in such reference frame that are non-zero. For example, the upper assembly <NUM> may rotate about both the lateral axis <NUM> and the pinch axis <NUM> simultaneously. As further example, the upper assembly <NUM> may rotate about only the lateral axis <NUM>. In these and other instances, the corresponding rotation vector of the upper assembly <NUM> may have multiple components that are non-zero. In some embodiments, the rotation vector of the upper assembly <NUM> may change magnitude and/or direction as the upper assembly rotates.

In some embodiments, rotation of the upper assembly <NUM> may be described with respect to Euler angles. As is understood in the art, Euler angles are three angles that describe the orientation of a body with reference to a fixed reference frame. In some embodiments, a fixed reference frame may be as described above, for example an X-Y-Z axis system fixed with respect to the mount <NUM>. The upper assembly <NUM> may have a local reference frame that moves with the upper assembly <NUM>. In some embodiments, Euler angles may describe the relationship between a final orientation of the upper assembly <NUM> relative to an initial orientation, by describing the angular rotations of the local reference frame relative to the fixed reference frame. In some embodiments, rotation of the upper assembly <NUM> may be described with one, two or three non-zero Euler angles. For example, the upper assembly <NUM> may rotate about both the lateral axis <NUM> and the pinch axis <NUM> simultaneously. As further example, the upper assembly <NUM> may rotate about only the lateral axis <NUM>. In these and other instances, the relative orientation between a starting orientation of the upper assembly <NUM> prior to rotating and a final orientation after rotating may be described with one, two or three Euler angles that are non-zero.

<FIG> show the lower assembly <NUM> in isolation from the remaining parts of the thumb <NUM>. <FIG> is an exploded view of the lower assembly <NUM>. As shown in the figures, the lower assembly <NUM> may include a plate <NUM>. The plate <NUM> may be configured to attach to the hand <NUM>. For example, the plate <NUM> may be attached on a first side thereof to the prosthetic hand <NUM>, e.g. in a location where a sound thumb would be located. The plate <NUM> may be attached on an opposite second side thereof to a mount <NUM>. The plate <NUM> may attach to the hand <NUM> and/or mount <NUM> with fasteners, other mechanical attachments, adhesives, other suitable attachment means, or combinations thereof.

The mount <NUM> may be a structural component configured to attach to the plate <NUM> and/or other structure and to attach, for example rotatably attach, to various parts of the middle assembly <NUM>. The mount <NUM> may include a base <NUM>. The base <NUM> provides a structural foundation for the mount <NUM>. The base <NUM> may include one or more holes <NUM> extending therethrough. As shown there may be three holes <NUM>. The holes <NUM> may receive a fastener, for example a screw, therethrough to attach the base <NUM> with the plate <NUM>.

The mount <NUM> may include a first projection <NUM>. The first projection <NUM> may provide attachment points for various components of the middle assembly <NUM>. The first projection may be a raised portion of the mount <NUM> extending distally from the mount <NUM>. The first projection <NUM> may include a first ear <NUM> and/or a second ear <NUM>. The first and second ears <NUM>, <NUM> may be projections extending distally from the first projection <NUM>. The first ear <NUM> may include an opening <NUM> extending therethrough. The opening <NUM> may extend along and may align with a rocker axis <NUM>. The opening <NUM> may define the rocker axis <NUM>. The rocker axis <NUM> may align with an axis of rotation for various components of the middle assembly <NUM>, such as a proximal portion of the rocker <NUM> as further described. The second ear <NUM> may include an opening <NUM> extending therethrough. The opening <NUM> may extend along and align with and/or define a lateral axis <NUM>. The lateral axis <NUM> may align with an axis of rotation for various components of the middle assembly <NUM>, such as a proximal portion of the coupler <NUM>, as further described.

The mount <NUM> may include a second projection <NUM> extending distally from the mount <NUM> and spaced from the first projection <NUM>. The second projection <NUM> may be laterally spaced from the first projection <NUM> to define one or more spaces therebetween. The second projection <NUM> may provide attachment points for various components of the middle assembly <NUM>. The second projection <NUM> may include an opening <NUM> extending therethrough. The opening <NUM> may extend along and align with the rocker axis <NUM>. The opening <NUM> may define the rocker axis <NUM>. The opening <NUM> may therefore align or generally align with the opening <NUM>. The portion of the second projection <NUM> having the opening <NUM> may be spaced from the portion of the first ear <NUM> having the opening <NUM> to define a space <NUM> therebetween. The second projection <NUM> may include an opening <NUM> extending therethrough. The opening <NUM> may align with the lateral axis <NUM>. The opening <NUM> may define the lateral axis <NUM>. The opening <NUM> may therefore align or generally align with the opening <NUM>. The portion of the second projection <NUM> having the opening <NUM> may be spaced from the portion of the second ear <NUM> having the opening <NUM> to define a space <NUM> therebetween.

The lower assembly <NUM> may include a rocker pivot shaft <NUM>. The shaft <NUM> may include a first end <NUM> and an opposite second end <NUM>. The shaft may be an elongated structural element extending from the first end <NUM> to the second end <NUM>. The shaft <NUM> may be located in the space <NUM> and received into the opening <NUM> and the opening <NUM>. The first end <NUM> of the shaft <NUM> may be received by the opening <NUM>, and the second end <NUM> may be received by the opening <NUM>. The second end <NUM> may include a notch <NUM>, for example a flat recess as shown. The notch <NUM> may allow for receiving a tool therein to adjust, for example rotate, the shaft <NUM>. The shaft <NUM> may be aligned with, for example extend along, the rocker axis <NUM>. The shaft <NUM> may provide a structural support for rotating the rocker <NUM> about the rocker axis <NUM>, as further described. The shaft <NUM> may be rotatably stationary about the axis <NUM>. In some embodiments, the shaft <NUM> may be configured to allow for rotation about the axis <NUM>.

The lower assembly <NUM> may include a swaying chassis pivot shaft <NUM>. The shaft <NUM> may include a first end <NUM> and an opposite second end <NUM>. The shaft <NUM> may be an elongated structural element extending from the first end <NUM> to the second end <NUM>. The shaft <NUM> may be located in the space <NUM> and received by the opening <NUM> and the opening <NUM>. As shown the first end <NUM> may be received by the opening <NUM> and the second end <NUM> received by the opening <NUM>. The shaft <NUM> may be threaded or not threaded. The shaft <NUM> may be aligned with, for example extend along, the lateral axis <NUM>. The shaft <NUM> may provide a structural support for rotating the swaying chassis <NUM> about the lateral axis <NUM>, as further described. The shaft <NUM> may be rotatably stationary about the lateral axis <NUM>. In some embodiments, the shaft <NUM> may be configured to allow for rotation about the lateral axis <NUM>.

The lower assembly <NUM> may include a pogo plate <NUM>. The pogo plate <NUM> may receive one or more pogo pins <NUM>. The lower assembly <NUM> may include a distribution circuit board <NUM>. The pins <NUM> may establish a temporary connection between the circuit board <NUM> and other electronics of the thumb <NUM> and/or hand <NUM>. This pins <NUM> may be slender cylinders containing two sharp, spring-loaded pins. The board <NUM> may be attached to the plate <NUM> and/or the mount <NUM>. The board <NUM> may be in electrical communication with the pins <NUM>. The pins <NUM> may actuate to establish the connection with the board <NUM>. The board <NUM> may be in electrical communication with a circuit connection <NUM>, such as a printed circuit board (PCB) connection. The circuit connection <NUM> may be on an actuator cable circuit board <NUM>. The board <NUM> may include a series of circuit pins <NUM> which may be mounted to the circuit connection <NUM>. The board <NUM> may be located inside the second projection <NUM> of the mount <NUM>.

The lower assembly <NUM> may include a sensor <NUM>. As shown the sensor <NUM> may be a Hall Effect sensor or Hall Effect sensor assembly. The sensor <NUM> may be a Hall Effect sensor assembly that senses one or more magnets of the thumb <NUM>, as further described herein. The sensor <NUM> signals with different levels of current output depending on the proximity of a magnetic field. Thus a small magnet (e.g. about <NUM>-<NUM> diameter, preferably <NUM> or <NUM> diameter) may be positioned on one of the rotating links, such as the coupler <NUM>, and as the link rotates the distance between the magnet and the sensor <NUM> changes. This in turn results in different values of current being signaled by the sensor <NUM>. By calibrating the variation of the signaled current by the sensor <NUM> versus the associated angle that the thumb <NUM> or portions thereof such as the coupler <NUM> rotates, the signals may be read from the sensor <NUM> to determine the angular position of the thumb <NUM> or portions thereof, such as the coupler <NUM> and/or upper assembly <NUM>. This data may be used to decide the next commands to the actuators to reduce or increase the angular position.

The sensor <NUM> may be located within the second projection <NUM>. The sensor <NUM> may be positioned as an angle of <NUM> degrees or about <NUM> degrees. The sensor <NUM> may be positioned as an angle of <NUM> degrees or about <NUM> degrees relative to the base <NUM> and/or second projection <NUM>. This positioning may account for outside effects such as the upper assembly <NUM> which may be metallic. As shown, the sensor <NUM> may be exposed through an opening <NUM> of the second projection <NUM>. The sensor <NUM> may communicate with other components of the thumb <NUM> through the opening <NUM>. For example, the sensor <NUM> may be a Hall Effect sensor assembly that communicates electromagnetically with one or more magnets, as further described herein.

The lower assembly <NUM> may be attached with the middle assembly <NUM>, as further described. The shafts <NUM>, <NUM> may provide rotational securements for various components of the thumb <NUM>, as further described. As shown, the shaft <NUM> may be angled with respect to the shaft <NUM>. The shaft <NUM> may be in a different plane than the shaft <NUM>. The shaft <NUM> may be in a different plane and angled with respect to the shaft <NUM>. The lateral axis <NUM> may be angled with respect to the axis <NUM>. The lateral axis <NUM> may be in a different plane than the axis <NUM>. The lateral axis <NUM> may be in a different plane and angled with respect to the axis <NUM>. The shafts <NUM>, <NUM> may align with respectively the axes <NUM>, <NUM>.

<FIG> and <FIG> are perspective and exploded views respectively of another embodiment of a lower assembly 300A that may be used with the thumb <NUM>. The lower assembly 300A may have the same or similar features and/or functions as the lower assembly <NUM>. In addition or alternatively to the features described with respect to the lower assembly <NUM>, the lower assembly 300A in some embodiments may include, for example, a plate <NUM> with a recess <NUM>. As illustrated in <FIG>, the recess <NUM> may help provide the lower assembly 300A with a low profile and allow for minimal invasion. The recess <NUM> can allow components of the lower assembly 300A, such as the circuit board <NUM> and the plate <NUM>, to fit together more tightly and create a lower overall profile on the thumb <NUM>.

The thumb <NUM> may rotate and/or move quietly (e.g., without producing much noise) due to the compactness and design of the various rotating parts of the thumb <NUM>. The thumb <NUM> may include at least one motor, such as the actuators <NUM>, <NUM> described herein and shown in <FIG>. For example, the motor may be a brushed DC motor or a brushless motor. The motor may advantageously be very quiet. The mechanics of the motor(s) and the moving parts of the thumb <NUM> may be efficient. For example, the parts may be small and packed tightly as described herein and provide for quiet and smooth operation of the thumb during rotation about one or more of the rotational axes.

The lower assembly 300A may include at least one opening <NUM> in the mount <NUM>. The opening <NUM> may be disposed on a top portion of the mount <NUM>. In some embodiments, there may be more than one opening <NUM>, such as with a dividing wall separating two or more openings <NUM>. The opening <NUM> may extend downwardly through the second projection <NUM> to allow access to electrical connections between the circuit board <NUM> and electronics of the upper assembly <NUM> and/or other parts of the thumb <NUM>. In some embodiments, the circuit board <NUM> may have a hole <NUM> configured to receive a fastener, such as a screw, to attach the circuit board <NUM> with other components of the lower assembly 300A.

Various components, such as the actuator cable circuit board <NUM> and/or the circuit board <NUM>, may be separate components or may be included in a single component. For example, as shown in <FIG>, the circuit board <NUM> may include a flexible portion comprising the actuator cable circuit board <NUM>. The board <NUM> may extend upwardly from the portion with the board <NUM>. The board <NUM> may be received into the opening <NUM> of the mount <NUM> through a lower portion of the opening <NUM> in the bottom of the mount <NUM> for electrical connection. In some embodiments, components such as the pogo plate <NUM>, pogo pins <NUM>, circuit connection <NUM>, and/or circuit pins <NUM> may not be included in the lower assembly 300A.

The lower assembly 300A may include a plug-in. The lower assembly 300A may not include the pogo plate <NUM> or pins <NUM> and instead have the plug-in. The plug-in may receive a standard type plug. The plug-in may be located for example on the bottom of the board <NUM>. The design of the board <NUM> with the upward extending board <NUM> may allow for a more compact design that incorporates the plug-in and further contributes to the compactness of the electronics and to the overall thumb <NUM>.

The lower assembly 300A may include one or more (e.g., <NUM> or <NUM>) sensors <NUM>. The sensor <NUM> may be coupled to the board <NUM>. For example, the sensor <NUM> may be soldered to a surface, such as a back surface as shown and as oriented in <FIG>, of the board <NUM>. Soldering the sensor <NUM> to the board <NUM> may reduce the number of parts in the lower assembly 300A. The use of fewer components may aid the reliability of the assembly 300A and simplify the manufacturing process. In some embodiments, the sensor <NUM> may be an analog Hall Effect sensor. The Hall Effect sensor may be used to obtain the absolute position of the thumb <NUM>.

In some embodiments, a potentiometer may be used to obtain the absolute position of the thumb <NUM>. In some embodiments, an incremental optical rotary encoder and/or gyro sensor may be used to control the thumb <NUM>. For example, an incremental optical rotary encoder can generate a signal when the motor moves. The motor may include absolute optical encoders. For example, the motor may include absolute optical encoders which monitor the internal position of the motor. The position of the thumb <NUM> can be derived from the motor's rotation. [<NUM>] <FIG> is a perspective view of the middle assembly <NUM>. <FIG> is an exploded view of the middle assembly <NUM>. As shown in the figures, the middle assembly <NUM> may include the swaying chassis <NUM>, the rocker <NUM> and the coupler <NUM>. <FIG> is a perspective view of the swaying chassis <NUM>. <FIG> is a perspective view of the rocker <NUM>. <FIG> is a perspective view of the coupler <NUM>. The middle assembly <NUM> may couple with the lower assembly <NUM>, as further described. As shown in <FIG>, a distal end of the rocker <NUM> may rotatably couple with the chassis <NUM> about a chassis axis <NUM>. A distal end of the coupler <NUM> may couple with the chassis <NUM> about a clutch axis <NUM>. The clutch axis <NUM> may be a rotation axis for a bevel gear to allow manual lateral rotation of the upper assembly <NUM>, for example in case of excessive applied force to the digit, as further described. The distal end of the coupler <NUM> may be rotationally fixed with the chassis <NUM> about the clutch axis <NUM> to allow for automatic lateral rotation by the actuator, as further described herein.

As shown in <FIG>, the swaying chassis <NUM> may include a rocker attachment portion <NUM>. The portion <NUM> may include a base <NUM> having a first ear <NUM> and a second ear <NUM> extending outwardly, for example perpendicularly, therefrom. The first and second ears <NUM>, <NUM> may be spaced to define a rocker receiving space <NUM> therebetween. The first ear <NUM> may include an opening <NUM> extending therethrough. The second ear <NUM> may include an opening <NUM> extending therethrough. The openings <NUM>, <NUM> may be aligned with and extend along or define the chassis axis <NUM>. The portion <NUM> may rotatably couple the chassis <NUM> with the rocker <NUM> about the chassis axis <NUM>, as further described.

The chassis <NUM> may include a coupler/upper assembly attachment portion <NUM>. The portion <NUM> may be attached to or integral with the portion <NUM>. The portion <NUM> may include a base <NUM>. The base <NUM> may include an opening <NUM> extending therethrough. The opening <NUM> may be aligned with and extend along or define the lateral axis <NUM>. The base <NUM> may include a first ear <NUM> and a second ear <NUM> extending outwardly, for example perpendicularly, therefrom. The first ear <NUM> and the second ear <NUM> may be spaced apart to define a main shaft receiving space <NUM> therebetween. The first ear <NUM> may include an opening <NUM> extending therethrough. The second ear <NUM> may include an opening <NUM> extending therethrough. The openings <NUM>, <NUM> may be aligned with and extend along or define a pinch axis <NUM>. The upper assembly <NUM> may rotate about the pinch axis <NUM> to open and close the digit, as further described.

The pinch axis <NUM> may be angled, for example perpendicular, with respect to the lateral axis <NUM>. The axes <NUM>, <NUM> may be oriented at other angles with respect to each other. The axes <NUM>, <NUM> may or may not intersect. The chassis axis <NUM> may be angled with respect to the axes <NUM> and/or <NUM>. The chassis axis <NUM> may be in a different plane than the axes <NUM> and/or <NUM>. The digit may rotate about the axis <NUM> in a first plane. The first plane may move as the digit laterally rotates. The first plane may rotate about the axis <NUM> as the digit rotates laterally. In some embodiments, the axis <NUM> may intersect the first plane. In some embodiments, the axis <NUM> may in the first plane.

As shown in <FIG>, the rocker <NUM> may include a body <NUM>. The body <NUM> may be a planar or generally planar structural support. The body <NUM> may include a first ear <NUM>, a second ear <NUM> and/or a third ear <NUM>. The ears <NUM>, <NUM>, <NUM> may be located on the same side of the body <NUM>. The ears <NUM>, <NUM>, <NUM> may extend away from the body <NUM>. The ears <NUM>, <NUM>, <NUM> may extend away from the body <NUM> in the same or generally the same direction.

The rocker <NUM> may include a proximal mount attachment portion <NUM>. The portion <NUM> may include a proximal portion of the body <NUM> and the first ear <NUM> and the second ear <NUM>. The first ear <NUM> may have an opening <NUM> extending therethrough. The second ear <NUM> may include an opening <NUM> extending therethrough. The openings <NUM>, <NUM> may be aligned with and/or define a local axis 60A. The axis 60A may be aligned with the rocker axis <NUM>, as further described, when the rocker <NUM> is assembled with the mount <NUM>. The first ear <NUM> and the second ear <NUM> may be spaced apart from each other to define therebetween a shaft receiving space <NUM>. The space <NUM> may receive therein the rocker pivot shaft <NUM> when the rocker <NUM> is assembled with the mount <NUM>. When assembled, the proximal portion of the rocker <NUM> may rotate on the shaft <NUM> relative to the mount <NUM> and about the axis <NUM>. There may be one or more bushings in the openings <NUM>, <NUM>.

The rocker <NUM> may include a distal chassis attachment portion <NUM>. The chassis attachment portion <NUM> may be attached to or integral with the portion <NUM>. The portion <NUM> may include a distal portion of the body <NUM> and the third ear <NUM>. The ear <NUM> may include an opening <NUM> extending therethrough. The opening <NUM> may be aligned with and/or define a local chassis axis 70A. The local chassis axis 70A may align with the chassis axis <NUM> when the rocker <NUM> is assembled with the chassis <NUM>. When assembled, the distal portion of the rocker <NUM> may rotate about the axis <NUM> relative to the chassis <NUM>. There may be one or more bushings in the opening <NUM>.

As shown in <FIG>, the coupler <NUM> may include a body <NUM>. The body <NUM> may include a mount attachment portion <NUM> at a proximal end thereof. The portion <NUM> may include an opening <NUM> extending therethrough. The opening <NUM> may be aligned with and/or define a local axis 50A. The local axis 50A may align with the lateral axis <NUM> when the coupler <NUM> is assembled with the lower assembly <NUM>, such as the mount <NUM>. When assembled, the proximal end of the coupler <NUM> may rotate relative to the mount <NUM> and about the axis <NUM>.

The body <NUM> may include a chassis attachment portion <NUM> at a distal end thereof. The chassis attachment portion <NUM> may be attached to or be integral with the portion <NUM>. The portion <NUM> may extend away from an end of the portion <NUM> at an angle, as shown. The portion <NUM> may include an opening <NUM> extending therethrough. There may be a counter bore in the opening <NUM> as shown. The opening <NUM> may be aligned with and/or define a local axis 80A. The local axis 80A may align with the clutch axis <NUM> when the coupler <NUM> is assembled with the chassis <NUM>. When assembled, the distal end of the coupler <NUM> may be rotationally fixed relative to the chassis <NUM> by a clutch, as further described.

The portion <NUM> at the distal end of the rocker <NUM> may be rotatably coupled with the chassis <NUM> by a coupler pivot shaft <NUM>. (See <FIG>. ) The shaft <NUM> may include a first end 495A and an opposite second end 495B. The shaft <NUM> may be an elongated structural element extending from the first end 495A to the second end 495B. The shaft <NUM> may be received through the openings <NUM>, <NUM> of the chassis <NUM> to align with the chassis axis <NUM>. The second end 495B may be received by the opening <NUM> of the second ear <NUM>. The first end 495A may be received by the opening <NUM> of the first ear <NUM>. The rocker receiving space <NUM> of the chassis <NUM> may receive the third ear <NUM> of the rocker <NUM>, such that the shaft <NUM> extends through the opening <NUM> of the third ear <NUM>. The shaft <NUM> may therefore rotatably couple the rocker <NUM> with the chassis <NUM> by securing the third ear <NUM> rotatably within the space <NUM> of the chassis <NUM>.

In some embodiments, there may also be a bushing <NUM> and a bushing <NUM>. The bushing <NUM> may be located with the first end 495A and the bushing <NUM> may be located with the second end 495B of the shaft <NUM>. In some embodiments the mount attachment portion <NUM> of the rocker <NUM> may include one or more bushings. As shown, the first ear <NUM> and the second ear <NUM> may each receive a bushing <NUM> therein.

The distal end of the coupler <NUM> may be coupled with the chassis <NUM>. As shown, the chassis attachment portion <NUM> of the coupler <NUM> may be coupled with the base <NUM> of the chassis <NUM>. When assembled, the axis 80A defined by the coupler <NUM> may align with the axis 80B defined by the chassis <NUM>. The axes 80A, 80B may align with the clutch axis <NUM> when assembled with the thumb <NUM>. The distal end of the portion <NUM> that includes the opening <NUM> may be located with the opening <NUM> defined by the base <NUM> of the chassis <NUM>.

The openings <NUM>, <NUM> may receive therethrough a shaft 485A connected with a bevel gear <NUM>, or portions thereof. The bevel gear <NUM> may have a series of bevel teeth on a first end with an elongated structural element extending therefrom, such as the shaft 485A. The shaft 485A of the bevel gear may extend through the opening <NUM> of the chassis <NUM> and the opening <NUM> of the coupler <NUM> to couple the components together. A nut <NUM> may rotatably attach to an end of the shaft 485A. In some embodiments, there may be a clutch assembly <NUM>, as further described, which may be secured together by the nut <NUM>. The clutch assembly <NUM> may prevent rotation of various parts about the clutch axis <NUM>, as further described.

When the coupler <NUM> is assembled with the chassis <NUM>, the distal end of portion <NUM> of the coupler <NUM> may be rotationally fixed about the clutch axis <NUM> relative to the chassis <NUM>. The clutch assembly <NUM> may provide a compressive force that creates rotational resistance, as further described, at the connection between the coupler <NUM> and the chassis <NUM>. In some embodiments, structures of the chassis <NUM> and/or coupler <NUM> may be positioned to prevent relative rotation therebetween. For example, a surface <NUM> of the chassis <NUM> may contact a surface <NUM> of the coupler <NUM> to prevent rotation. As further example, the ears <NUM> and/or <NUM> of the chassis <NUM> may prevent rotation of the distal end of the coupler <NUM>. In some embodiments, the relative positioning and orientation of the axes 50A, 80A may prevent rotation of the coupler <NUM> about the clutch axis <NUM>.

As shown in <FIG>, the thumb <NUM> may include the clutch assembly <NUM>. The clutch assembly <NUM> may be located adjacent the chassis <NUM>, for example in between the body <NUM> and the nut <NUM> attached to the bevel gear <NUM>. As shown in <FIG>, the clutch assembly may include a friction plate bushing <NUM>, a clutch brake plate <NUM>, a friction plate <NUM>, and/or one or more compression springs <NUM>, shown here as Belleville washers. These components may be located in between the base <NUM> of the chassis <NUM> and the nut <NUM>.

In some embodiments, the clutch assembly <NUM> may include the compression springs <NUM> to provide axially outward forces to create frictional rotational resistance of the bevel gear <NUM>. For example, the compression spring <NUM> may be a Belleville washer or similar type structure. There may be multiple springs <NUM> stacked one on top of another. There may be one, two, three, four, five, six or more springs <NUM>. The clutch assembly <NUM> may be designed such that the springs <NUM> and friction plate <NUM> prevent rotation of the bevel gear <NUM> when the thumb <NUM> is operated electronically, for example powered by an actuator. However, the friction may be overcome, and thus the bevel gear <NUM> rotated, manually. For example, the upper assembly <NUM> may be grasped by the user's other sound hand and rotated to overcome the friction in the clutch assembly <NUM>. The nut <NUM> may be tightened accordingly to apply a desired compressive force on the spring <NUM> such that a desired frictional rotational resistance is provided to the bevel gear <NUM>. The rotational resistance of the bevel gear <NUM> may prevent it from rotating about the clutch axis <NUM>. Thus, when a corresponding bevel gear acts on the bevel gear <NUM>, as further described herein, the bevel gear <NUM> and the structures to which it is fixedly attached, such as the coupler <NUM> and the chassis <NUM>, may move to cause the rotation of the upper assembly <NUM> about the lateral axis <NUM>.

The coupler <NUM> may further include a bushing <NUM>. The bushing <NUM> may be located within the opening <NUM>. The opening <NUM> may be in the mount attachment portion <NUM> that attaches rotatably to the lower assembly <NUM>.

The coupler <NUM> at a proximal end thereof may be rotatably coupled with the lower assembly <NUM>. The opening <NUM> of the mount attachment portion <NUM> of the coupler <NUM> may be rotatably coupled on the shaft <NUM> of the mount <NUM> of the lower assembly <NUM>. The local axis 50A defined by the coupler <NUM> may align with the lateral axis <NUM> defined by the lower assembly <NUM> when assembled together. The proximal end of the coupler <NUM> may therefore rotate relative to the mount <NUM> about the lateral axis <NUM> on the shaft <NUM>. The proximal end of the mount attachment portion <NUM> having the opening <NUM> may therefore be located between the second ear <NUM> and the second projection <NUM> of the mount <NUM>.

The rocker <NUM> at a proximal end thereof may be rotatably coupled with the lower assembly <NUM>. The mount attachment portion <NUM> of the rocker <NUM> may be rotatably coupled with the mount <NUM>. The local axis 60A defined by the rocker <NUM> may be aligned with the rocker axis <NUM> of the mount <NUM> when assembled together. The openings <NUM>, <NUM> of the rocker <NUM> may receive therethrough the shaft <NUM> of the lower assembly <NUM>. Therefore, the rocker <NUM> may rotate about the rocker axis <NUM> on the shaft <NUM>. When assembled together, the first and second ears <NUM>, <NUM> of the rocker <NUM> may be located in between the first ear <NUM> and the second projection <NUM> of the mount <NUM>.

The middle assembly <NUM> may include a sensing element <NUM>. The sensing element <NUM> may be a magnet. The element <NUM> may be located within an opening <NUM> at the proximal end of the coupler <NUM>. The opening <NUM> may be in the mount attachment portion <NUM> of the coupler <NUM>. The opening <NUM> may receive the element <NUM> therein. In some embodiments, the element <NUM> is a magnet that interacts with the sensor <NUM> of the lower assembly <NUM>, for example a Hall Effect sensor assembly. The element <NUM> and the sensor <NUM> may provide data related to the position of the coupler <NUM> relative to the mount <NUM>. The data related to the relative position between the coupler <NUM> and the mount <NUM> may be used to control the thumb <NUM>, as further described.

As further shown in <FIG> and <FIG>, the middle assembly <NUM> may include a main shaft <NUM>. The main shaft <NUM> may be an elongated structural element configured to rotatably couple the middle assembly <NUM> with the upper assembly <NUM>, as further described. The shaft <NUM> may be received through and/or secured within the openings <NUM>, <NUM> of the swaying chassis <NUM>. The main shaft <NUM> may include a first end 489A and a second end 489B. The second end 489B may be received in and/or through the opening <NUM> and the first end 489A may be received in and/or through the opening <NUM> of the chassis <NUM>. The shaft <NUM> may extend between the first ear <NUM> and the second ear <NUM> of the chassis <NUM>. In some embodiments, the openings <NUM>, <NUM> may include a bushing <NUM> located therein.

The shaft <NUM> may have located thereon various components. As shown, the shaft may include a worm wheel <NUM>, a bushing <NUM>, a bevel gear <NUM> and a worm wheel <NUM>. The worm wheel <NUM> may be located near the first ear <NUM> and the worm wheel <NUM> may be located near the second ear <NUM>. The worm wheels <NUM>, <NUM> may be spaced apart from each other. In between the worm wheels <NUM>, <NUM> may be located the bevel gear <NUM>. In some embodiments, the bushing <NUM> is located between the worm wheel <NUM> and the bevel gear <NUM>.

The worm wheels <NUM>, <NUM> may be in mechanical communication with corresponding worm gears <NUM>, <NUM> as further described. The worm wheel <NUM> is rotationally fixed on the shaft <NUM> about the axis <NUM>. The worm wheel <NUM> may be rotationally fixed by a pin <NUM>. The pin <NUM> may extend into or through the wheel <NUM>, and into or through the first ear <NUM> of the chassis <NUM>, to prevent the wheel <NUM> from rotating about axis <NUM>. The pin <NUM> may extend into or through the opening <NUM> (shown in <FIG>) of the chassis <NUM>. The rotationally-fixed worm wheel <NUM> may interact with the worm gear <NUM> to cause a pinch rotation about the axis <NUM>, as further described.

The worm wheel <NUM> is rotatably coupled on the shaft <NUM> about the axis <NUM>. The bevel gear <NUM> is also rotatably coupled on the shaft <NUM> about the axis <NUM>. The bevel gear <NUM> is rotationally fixed with the worm wheel <NUM>. Rotation of the worm wheel <NUM> about the axis <NUM> will thus cause a corresponding rotation of the bevel gear <NUM> about the axis <NUM>. The bevel gear <NUM> may mechanically communicate with the bevel gear <NUM>. The mechanical communication between the bevel gears <NUM>, <NUM> may cause the upper assembly <NUM> to rotate about the lateral axis <NUM>, as further described.

<FIG> is a perspective view of another embodiment of a coupler 470A that may be used with the thumb <NUM>. The coupler 470A may have the same or similar features and/or functions as the coupler <NUM> described herein. In addition or alternatively to features described with respect to the coupler <NUM>, the coupler 470A in some embodiments may include, for example, more than one sensing element <NUM>. The sensing elements <NUM> may be magnets. The coupler 470A may include a first sensing element <NUM> such as a first magnet with a first polarity and a second sensing element <NUM> such as a second magnet with a second polarity opposite the first polarity. The elements <NUM> may be disposed in openings <NUM> on opposite sides of the coupler 470A. The openings <NUM> may be in the mount attachment portion <NUM> of the coupler 470A. The mount attachment portion <NUM> may protrude or extend (e.g., include additional surface area) to accommodate additional openings <NUM> and/or elements <NUM>.

The middle assembly <NUM> may include two sensing elements <NUM> which allow for the reduction of external noise during the calculation of the position of the coupler 470A relative to the mount <NUM>. One of the sensing elements <NUM> may be disposed close to the sensor <NUM> when the thumb <NUM> is rotated away from a palm of a hand. This can allow the element <NUM> to be close enough to the sensor <NUM> when the thumb <NUM> is rotated away from the palm, towards a lateral position, to overcome background and/or outside noise, e.g., from electro-magnetic compatibility (EMC) influence, such as electrostatic discharge (ESD), electromagnetic interference (EMI), or radio frequency interference (RFI), or from the earth's magnetic field, that might otherwise interfere with the sensor's <NUM> functionality. This can improve the accuracy of the estimated rotation of the thumb <NUM>.

In some embodiments, when the thumb <NUM> is rotated towards the palm there is a strong positive magnetic signal, and when the thumb <NUM> is rotated away from the palm there is a strong negative magnetic signal. The presence of a strong magnetic signal when the thumb <NUM> is in each of the aforementioned positions can reduce the effect of external noise on the sensor <NUM> and thereby increase the accuracy of calculations of the thumb's <NUM> rotation.

One or more of the sensors <NUM> and/or elements <NUM> may be disposed about various axes. The sensors <NUM> and/or elements <NUM> may be disposed about the local axis 50A of the coupler 470A and/or the rocker axis <NUM> of the rocker <NUM>, for example within the second projection <NUM> of the mount <NUM>. Sensors <NUM> and/or elements <NUM>, such as magnets, which are disposed about the local axis 50A may provide information about the rotational position of the thumb <NUM>. Sensors <NUM> and elements <NUM>, such as magnets, which are disposed about, for example, the local axis 50A can provide information about the position of the thumb <NUM> about the local axis 50A. Sensors <NUM> and elements <NUM> can be disposed about both the local axis 50A and/or the rocker axis <NUM> to provide information about the absolute position of the thumb <NUM> along both axes. In addition or alternatively, in some embodiments, the sensors <NUM> and/or elements <NUM> may be disposed about the local axis 80A of the coupler 470A.

<FIG> and <FIG> are perspective views of the upper assembly <NUM>. <FIG> is an exploded view of the upper assembly <NUM>. The upper assembly <NUM> may be described with respect to distal and proximal directions, as indicated in <FIG>. The upper assembly <NUM> may include a cover <NUM>. As shown in <FIG>, the upper assembly <NUM> or portions thereof may extend along and define a thumb longitudinal axis <NUM>. The cover <NUM> may extend along the axis <NUM>. As mentioned, the upper assembly <NUM> may be or include the digit, such as the thumb digit, that is rotated about the axes <NUM> and/or <NUM>. For example, the cover <NUM> may provide the outer structure for the digit that is rotated.

The cover <NUM> may provide a cover or housing for various components of the upper assembly <NUM>. The cover <NUM> may be a single piece or multiple pieces. As shown, the cover <NUM> may include a distal tip cover <NUM>, a lower cover <NUM>, and a actuator housing <NUM>. The distal cover <NUM> may cover a distal end of the upper assembly <NUM>. The distal tip may be fully rubber or other materials that provide high friction, better grip at all positions, and is flexible to allow large forces for gripping/pinching.

The lower cover <NUM> may be attached to the distal cover <NUM>. The actuator housing <NUM> may be attached to the lower cover <NUM>. The various components of the cover <NUM> may have a thumb shape or a general thumb shape.

The cover <NUM> may include a gearing cover <NUM>. As shown, the cover <NUM> may be part of the housing <NUM>. The housing <NUM> may include an opening <NUM> and an opening <NUM> on a proximal end thereof. The opening <NUM> may include a bushing <NUM> therein. The opening <NUM> may include a bushing <NUM> therein. The openings <NUM>, <NUM> may support ends of corresponding bushings <NUM>, <NUM>, as further described.

The cover <NUM> may include a first ear <NUM> and a second ear <NUM>. The first and second ears <NUM>, <NUM> may be located at a proximal end of the cover <NUM>. The first and second ears <NUM>, <NUM> may extend away from the cover <NUM> to define therebetween a main shaft receiving space <NUM>. The space <NUM> may receive therein the main shaft <NUM> and the various components thereon, as described in further detail for example with respect to <FIG>. The first ear <NUM> may include an opening <NUM> extending therethrough. The second ear <NUM> may include an opening <NUM> extending therethrough. The main shaft <NUM> may be supported by the first and second ears <NUM>, <NUM>. The first end 489A of the shaft <NUM> may be supported within the opening <NUM> of the second ear <NUM>. The second end 489B of the shaft <NUM> may be supported by the opening <NUM> of the first ear <NUM>.

The openings <NUM>, <NUM> may be aligned with each other and define a local axis 90A. The axis 90A may align with the main shaft <NUM> when the shaft <NUM> is located within the receiving space <NUM>. The axis 90a may align with the pinch axis <NUM> when assembled with the middle assembly <NUM>. The upper assembly <NUM> may rotate about the pinch axis <NUM>.

As shown in <FIG>, the upper assembly <NUM> may include one or more actuator wires <NUM>. As shown, the actuator wires <NUM> may extend away from a proximal end of the upper assembly <NUM>. The actuator wires <NUM> may be connected to a processor, for example via the actuator cable circuit board <NUM>.

As shown in <FIG>, the upper assembly <NUM> may include a first worm gear <NUM>. The upper assembly <NUM> may include a second worm gear <NUM>. The worm gears <NUM>, <NUM> may be rotated by one or more actuators <NUM>, <NUM>, as further described. The worm gears <NUM>, <NUM> may be located adjacent the receiving space <NUM>. The gears <NUM>, <NUM> may mechanically communicate respectively with the worm wheels <NUM>, <NUM> of the middle assembly <NUM>. Mechanical communication of the worm gears <NUM>, <NUM> with the worm wheels <NUM>, <NUM> may cause the upper assembly <NUM> to rotate about the pinch axis <NUM> and/or the lateral axis <NUM>, as further described.

The upper assembly may include a first actuator <NUM>. The upper assembly <NUM> may include a second actuator <NUM>. In some embodiments, the upper assembly <NUM> may include only one of the actuators. In some embodiments, the upper assembly <NUM> may include more than two actuators. As shown, the first actuator <NUM> may be in mechanical communication with the first worm gear <NUM>. The first actuator <NUM> may actuate, for example rotate, the first worm gear <NUM>. In some embodiments, the upper assembly <NUM> may include a first actuator bushing <NUM>. The actuator bushing <NUM> may be attached to a proximal end of the first actuator <NUM> and/or a distal end of the first worm gear <NUM>. A proximal end of the first worm gear <NUM> may be coupled with a bushing <NUM> which may be secured with the opening <NUM> of the cover <NUM>.

The upper assembly may include the second actuator <NUM>. The second actuator <NUM> may be in mechanical communication with a second worm gear <NUM>. The second actuator <NUM> may actuate, for example rotate, the second worm gear <NUM>. In some embodiments, the second actuator <NUM> may be coupled with a second actuator bushing <NUM>. The second actuator bushing <NUM> may be located at a proximal end of the second actuator <NUM>. A proximal end of the second worm gear <NUM> may be coupled with a bushing <NUM>. The bushing <NUM> may be may be secured with the opening <NUM> of the cover <NUM>.

The first and/or second actuator <NUM>, <NUM> may extend along or parallel to the longitudinal axis <NUM>. As shown, the actuators <NUM>, <NUM> are located adjacent to each other within the cover <NUM> and extend along the longitudinal axis <NUM>. The first and second worm gears <NUM>, <NUM> are located at a proximal end of the upper assembly <NUM>. The actuators <NUM>, <NUM> actuate the respective worm gears <NUM>, <NUM> to cause rotation of the upper assembly <NUM> about the axis pinch <NUM>, as further described.

The upper assembly <NUM> may include the gearing cover <NUM> located above the first and second worm gears <NUM>, <NUM>. In some embodiments, the upper assembly <NUM> may include one or more pins <NUM>. In some embodiments, the upper assembly <NUM> may include a screw <NUM> and a screw <NUM>. The screws <NUM>, <NUM> may attach to various components of the upper assembly <NUM>. In some embodiments, other suitable attachments besides fasteners may be used, for example adhesives, ties, or other suitable means.

The upper assembly <NUM> may rotate about a first axis and/or a second axis. The upper assembly <NUM> may rotate simultaneously about the first axis and the second axis. The upper assembly <NUM> may rotate about only the first axis or only about the second axis.

In some embodiments, rotation of the upper assembly <NUM> about the first and second axes may mimic rotation of a human sound thumb by performing rotations about axes where the axes are moving relative to a fixed reference frame, such as the mount <NUM>. The first axis may be the pinch axis <NUM>, for example as shown in <FIG>. The second axis may be the lateral axis <NUM>, for example as shown in <FIG> and <FIG>. The upper assembly <NUM> may rotate simultaneously about the axes <NUM>, <NUM> to mimic movement of a sound thumb. Rotation of the upper assembly <NUM> about the lateral axis <NUM> may result in a sweeping motion of the upper assembly <NUM> about the lateral axis <NUM>. This sweeping motion of the upper assembly <NUM> may resemble an arc. The sweeping motion may cause the upper assembly <NUM> to effectively rotate about a local longitudinal axis extending along the digit due to the separation of the lateral axis <NUM> from the rotating digit.

The upper assembly <NUM> may rotate about the various axes by actuating the first actuator <NUM> and/or the second actuator <NUM>. Rotation of the first worm gear <NUM> by the first actuator <NUM> may cause the upper assembly <NUM> to rotate about the pinch axis <NUM>. Rotation of the second worm gear <NUM> by actuation of the second actuator <NUM> may, depending on the speed of rotation, allow for rotation about only the pinch axis <NUM> or cause rotation of the upper assembly <NUM> about the lateral axis <NUM>. In some embodiments, only one of the actuators <NUM>, <NUM> may be actuated at a time. In some embodiments, both of the actuators <NUM>, <NUM> may be actuated at a time. In some embodiments, the first and second actuators <NUM>, <NUM> may be actuated simultaneously. Actuation of the first actuator <NUM> may contribute to rotation of the upper assembly <NUM> about the pinch axis, while actuation of the second actuator <NUM> may contribute to rotation of the upper assembly <NUM> about both the pinch axis <NUM> and the lateral axis <NUM>.

Rotation of the upper assembly <NUM> about the pinch axis <NUM> may be due to mechanical communication between the rotating worm gear <NUM> and the worm wheel <NUM>. That is, rotation of the first worm gear <NUM> may cause interaction with the worm wheel <NUM>. Interaction of the gear teeth of the first worm gear <NUM> with the complementary projections of the worm wheel <NUM> will cause the gear <NUM> to advance along the outer circumference of the wheel <NUM>. Advancement of the gear <NUM> along the wheel <NUM> will cause the upper assembly <NUM> to rotate in an open or closed direction about the pinch axis <NUM>, depending on the direction of rotation of the worm gear <NUM>. By "open" it is meant that the upper assembly <NUM> moves in a direction associated with opening a grip. For example, the upper assembly <NUM> may open by rotating away from a palm of the hand <NUM>. By "closed" it is meant that the upper assembly <NUM> moves in a direction associated with closing a grip. For example, the upper assembly <NUM> may close by rotating away toward a palm of the hand <NUM>.

Further, the pinch axis <NUM> may change orientation relative to a fixed reference frame, such as the mount <NUM>, which may be fixed to the hand <NUM> or other component and may be considered an example of a fixed reference frame for purposes of description of the moving axes. The pinch axis <NUM> may change orientation due to lateral rotation of the upper assembly <NUM> about the lateral axis <NUM>. The pinch axis <NUM> may rotate about the lateral axis <NUM> during lateral rotation. The pinch axis <NUM> may make a sweeping motion while rotating, as described with respect to lateral rotation of the digit, for example due to separation between the pinch axis <NUM> and the lateral axis <NUM>. Thus, when the upper assembly <NUM> is later rotated about the pinch axis <NUM> after rotating about lateral axis <NUM>, the orientation of the pinch axis <NUM> relative to the mount <NUM> may have changed. For example, the pinch axis <NUM> may move relative to the mount <NUM> as the upper assembly <NUM> rotates. The pinch axis <NUM> may move to change angles and/or planes.

As the upper assembly <NUM> rotates about the pinch axis <NUM>, the second worm gear <NUM> will also rotate with the upper assembly <NUM> about the axis <NUM>. The second worm gear <NUM> may have a series of teeth that interact with a series of projections on the worm wheel <NUM>. Because the worm wheel <NUM> is rotationally fixed with the bevel gear <NUM>, the bevel gear <NUM> will also rotate about the pinch axis <NUM> and thereby act against the bevel gear <NUM>, which causes lateral rotation, as further described. Therefore, appropriate rotation of the bevel gear <NUM> during pinch axis rotation will allow for rotation of the upper assembly <NUM> about the pinch axis. For example, the bevel gear <NUM> may be rotated by the second actuator <NUM> at a particular speed and direction in order to allow for the first actuator <NUM> to cause the desired pinch rotation. The bevel gear <NUM> may be rotated at a corresponding speed and direction to move the teeth of gear <NUM> between the teeth of gear <NUM> in order to not transmit forces to the gear <NUM> sufficient to induce lateral rotation of the upper assembly <NUM> about the lateral axis <NUM>. In this way, the upper assembly <NUM> may rotate only about the pinch axis <NUM>. The corresponding speed of rotation of the bevel gear <NUM> to only allow for pinch axis rotation will depend on the particular geometry of the bevel gear <NUM> and bevel gear <NUM>, such that the teeth of each gear <NUM>, <NUM> will not interact in a manner to cause lateral rotation. If lateral rotation about the lateral axis <NUM> while rotating about the pinch axis <NUM> is desired, the bevel gear <NUM> may be rotated at a different speed, as further described.

Rotation of the upper assembly <NUM> about the lateral axis <NUM> may be due to mechanical communication between the rotating worm gear <NUM> and the worm wheel <NUM>, which rotates the bevel gear <NUM>, as described. Further, the clutch axis <NUM> may align with the axes 80A and 80B as shown respectively in <FIG> and <FIG>. The clutch axis <NUM> may further align with the shaft 485A of the bevel gear <NUM>. As described, a shaft 485A of the bevel gear <NUM> may extend through the opening <NUM> of the coupler <NUM> and the opening <NUM> of the swaying chassis <NUM> and secure together the coupler <NUM> and chassis <NUM> with the nut <NUM> and clutch assembly <NUM>. The bevel gear <NUM> may thus be rotationally connected about the clutch axis <NUM> due to the clutch assembly <NUM> with a certain amount of rotational resistance.

The mechanical communication of the bevel gear <NUM> with the bevel gear <NUM> may cause relative rotation between the swaying chassis <NUM> and the mount <NUM>. This relative rotation may be about the lateral axis <NUM>. The bevel gear <NUM> may be rotationally fixed due to the clutch assembly <NUM> such that the interaction of teeth of the bevel gear <NUM> with teeth of the bevel gear <NUM> will apply a lateral force to the bevel gear <NUM> and thus the distal end of the coupler <NUM> and chassis <NUM>, to cause the chassis <NUM> to move, for example sway. This lateral movement of the chassis <NUM> will cause movement of the coupler <NUM> and rocker <NUM>. The proximal end of the coupler <NUM> will rotate about the axis <NUM> relative to the mount <NUM>, the proximal end of the rocker <NUM> will rotate about the axis <NUM> relative to the mount <NUM>, and the distal end of the rocker <NUM> will rotate about the axis <NUM> relative to the chassis <NUM>. This movement will cause the upper assembly <NUM>, which is coupled with the chassis <NUM>, to rotate about the lateral axis <NUM> relative to the mount <NUM>. Thus, the upper assembly <NUM> may perform a sweeping motion, as described, as the upper assembly <NUM> moves due to separation of the upper assembly <NUM> and the lateral axis <NUM>.

Further, as the chassis <NUM> rotates, the orientation of the clutch axis <NUM> may change as well, for example with respect to the mount <NUM>. For example, the clutch axis <NUM> may move relative to the mount <NUM> as the upper assembly <NUM> rotates. The clutch axis <NUM> may move to change angles and/or planes. Because the chassis <NUM> will be moving relative to the mount <NUM>, the clutch axis <NUM> will also be moving relative to the mount <NUM>.

Simultaneous rotation of the upper assembly <NUM> about the pinch axis <NUM> and lateral axis <NUM> may be due to mechanical communication between the rotating worm gears <NUM>, <NUM> and the respective worm wheels <NUM>, <NUM>. The interactions may be as described above individually for pinch and lateral rotation, but with the worm gear <NUM> rotating the worm wheel <NUM> (and thus bevel gear <NUM>) at an appropriate speed. For example, the bevel gear <NUM> may be rotated at a sufficiently slow or fast speed to cause the lateral forces described above to be imparted on the bevel gear <NUM> to cause the movement of the chassis <NUM> and the rotation about the lateral axis <NUM>. The desired direction of lateral rotation can be controlled by the direction of rotation of the bevel gear <NUM>.

The various devices and systems discussed herein may be embodied in software and/or hardware in a number of configurations. <FIG> is a block diagram of an embodiment of a thumb <NUM>. The thumb <NUM> may have the same or similar features and/or functionalities as the thumb <NUM>, and vice versa. In some embodiments, some or all of the components of the thumb <NUM> are shared with the hand <NUM>.

The thumb <NUM> has a set of components including a processor <NUM> in electrical communication with a sensor <NUM>, a working memory <NUM>, a memory storage <NUM>, first and second actuators <NUM>, <NUM>, a communications subsystem <NUM>, and a module memory <NUM>. The components may be in communication via wired or wireless connections.

In some embodiments, the sensor <NUM> may be the sensor <NUM>, such as a Hall Effect sensor. The first actuator <NUM> may be the actuator <NUM>. The second actuator <NUM> may be the actuator <NUM>. The processor <NUM> may be part of the board <NUM> or <NUM>. The processor <NUM> may be separate from the thumb <NUM> and be located on the hand <NUM>. The processor <NUM> may be a general purpose processing unit or a processor specially designed for prosthetic applications. A general purpose processor can be a microprocessor, but in the alternative, the processor can be any conventional processor, controller, microcontroller, or state machine. The working memory <NUM> may be used by the processor <NUM> to store a working set of processor instructions contained in the modules of memory <NUM>. Alternatively, working memory <NUM> may also be used by the processor <NUM> to store dynamic data created during the operation of the thumb <NUM>.

In some embodiments, the processor <NUM> is configured by the several modules stored in the memory <NUM>. The modules in memory <NUM> may be software, such as programs or applications. A plurality of modules may be in the thumb <NUM>. These modules include instructions that configure the processor <NUM> to perform various control or other type tasks. In the embodiment shown, the memory <NUM> stores module one <NUM>, module two <NUM>, etc. to module "N" <NUM>. The modules may be related to, for example, processing data from the sensor <NUM>, detection of current orientation of the thumb <NUM>, determination of how to achieve a desired orientation with the thumb <NUM>, commanding the thumb <NUM> for example the actuators <NUM>, <NUM> to perform a rotation or movement, tracking movement of the thumb <NUM>, etc. Further example methods of operation of the modules are further described herein, for example with respect to <FIG>.

The memory <NUM> may include an operating system module, such as module one <NUM>, that configures the processor <NUM> to manage the memory and processing resources of the thumb <NUM>. For example, the operating system module may include device drivers to manage hardware resources such as the sensor <NUM>, actuators <NUM>, <NUM>, or storage <NUM>. Instructions contained in the modules of memory <NUM> may thus not interact with these hardware resources directly, but instead interact through standard subroutines or APIs located in an operating system component. Instructions within the operating system may then interact directly with these hardware components.

In some embodiments, the operating system and/or other modules or components of the thumb <NUM> are on a separate device, such as a mobile device or remote processor. For example, the operating system may be a remote operating system of a remote device that is in communication with the thumb <NUM> via the communications subsystem <NUM>. The mobile operating system may be on a mobile device, such as a smartphone, and may be Google's Android, Apple's iOS, Symbian, Blackberry Ltd's BlackBerry <NUM>, Samsung's Bada, Microsoft's Windows Phone, Hewlett-Packard's webOS, embedded Linux distributions such as Maemo and MeeGo, Mozilla's Firefox OS, Canonical Ltd. 's Ubuntu Phone, Tizen, or others. The remote device can receive multiple operating system module updates over its lifetime.

The processor <NUM> may write data to the storage <NUM>. While the storage <NUM> may be a traditional disk device, it may also be a disk based storage device or one of several other type storage mediums to include a memory disk, USB drive, flash drive, remotely connected storage medium, virtual disk driver, or the like.

<FIG> depicts the thumb <NUM> comprising separate components to include a processor, imaging sensor, and memory, however these separate components may be combined in a variety of ways to achieve particular design objectives. For example, in an alternative embodiment, the memory components may be combined with processor components to save cost and improve performance. Further the memory components may be combined with each other.

<FIG> is a flow chart showing an embodiment of a method <NUM> of rotating a powered prosthetic thumb. The method <NUM> may be performed by the thumb <NUM> or <NUM>. Other rotations and movements may also be performed besides those described in the method <NUM>. For example, the thumb may include other joints along the digit that rotate as well.

The method <NUM> begins with block <NUM> wherein a thumb command is received. The thumb command may be a command to perform a particular rotation or form a desired orientation or grip. The command may include instructions to perform a pinch rotation of the upper assembly <NUM> about the pinch axis <NUM> and/or a lateral rotation about the lateral axis <NUM>. Block <NUM> may include the thumb <NUM> receiving a command via the board <NUM>, or the thumb <NUM> may receive a command via the communications subsystem <NUM>. The command may be manually communicated from a user or automatically generated in response to detecting certain preconditions that trigger automatic movement. The command may be generated via gesture control or other techniques, for example techniques as described in <CIT>. The processor <NUM> may receive the command and query one or more modules of memory <NUM> and/or memories <NUM>, <NUM>.

The method <NUM> next moves to block <NUM> wherein the thumb orientation is determined. The orientation of the thumb <NUM> or <NUM> or portions thereof may be determined. The orientation may be determined using the sensors <NUM> and element <NUM>, such as a Hall Effect sensor and a magnet as described. The sensor <NUM> may be used. Data from the sensors may be communicated and/or processed by the processor <NUM> or the board <NUM>, <NUM>. The data may be analyzed by running one or more of the modules in memory <NUM> or with memories <NUM>, <NUM>. The orientation may be used to determine which movements of the upper assembly <NUM> are needed to achieve the desired orientation as commanded in block <NUM>.

The method <NUM> next moves to step <NUM> wherein the actuators are commanded to effect the movement of the thumb <NUM> or <NUM>. The actuators <NUM> and/or <NUM> may be commanded. The actuators <NUM> and/or <NUM> may be commanded. The actuators may be commanded to perform a rotation of the upper assembly <NUM> about the pinch axis <NUM> and/or lateral axis <NUM>. The actuators may be commanded to actuate, for example rotate, as various speeds or according to various operating profiles, such as ramp up, constant, ramp down. The actuators may be operated at desired speeds and directions to cause a desired lateral or pinch rotation, as described above.

The method <NUM> next moves to block <NUM> wherein the upper assembly <NUM> rotates about a pinch axis. The pinch axis may be the pinch axis <NUM>. The actuator <NUM> or <NUM> may be commanded, for example to rotate in a first direction. The actuators may actuate in the manners described herein. The rotation may be mechanically communicated as described herein, for example with mechanical communication between the actuator <NUM>, worm gear <NUM>, and worm wheel <NUM>.

The method <NUM> next moves to block <NUM> wherein the upper assembly <NUM> rotates about a lateral axis. The lateral axis may be the lateral axis <NUM>. The actuator <NUM> or <NUM> may be commanded, for example to rotate in a first direction. The actuators may actuate in the manners described herein. The rotation may be mechanically communicated as described herein, for example with mechanical communication between the actuator <NUM>, worm gear <NUM>, worm wheel <NUM>, and bevel gears <NUM> and <NUM>. The rotation shown and described with respect to <FIG> may be effected. In some embodiments, block <NUM> may not be performed, for example where rotation is only about the pinch axis. In some embodiments, blocks <NUM> and <NUM> are performed simultaneously, for example where the digit rotates about both axes <NUM>, <NUM> simultaneously.

The method <NUM> next moves to block <NUM> wherein the orientation of a clutch axis is adjusted. The clutch axis <NUM> may be adjusted. The clutch axis <NUM> may be adjusted due to rotation of the thumb <NUM> or <NUM>, for example the upper assembly <NUM>, about the lateral axis <NUM>, which may move the clutch axis, as described. The orientation of the clutch axis may be adjusted relative to a fixed reference frame, such as the mount <NUM>. In some embodiments, block <NUM> may not be performed, for example where rotation is only about the pinch axis and the clutch axis does not change orientation.

The method <NUM> next moves to block <NUM> wherein the orientation of a pinch axis is adjusted. The pinch axis <NUM> may be adjusted. The pinch axis may be adjusted due to rotation of the thumb <NUM> or <NUM>, for example the upper assembly <NUM>, about the lateral axis <NUM>, which may move the pinch axis, as described. The orientation of the pinch axis may be adjusted relative to a fixed reference frame, such as the mount <NUM>. In some embodiments, blocks <NUM> and <NUM> are performed simultaneously, for example where the thumb rotates about both axes <NUM>, <NUM> simultaneously.

In some embodiments, two or more of the steps of the method <NUM> may be performed simultaneously. For example, all steps of the method <NUM> may be performing at the same time. Steps <NUM>, <NUM>, <NUM>, <NUM> and <NUM> may all be performing at the same time. Other combinations of multiple steps may be performed simultaneously, as will be apparent from the description herein.

<FIG> and <FIG> are front and back views respectively of an embodiment of a partial prosthetic hand 120A having the thumb <NUM>. The hand 120A may have only four finger digits <NUM> attached to a palm <NUM>. The hand 120A may have a wrist connector <NUM> configured to attach the hand to an arm, such as a prosthetic arm, or to a corresponding connector on a prosthetic or natural arm. The hand 120A may be configured to have a thumb attached to it. The thumb <NUM> may be attached to the hand 120A as shown. The lower assembly <NUM> of the thumb <NUM> may attach to the hand 120A, such as to the palm <NUM>. The thumb <NUM> may be operated on the hand 120A in conjunction with the other digits <NUM> to form desired grips or other movements. The thumb <NUM> may be attached to a variety of different hands, such as a hand that is partially prosthetic and partially natural. The thumb <NUM> may attach directly to a residual (natural) or prosthetic arm or palm, such as the arm <NUM> or palm <NUM> as shown and described with respect to <FIG> and <FIG>.

Any specific order or hierarchy of steps or blocks in any disclosed process is an example of a sample approach. Based upon design preferences, it is understood that the specific order or hierarchy of steps or blocks in the processes can be rearranged while remaining within the scope of the present disclosure. Any accompanying that claims present elements of the various steps or blocks in a sample order are not meant to be limited to the specific order or hierarchy presented.

A person/one having ordinary skill in the art would appreciate that any of the various illustrative logical blocks, modules, controllers, means, circuits, and algorithm steps or blocks described in connection with the aspects disclosed herein can be implemented as electronic hardware (e.g., a digital implementation, an analog implementation, or a combination of the two, which can be designed using source coding or some other technique), various forms of program or design code incorporating instructions (which can be referred to herein, for convenience, as "software" or a "software module"), or combinations of both.

Certain features that are described in this specification in the context of separate implementations also can be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation also can be implemented in multiple implementations separately or in any suitable sub-combination. Moreover, although features can be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination can be directed to a sub-combination or variation of a sub-combination.

In general, terms used herein are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). If a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present.

However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to embodiments containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations.

Claim 1:
A powered prosthetic thumb, comprising:
a mount (<NUM>);
a digit rotatably coupled with the mount (<NUM>) about a first axis (<NUM>) and a second axis (<NUM>), the first axis non-parallel with the second axis; and
an actuator (<NUM>) configured to cause rotation of the digit about the first axis (<NUM>);
a second actuator (<NUM>) configured to cause the digit to rotate about the second axis (<NUM>);
a first bevel gear (<NUM>) and a second bevel gear (<NUM>) in mechanical communication with the first bevel gear;
wherein an orientation of the first axis (<NUM>) relative to the mount (<NUM>) changes as the digit rotates about the second axis (<NUM>), and
wherein the second actuator (<NUM>) is configured to cause rotation of the digit about the second axis (<NUM>) by causing rotation of the first bevel gear (<NUM>).