Patent ID: 12201537

The foregoing and other features of the present development will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several embodiments in accordance with the development and are not to be considered limiting of its scope, the development will be described with additional specificity and detail through use of the accompanying drawings. In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here. It will be readily understood that the aspects of the present development, as generally described herein, and illustrated in the drawings, can be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and make part of this disclosure.

DETAILED DESCRIPTION

Although certain embodiments and examples are described herein, this disclosure extends beyond the specifically disclosed embodiments and/or uses and obvious modifications and equivalents thereof. Thus, it is intended that the scope of this disclosure should not be limited by any particular embodiments described below.

Previous methods of manufacturing a composite article (e.g., a prosthetic foot) with varying dimensions using layers of fibrous material (e.g., carbon fiber) include curing a block of a composite material and removing portion of the composite material to create shapes with varying dimensions. For example, manufacturing a footplate10shown inFIG.1would include curing a composite block having a width of a toe section and removing (e.g., cutting) portions of the block to create a heel section having a smaller width than the toe section.

Previous methods of manufacturing a composite article include placing layers of, for example, fibrous material in a linear orientation illustrated by lines12. When portions of a block of composite material is removed (e.g., cut away), some of the layers of fibrous material would be cut and be exposed at edges of a final product, as shown inFIG.1.

The exposed edges of the layers of fibrous material can, over time, lead to splinters forming at the outer edge of, for example, a prosthetic foot.FIG.2illustrates an example of splinters14at an outer edge of a prosthetic foot made as described above by cutting material to produce a footplate of varying width. The splinters14can be created by cyclic bending of a composite article at areas near where the exposed edges of the layers are present. Splinters14can result in delamination and noise in the prosthetic foot, and can be a reason for product returns.

The method of manufacturing composite articles described herein advantageously eliminate the need to remove portions of a composite material. In some implementations, a mold having a desired shape (e.g., having the shape of a limb support device100shown inFIG.3D) may be used. An example method of manufacturing composite articles is schematically illustrated inFIG.3A. Layers of, for example, fibrous material60may be placed in a mold50in a manner illustrated by lines102as shown inFIG.3B. The layer of fibrous material60may be uncured laminate. Once a curing process is applied to the layers, the layers may fill the cavity of the mold and realign in the desired shape (e.g., a shape of the mold). In some implementations, the curing process include applying heat and pressure70to the layers of fibrous material placed in the mold. The pressure (and/or heat) applied to the layers can cause the layers to fill the mold50. The heat applied can increase viscosity of the layers of fibrous material60(e.g., uncured laminate) so that the layers of fibrous material60can fill the mold. In some implementations, a curing agent may be added before or during the curing process to help with the curing of the layers of fibrous material60. The curing agent can be a thermoset matrix (e.g., resins such as epoxide, Polyurethane, unsaturated polyester, phenolic, cyanate ester, vinyl, silicones, bis-maleimide, etc.) or a thermoplastic matrix (e.g., resins such as polycarbonate, acrylic, nylon, polyethylene, polypropylene, polystyrene, polyvinyl chloride, fluoropolymers (Teflon), acetal polyoxymethylene, etc.). In the example illustration shown inFIG.3C, the layers of fibrous material60may be placed and cured in a mold in a manner illustrated by lines102. In some examples, the layers of fibrous material60may be placed in a manner such that some of the layers (e.g., layers closer to the edges of the mold) may correspond to (e.g., track or approximate) an overall shape of the mold as shown inFIG.3C, as opposed to being placed in a mold in a linear manner as illustrated by lines102inFIG.3B.

In some implementations, the amount of heat applied during curing can vary depending on a curing agent or a composite material used. For example, between about 50 degree Celsius and about 200 degree Celsius of heat may be applied during the curing process. When the amount of heat is reduced, the amount of time needed for curing may increase, and vice versa.

FIG.3Cillustrate a portion of an example limb support device100manufactured using the method schematically illustrated byFIG.3A. The limb support device100can be a prosthetic foot. In some example, the limb support device100can be a crutch. The limb support device100may be a blade of a crutch or a prosthetic footplate. As discussed above, a mold (e.g., the mold50) having a shape of the limb support device100may be used. Layers of fibrous materials (e.g., the layers of fibrous material60) may be placed in the mold and cured. In some implementations, the layers of fibrous materials may be impregnated with curing agent. During a curing process, the layers may fill the mold and realign in a desired shape/contour. In some implementations, a curing agent may be added before or during the curing process and aid the layers to fill the mold and assume a shape corresponding to (e.g., approximating) a contour of the mold. In another example, the expansion of the curing agent may cause at least one of the layers of fibrous material to realign with the contour of the mold used. Since the mold has the desired shape of the limb support device100, the limb support device100does not need to be cut into a desired shape once it is removed from the mold, other than minor sanding or smoothing process. Therefore the layers of fibrous material do not need to be cut and outer edges of the limb support device100do not include cut and exposed fibrous materials, thereby advantageously inhibiting (e.g., preventing or avoiding) delamination of the fibers.

In the example illustrated byFIG.3C, the limb support device100can include a first portion104, a second portion106, and a transition portion108. The first portion104can have a first width and the second portion106can have a second width. The second width can be different from the first width. For example, the width of the second portion106(that is, the second width) may be greater than that of the first portion104(that is, the first width). The transition portion108can be between the first portion104and the second portion106, and its outer edges can correspond to a change of the width of the limb support device100between the first portion104and the second portion106. The width of the transition portion108can taper (e.g., linearly or in a curved manner) between the second width and the first width with a contour112. For example, the width of the transition portion108can transition from the first width to the second width.FIG.3Dillustrates an example of the limb support device100manufactured using the mold50shown inFIG.3B.

When layers of fibrous material are added into a mold, the layers may be a rectangular block of uncured laminate and may not have a desired contour of the limb support device100. A laminate may include composite fibers (e.g., carbon fibers or glass fibers) and/or curing agent. In some implementations, some of the layers (e.g., ones placed substantially middle of a mold) may be placed in a linear orientation while other layers (e.g., ones placed closer to side edges of a mold) may be placed in a non-linear orientation (e.g., curved). The layers of fibrous material may extend between the first portion104and the second portion106via the transition portion108continuously without any breaks. As discussed herein, the layers may fill the mold during a curing process such that at least some of the layers of fibrous material realign to the contour of the mold. The curing process, for example, may include application of heat and pressure directly to the layers of fibrous material (e.g., uncured laminate) to allow the layers to fill the mold. As such, at least some of the fiber in the layers of fibrous material may realign to a contour of the mold.

The improved method of manufacturing composite articles (e.g., limb support device100) can advantageously reduce the manufacturing cost of composite articles such as prosthetic devices. Since the improved method eliminates the need to remove (e.g., cut away) portion of a block of composite material to achieve a desired shape of the composite material, it can reduce or eliminate the amount of waste produced during manufacturing process. In addition, the improved method of manufacturing composite articles can advantageously improve the structural integrity of the end products (e.g., crutch or prosthetic foot). Since the improved method does not involve removing a portion of a block of composite material, edges of layers of fibrous material may not be exposed and therefore reduce the likelihood of delamination or the product developing splinters over time.

The structural integrity of a composite article (e.g., the limb support device100) may further be improved by adding a protruded structure.FIGS.4A and4Cshow various views of the limb support device100(e.g., a prosthetic crutch) having a protruded structure (e.g., a fin). In the example illustrated inFIGS.4A and4C, the limb support device100may include a fin110formed on a rear surface thereof. In some implementations, the fin110may be formed on a front surface thereof. In some implementations, the fin110may be formed on both the front and the rear surface thereof. Though the limb support device100shown inFIGS.4A-4Cis a crutch, the features (e.g., the fin100) discussed in connection withFIGS.4A-4Ccan also be incorporated into other limb support devices (e.g., a prosthetic footplate).

FIG.4Bshows different cross-sections of the limb support device100. A cross-section B-B of the limb support device100includes the fin110while a cross-section A-A of the limb support device110does not include the fin110. As shown inFIG.4B, the fin110may be a generally triangular or contoured protrusion extending away from, for example, the rear surface of the limb support device100. In some embodiments, the fin110may be semi-circular, trapezoidal, semi-elliptical, rectangular, or any suitable shape to increase stiffness of the limb support device100.

In some implementations, the limb support device100can include chamfered surfaces143(seeFIGS.6A-6B) that may be positioned between a rear surface (that is, a surface that faces rearward during use of the limb support device100) or a front surface (that is, a surface that faces forward during use of the limb support device100) and the side surfaces.

In some implementations, the fin110can increase the thickness of the centerline of the limb support device100. Additionally and/or alternatively, the thickness of the outer edges of the limb support device100may be reduced when the limb support device100includes the fin110. In some implementations, the thickness of the outer edges of the limb support device100may remain the same regardless of whether the limb support device100includes the fin110.

The fin110can be added to various portions of the limb support device100. For example, as discussed herein and shown inFIGS.4A and4C, the limb support device100can be a crutch having a foot portion130, an ankle portion140, and a calf portion150. The foot portion130and the ankle portion140can have a varying width and be connected via a transition portion160with a tapering width between the width of the foot portion130and the width of the ankle portion140. The fin110can extend over at least a portion or the entirety of a portion of the limb support device100. The fin110can extend over one or more portions of the limb support device100. For example, as shown inFIG.4C, the fin110can extend over the ankle portion140and the calf portion150of the limb support device100. In another example, the fin110may extend over just the ankle portion140of the limb support device100.

In some implementations, the fin110can be localized in certain areas of the limb support device100. For example, the fin110can be localized in an area of the limb support device100where the ankle portion140connects with the calf portion150. As such the fin110may increase stiffness of the limb support device100at certain, desired locations.

FIG.5illustrates a perspective view of a calf portion of an example limb support device100. In the example illustrated inFIG.5, the calf portion of the limb support device100includes the fin110extending along the entire length of the calf portion where the fin110is a rounded-edge formed on a back side of the calf portion.

In some implementations, adding the fin110to the limb support device100(e.g., a blade of a crutch) can allow manufacturers to increase the level of stiffness for the limb support device100using the same amount of material.FIGS.6A and6Bshow example cross-sectional dimensions of the limb support device100with and without the fin110.FIG.6Ashows an example cross-sectional areas of the limb support device100with and without the fin110that are the same (that is, 351 mm2).

To determine the level of stiffness of the limb support device100with and without the fin110, a single load cantilever beam deflection formula may be used. The single load cantilever beam deflection formula is shown below:

δ=F⁢L/3⁢E⁢I

where F is the force applied on a prosthetic device at a single point, L is the length of beam (e.g., a portion of the limb support device100), δ is the amount of deflection, E is flexural modulus (or modulus of elasticity), and I is moment of inertia. By equating the amount of force applied, the material used, and the length of beam, a ratio between the amount of deflection with the fin110and without the fin110can be calculated by using the equation shown below.

ratio=Ifin⁢beam/Irectangular⁢beamwhere Ifin beamis moment of inertia of the limb support device100with the fin110and Irectangular beamis moment of inertia of the limb support device100without the fin110.

Using the example dimensions shown inFIG.6A, the ratio between the amount of deflection with the fin110and without the fin110is about 1.26, which indicates that the limb support device100with the fin110is approximately 26% stiffer than the limb support device100without the fin110.

In some implementations, adding the fin110to the limb support device100(e.g., a prosthetic foot or a crutch) can advantageously achieve the same level of stiffness for the limb support device100using less material. To achieve the same level of stiffness, the amount of deflection for the limb support device100with the fin110and the limb support device100without the fin110can be equated. Using the single load cantilever beam deflection formula described herein, the deflections of the limb support device100with the fin110and the limb support device100without the fin110can be calculated with following equations:

δfin=F⁢L/3⁢E⁢Ifin⁢δrectangular⁢beam=F⁢L/3⁢E⁢Irectangular⁢beam

When the amount of deflections are the same (that is, the same level of stiffness) between the limb support device100with fin110and the limb support device100without the fin110, the two equations above can be combined into the following.

F⁢L/3⁢E⁢Ifin=F⁢L/3⁢E⁢Irectangular⁢beam

Assuming that the amount of force applied, the material used, and the length of beam are the same between the limb support device100with fin110and the limb support device100without the fin110, the above equation becomes:

Ifin=Irectangular⁢beam

This indicates that the level of stiffness with the fin110and without the fin110is the same when the moment of inertia for the cross-sectional shapes of the limb support device100with the fin110and the limb support device100without the fin110are the same.FIG.6Bshows example cross-sectional dimensions of the limb support device100with the fin110and the limb support device100without the fin110having the same moment of inertia. Calculating the cross-sectional areas of the two, the cross-sectional area of the limb support device100with the fin110is 8% less than that of the limb support device100without the fin110. Assuming that the lengths of the limb support device100with the fin110and the limb support device100without the fin110are the same and that both are made from the same material, the limb support device100with the fin110can achieve the same level of stiffness with 8% less material used.

AlthoughFIGS.6A and6Bshow cross-sectional dimensions of the limb support device100, those dimensions are examples only. It is contemplated that different cross-sectional dimensions may be used for the limb support device100.

FIG.6Cillustrates some example configurations of the fin110for the limb support device100. As described herein and shown inFIG.6C, the fin110can have various different configurations, dimensions, or positions. In some examples, the fin110can diagonally extend along the length, or a portion of the length, of the limb support device100from a first side (e.g., medial side of the limb support device100) to a second side (e.g., lateral side of the limb support device100), or from the second side to the first side. In another example, the fin110may extend along only the first side (e.g., medial side of the limb support device100) but not the second side (e.g., lateral side of the limb support device100), or only the second side and not the first side.

Although the example calculations described herein used the fin110with substantially triangular cross-sectional shape, other cross-sectional shapes of the fin110can be used. Additionally and/or alternatively, the limb support device100may include more than one fins110(e.g., two fins, three fins) to, for example, increase its stiffness. In addition, different designs of the cross-section of the limb support device100can also change the stiffness of the prosthetic device110.

In some implementations, the fin110can include at least a portion of fibrous material within the limb support device100. This can advantageously increase stiffness of the fin110and may allow the fin110to withstand greater amount of bending or stress during use. A mold for the limb support device100can include a cavity that corresponds to the fin110. When layers of fibrous material is added and cured (e.g., heat and pressure is applied), the layers can flow into and fill the cavity to form the fin110.

In some implementations, the limb support device100can include the fin110in certain areas that can benefit from increased stiffness. For example, a portion of a prosthetic device may be reinforced by changing the cross-sectional shape, dimension, or both of the prosthetic device in that area. For example, the fins110can be positioned at areas or portions of the limb support device100where there is a change in thickness or an angled portion.

In some implementations, a customized degree of stiffness may be achieved by using customized cross-sectional shape, dimension, or both. Depending on the use of a prosthetic device (e.g., sports, leisure, or every-day use), varying level of stiffness and flexibility may be achieved using different cross-sectional shapes, dimensions, or both, and/or having, for example, the fin110at different locations.

In some implementations, the fin110may or may not extend along centerline the limb support device100. The fin110can extend along an axis that is not parallel to the centerline of the limb support device100. The fin110may extend at an angle with respect to the centerline of the limb support device100. In some examples, the angle between the fin110and the centerline of the limb support device100may vary. In another example, the fin110may extend along an axis that is parallel to and offset from the centerline of the limb support device100.

In some implementations, the height of the fin110may or may not remain constant. As such the height of the fin110may vary at certain portions or areas of the limb support device100. For example, the height of the fin110may be increased at areas (e.g., an ankle portion of a limb support device) that experience more bending or stress during use. Such configuration can advantageously increase (or decrease) the level of stiffness of the limb support device100at those areas. Additionally, such configuration can reduce the amount of wear and tear during use.

In some implementations, the base width of the fin110may or may not remain constant. As such, the base width of the fin110may vary at certain portions or areas of the limb support device100. This can advantageously increase (or decrease) the level of stiffness of the limb support device100at those areas.

In some implementations, the limb support device100can include more than one fin110. The fins110may extend along the length of the limb support device100and be centered relative to the centerline (e.g., parallel to and equidistant from the centerline) of the limb support device100. For example, the fins110may extend along axes that are parallel and offset (e.g., by equal amounts) relative to the centerline of the limb support device100(e.g., a blade portion or a foot portion of the limb support device100). In another example, the fins110may extend along axes that are parallel and offset (but by unequal amounts) relative to the centerline of the limb support device100. In another example, the fins110may extend along axes that are not parallel to the centerline of the limb support device100.

The more than one fins110can have the same size, shape, and position with respect to the centerline of a limb support device such that the increase in stiffness of a limb support device corresponding to each of the fins110is even. This can advantageously cause the limb support device to experience even bending.

In some implementations, however, it may be advantageous for the limb support device to experience a certain amount of torsion during use. In order to generate torsion of the limb support device during use, the size, shape, and/or position of the fins110can be different. For example, a first fin may be further away from the centerline of the limb support device than a second fin. As such a portion (or area) of the limb support device around the first fin may be less stiff than a portion (or area) of the limb support device around the second fin. In some examples, one of the fins110may be bigger (e.g., wider, taller, or both) than the other. In another example, one of the fins110may have a different shape (e.g., semi-oval) than the other (e.g., generally triangular). The torsion generated at least in part by the differences between the fins110can be useful in applications in which a limb support device undergoes a certain base amount of torsion during use. As such, the fins110may be used to counter the base amount of torsion to, for example, reduce the amount of shear stress applied to the limb support device. The fins110can therefore be sized, shaped and/or positioned to advantageously generate torsion forces on the limb support device (e.g., crutch or prosthetic foot) that can aid or improve the rollover of the limb support device during ambulation of the user.

The fin110may affect response (e.g., deformation) of the limb support device100when a torsional moment is applied to the limb support device100. The location of the fin110(e.g., extending only along the medial/lateral side, extending diagonally from the medial/lateral side to the lateral/medial side, and the like) can impact the trajectory and displacement of different portions of the limb support device100when the limb support device100experiences torsion (e.g., when a user of the limb support device100pivots). For example, when the fin110extends only along the medial side of the limb support device100, the medial side of the limb support device100undergoes greater deformation (e.g., bends and/or rotates) more than when the fin110extends along the centerline of the limb support device100. As such, various configuration of the fin110(or fins110) may be used to change and control how the limb support device100reacts or deforms (e.g., rotation, bending, and the like) when torque is applied to the limb support device100. For example, customized torsional response of the limb support device100can be used to guide the deformation of the limb support device100during ambulation by the user.

With reference toFIGS.7A-7N, example soles200A,200B,200C for a limb support device (e.g., the limb support device100ofFIGS.4A and4C) are described herein. The soles200A,200B,200C may be removable or fixed to the limb support device. The soles200A,200B,200C might be universal or be designed to have a left/right profiles. The soles200A,200B,200C can be made out of EVA, rubber, or other suitable materials (e.g., resilient materials, compressible materials). In some implementations, one or more materials may be used for manufacturing the soles200A,200B,200C. As discussed above, the limb support device can be, for example, a crutch. In another example, the limb support device can be a prosthetic footplate.

The soles200A,200B,200C can include distal ends202A,202B,202C and proximal ends204A,204B,204C respectively. The soles200A,200B,200C can receive a distal portion of a limb support device via the proximal ends204A,204B,204C and the limb support device can slide from the proximal ends204A,204B,204C towards the distal ends202A,202B,202C.

The soles200A,200B,200C can include a bottom portion250that provides additional support (e.g., cushioning support) for the limb support device. The bottom portion250may be compressible such that it can, for example, reduce the amount of impact force transferred to the limb support device from the ground during use. The bottom portion250can include a support surface206that is an underside of the bottom portion250. As shown inFIG.7C, the support surface206can include traction marks208A,208B or any other types of traction marks suitable for different uses (e.g., hiking, climbing, running, walking, indoor, and the like), so that the soles200A,200B,200C can provide traction to the limb support device.

The soles200A,200B,200C can include one or more features that can prevent or reduce the likelihood of a limb support device (e.g., the limb support device100shown inFIGS.4A and4C) being separated (e.g., sliding out) from the soles200A,200B,200C during use.

The bottom portion250of the soles200A,200B,200C can include side edges234and a front edge235. The side edges234can extend upwards (e.g., vertically) from medial and lateral sides of the bottom portion250. The front edge235can extend upwards (e.g., vertically) from a distal end of the bottom portion250. The front edge235can form the distal ends202A,202B,202C of the soles200A,200B,200C. During use, the side edges234can inhibit (e.g., prevent) limb support device from moving medially or laterally relative to the soles200A,200B,200C, and thus retains the limb support device positioned between the side edges234. The front edge235can inhibit (e.g., prevent) the limb support device from sliding further forward relative to the soles200A,200B,200C.

In some implementations, the soles200A,200B,200C can include a slot or recess210. The slot210can be circular (as shown in, e.g., inFIGS.7A and7B), oval, rectangular, or any other suitable shape. The slot210may engage or interact with a corresponding protrusion212of a limb support device (e.g., the limb support device100).FIGS.7L and7Millustrate an interaction between the slot210and the corresponding protrusion212.

In some implementations, the slot210can include a magnet214or any magnetic material (e.g., iron) at its bottom. Additionally and/or alternatively, the magnet214can be positioned below the bottom surface of the slot210. A limb support device (e.g., the limb support device100) can include a corresponding protrusion212that can mate with the slot210. In some examples, the corresponding protrusion212can be positioned at the back of the limb support device, either by gluing it on or by forming it integrally with a mold. The corresponding protrusion212can include a magnet or any magnetic material (e.g., iron) that, when the corresponding protrusion212is inserted within the slot210, can magnetically interact with or engage the magnet or magnetic material214of the slot210, so that a magnetic force (e.g., attractive force) between the protrusion212and the slot210at least partially couples the soles200A,200B,200C and the limb support device together. Alternatively, the prosthetic device can instead include the slot210and the soles200A,200B,200C can include the corresponding protrusion212.

The positions of the slot210and the corresponding protrusion212may be offset (e.g., along the centerline of the limb support device100) from one another such that the soles200A,200B,200C need to be pulled (e.g., stretched) towards the ankle portion of the limb support device (e.g., the ankle portion140of the limb support device100as shown inFIG.4A) in order for the protrusion212to be inserted into the slot210. As such, both the magnetic force between the magnet214and the protrusion212and mechanical interaction between the slot210and the protrusion212(e.g., caused by retracting force of the soles200A,200B,200C) can help maintain coupling between the soles200A,200B,200C and the limb support device100.

Additionally or alternatively (e.g., when the protrusion212and slot210do not have magnets or magnetic material), the interaction between the slot210and the corresponding protrusion212of the prosthetic device can generate a mechanical lock between the soles200A,200B,200C and the prosthetic device. For example, when the corresponding protrusion212is at least partially inserted within the slot210, the circumferential edge of the protrusion212can abut the inner edges of the slot210. The abutment between the circumferential edge of the protrusion212and the inner edges of the slot210can inhibit (e.g., prevent) the protrusion212from sliding out from the slot210.

The proximal ends204A,204C of the soles200A,200C can include a slit232through which an end of the limb support device (e.g., distal end of crutch, prosthetic footplate) can be extended.FIGS.7J and7Kshow the sole200C with an example slit232. The slit232can include chamfered edges243that corresponds to chamfered edges of the sides of a limb support device, for example. The slit232can be formed between the bottom portion250, a cover240, and slide edges234as shown inFIG.7K.

In some implementations, the opening associated with the slit232can be tapered.FIG.7Nshows an example cross-section of the slit232. The inner surface of the side edges234may taper so as to correspond to the tapering width of the limb support device100. For example, as shown inFIG.7N, a proximal opening of the slit232(that is, an opening further away from the front edge235) can have a first width and a distal opening (that is, an opening close to the front edge235) of the slit232can have a second width, where the second width of the slit232is greater than the first width of the slit232. For a limb support device having a foot portion (or a blade portion) wider than, for example, an ankle or a calf portion, such configuration of the slit232(e.g., tapering width) can inhibit (e.g., prevent) the foot portion (or the blade portion) from sliding out from, for example, the sole200C, through the slit232. Since the foot portion is wider than the proximal opening of the slit232, the width of the proximal opening can help secure the foot portion of the limb support device in the sole200C.

As discussed herein, the soles200A,200B,200C can include side edges234that can extend (e.g., vertically) upwards from the bottom portion250. Together with a support surface230(that is, a top surface of the bottom portion250), the side edges234can receive a foot portion of a limb support device (e.g., crutch, prosthetic footplate). While the support surface230can support the bottom of the foot portion, the side edges234can provide medial-lateral support and inhibit (e.g., prevent) lateral displacement of the limb support device within the soles200A,200B,200C. In some implementations, the side edges234can include a chamfered edge243that correspond to chamfered edges of the limb support device. For example,FIG.7Gshows the chamfered edges243of the side edges234of the sole200A abutting chamfered edges of an example limb support device. In some implementations, as shown inFIG.7G, the chamfered edge243can be located proximate to the support surface230(e.g., located between the bottom portion250and the side edges234). Additionally or alternatively, the chamfered edge243can be located opposite from the support surface230(e.g., located between the lip242and the side edge234).

Additionally, the side edges234can include lips242that can extend from the top of the side edges234towards the middle of the soles200A,200B,200C. As shown inFIG.7I, the bottom surface of the lips242can, when a limb support device is slid into the soles200A,200B,200C, and rest against a top surface of the limb support device.

The corresponding shapes (or contours) of the side edges234(e.g., including the chamfered edges243and the lips242) of the soles200A,200B,200C and chamfered edges of a limb support device can retain the limb support device within the soles200A,200B,200C between the side edges234. As such, the soles200A,200B,200C can function as a sleeve into which a prosthetic device can be slid into.

With reference toFIG.7A, in some implementations, the soles200A,200B,200C can include an opening220that can receive a button222attached to a limb support device (e.g., the limb support device100shown inFIGS.4A and4C). The opening220can be formed on a top portion (e.g., the cover240) or a bottom portion (e.g., the bottom portion250) of the soles200A,200B,200C. In the example shown inFIG.7A, the opening220is formed on the top portion of the sole200A such that the button222is attached or formed on a top surface of a limb support device. The opening220can be formed on the cover240positioned near the proximal end204A,204B,204C. In some examples, the opening220is formed on the bottom portion250of the200A,200B,200C such that the button222is attached or formed on a bottom surface (e.g., bottom or rear facing surface) of a limb support device.

The shape of the opening220can correspond to the shape of the button222such that the opening220can receive the button222. When the opening220receives the button222, the interaction (e.g., coupling) between the button222and the opening220can aid in inhibiting (e.g., preventing) the limb support device from being dislodged (e.g., slipping off) from the soles200A,200B,200C. As the limb support device with the button222is inserted into the soles200A,200B,200C, the cover240may slide over the button222. Once the limb support device is fully inserted into the soles200A,200B,200C, at least a part of the cover240may extend adjacent a proximal side (that is, side that is closer to the proximal end of the sole) of the button222. In some examples, as shown with the sole200C inFIG.7B, the cover240may extend adjacent both a proximal side and a distal side (that is, side that is closer to the distal end of the sole). In some example, the cover240may surround the entire outer surface of the button222.

The front edge235of the soles200A,200B,200C can also include the lip242. As shown in, for example,FIGS.7D and7F, the lip242can extend from the front edge235towards the proximal ends204A,204B,204C. The lip242, the front edge235, and the bottom portion250can together define a cavity236. The cavity236can be dimensioned to receive a front end of a limb support device (e.g., the limb support device100as shown inFIG.4A). The lip242and the front edge235can form the chamfered edge243. The chamfered edge243can, as described herein, help with retaining the front edge of a limb support device (e.g., the limb support device100shown inFIGS.4A and4C). The lip242can include an engagement surface252that can (e.g., when a limb support device is inserted into the sole200A,200B,200C) engage a top surface of the limb support device. As shown in, for example, inFIG.7G, the engagement surface252of the lip242can be positioned opposite of the bottom portion250and engage (e.g., rest against or abut) the top surface of the limb support device during use.

In some implementations, as shown inFIG.7H, the side edges234and/or the front edge235may not include the lip242.

With reference toFIGS.8A-9B, an example sole system300for a limb support device and its various features are described herein. The sole system300can include an intermediate piece304and a sole body302. The sole body302includes a support surface308that can be dimensioned to receive the intermediate piece304. The intermediate piece304can include a support surface310that can be dimensioned to receive at least a portion of a limb support device, such as the limb support device100.

The removable sole300can include a clamp306that can attach the intermediate device304to the limb support device100. The clamp306can include arms316that can wrap around both the intermediate device304and the limb support device100. The arms316can include openings314that can receive a screw that can be tightened bring the arms316towards each other, thereby securing the limb support device100to the intermediate piece304, or vice versa. Other methods may be used to bring and/or retain the arms316towards each other.

As shown inFIGS.8A-8D, the clamp306may wrap around both the intermediate piece304and the limb support device100at a portion where both the intermediate piece304and the limb support device100tapers (e.g., the width decreases). In some implementations, at least a portion of the arms316may be angled to accommodate the tapering width of both the intermediate piece304and the limb support device100. Such feature of the clamp306(e.g., angled arms316) can prevent, for example, a foot portion, of the limb support device100(that is a portion of the limb support device100below the clamp306) from sliding up towards the clamp306and dislodged from the intermediate piece304.

FIG.8Eshows the sole body302, the intermediate piece304, and the limb support device100detached from each other.FIGS.8F-8Hshow cross-section views of the sole body302, the intermediate piece304, and the limb support device100. The limb support device100can include a blade portion (or a foot portion) that includes side surface170, a top surface180, and a bottom surface190. In some implementations, the limb support device100can include chamfered portion between the side surfaces170and the bottom surface190.

As shown inFIG.8G, the intermediate portion304can include a first chamfered surface343that corresponds to the chamfered portion143of the limb support device100. The chamfered surface343can be disposed between side edges and the support surface310. The chamfered surface343can be dimensioned to abut the chamfered portion143of the limb support device100to prevent or reduce the likelihood of the limb support device100slipping out of the intermediate portion304. In some implementations, the intermediate portion304can include a second chamfered surface380.

The intermediate portion304can be coupled to the sole body302. In some example, the intermediate portion304may be adhered to the sole body302using adhesives. In another example, the intermediate portion304may be coupled to the sole body302using various types of fastening mechanisms including, but not limited to, press fit connection, screws, nuts and bolts, clasps, pins, rivets, snap-fit connection, and the like. In some implementations, the intermediate portion304may be permanently or removably coupled to the sole body302.

The sole body302can include side edges320and the support surface308. In some implementations, the sole body302can include chamfered surface382that can correspond to the second chamfered surface380of the intermediate portion304.

With reference toFIGS.10A-10C, an example intermediate support piece400for coupling with a limb support device (for example, the limb support device100, for example, shown inFIGS.4A and4C) and its various features are described herein. The intermediate support piece400may be a stiff piece placed between a sole (e.g., the sole body302shown inFIG.8D) and a limb support device (e.g., a foot portion of the prosthetic leg or a prosthetic crutch). The intermediate support piece400may be fixedly attached to the sole and may include a support surface402and a recess410formed on the support surface402. The intermediate support piece400may be permanently or removably coupled to the sole. The intermediate support piece400may be coupled to the sole body302using various types of fastening mechanisms including, but not limited to, adhesive(s), press fit connection, screws, nuts and bolts, clasps, pins, rivets, snap-fit connection, and the like.

The support surface402may receive a limb support device (e.g., a foot portion of the prosthetic leg or a prosthetic crutch). The recess410can mate with a corresponding protrusion of the limb support device (e.g., on a rear or bottom surface of the limb support device) to further assist in coupling the intermediate support piece400to the limb support device. In some implementations, the coupling between the recess410and the corresponding protrusion of the limb support device can be mechanical. Additionally and/or alternatively, the coupling between the recess410and the corresponding protrusion of the limb support device can be magnetic.

The intermediate support piece400can include a cover442and a slot436. The slot436can be formed below the cover442that is positioned about a distal end of the intermediate support device400. The slot436may be dimensioned to receive a toe portion of a limb support device (e.g., a prosthetic foot). Once the toe portion of the limb support device is inserted into the slot436, the cover442can prevent the limb support device from being dislodged from the intermediate support piece400in a direction substantially orthogonal with respect to the body of the intermediate support piece400.

In some implementations, the intermediate support device400can include knobs460. The knobs460can extend laterally from side edges of the intermediate support device400. During use, an elastic member480(e.g., a rubber O-ring or band) can be looped over the knobs460such that a limb support device (e.g., the limb support device100shown inFIG.4A) is positioned between the elastic member480and the intermediate support device400. The elastic member480can provide additional support that keeps the limb support device and the intermediate support device400coupled together.

Prosthetic Device

A fin, as described herein, can be implemented in a prosthetic device to improve the stiffness to weight ratio of the prosthetic device. In this way, a prosthetic device with a fin can achieve an increased stiffness and/or a reduced mass, as compared to a similar prosthetic device without a fin. Furthermore, the prosthetic device with the fin can retain energy storage capabilities (e.g., when a portion of the prosthetic foot is flexed under load) and can also retain energy return capabilities (e.g., when the prosthetic foot moves back from a flexed position responsive to a release of the applied load). The following disclosure describes non-limiting examples of a prosthetic foot or a component thereof, any of which may be manufactured using any combination of the methods described above.

FIG.11Aillustrates a cross-sectional view of an example prosthetic foot1110that does not include a fin. As shown, the prosthetic foot1110has a rectangular cross section with a width of 43 mm and a thickness of 6.5 mm, and the cross-sectional area of the prosthetic foot1110is 279 mm2. Furthermore, the moment of inertia about the horizontal x-axis (Ix_Figure11A) is approximately 984 mm4, and the moment of inertia about the vertical y-axis (Iy_Figure11A) is approximately 43,066 mm4. To calculate the moment of inertia, the following relationship can be used:

Ix=b⁢h31⁢2(Equation⁢1)Iy=h⁢b31⁢2(Equation⁢2)
where b is the length of the base (this this example, 43 mm), and h is the height (in this example, 6.5 mm).

FIG.11Billustrates a cross-sectional view of a prosthetic foot1120with a fin1122. As shown, the prosthetic foot1120has a width of 43 mm and a varying thickness along the width. In particular, the cross section of the prosthetic foot1120has a thickness of 6.5 mm at the edges and increases in thickness at the fin1122. For instance, in this example, the fin1122has a length (L1) of 25 mm and a center height (H1) of 3 mm. Furthermore, in this example, the cross-sectional area of the prosthetic foot1120is approximately 330 mm2. Furthermore, the moment of inertia about the horizontal x-axis (Ix_Figure11B) is approximately 1,870 mm4, and the moment of inertia about the vertical y-axis (Iy_Figure11B) is approximately 44,770 mm4.

Consider a scenario in which a portion of each of the prosthetic feet1110,1120is supported from a single end. In such a scenario, the maximum deflection at an opposite end of the portion of the prosthetic feet1110,1120can be expressed using the single load cantilever beam deflection formula shown below:

δ=FL33⁢EI(Equation⁢3)
where L is the length of the portion of the prosthetic foot, δ is the deflection of the portion of the prosthetic foot, F is the force applied on the opposite end, E is flexural modulus (or modulus of elasticity), and I is moment of inertia of the portion of the prosthetic foot.

Assuming that the prosthetic devices1110,1120are made from the same material, that the portions are the same length, and that the same amount of force applied, then a ratio between the moment of inertia of the prosthetic device1110and the moment of inertia of the prosthetic device1120can be used to determine a comparison of the stiffness of the prosthetic devices1110,1120. Accordingly, in this example, the ratio

(IFig.11AIFig.11B=9⁢8⁢41⁢8⁢7⁢0=0.53)
indicates that the prosthetic device1120(with the fin1122) is about 53% stiffer than the prosthetic device1110(without a fin) for the same mass. Furthermore, the ratio of areas

(AreaFIG.11BAreaFIG.11A=3⁢3⁢02⁢7⁢9≈1.18)
indicates that the prosthetic device1120(with the fin1132) allows for 53% increase in stiffness with only an 18% mass increase, as compared to the prosthetic device1110.

The results of the foregoing stiffness comparison can be confirmed by deflection measurements (e.g., calculated by Equation 3). In particular, the deflection of the prosthetic device1110is 13 mm, while the deflection of the prosthetic device1120is 7 mm. A ratio of the deflections (7 mm/13 mm) also indicates that the prosthetic device1120is about 53% stiffer than the prosthetic device1110.

FIG.11Cillustrates a cross-sectional view of a prosthetic foot1130with a fin1132. As shown, the prosthetic foot1130has a width of 43 mm and a varying thickness along the width. In particular, the cross section of the prosthetic foot1130has a thickness of 4.9 mm at the edges and increases in thickness at the fin1132. For instance, in this example, the fin1132has a length (L2) of 25 mm and a center height (H2) of 3 mm. Furthermore, in this example, the cross-sectional area of the prosthetic foot1120is approximately 261 mm2. Furthermore, the moment of inertia about the horizontal x-axis (Ix_Figure11C) is approximately 991 mm4.

Consider a scenario in which a portion of each of the prosthetic feet1110,1130is supported from a single end. In such a scenario, the maximum deflection at an opposite end of the portion of the prosthetic feet1110,1120can be expressed using Equation 3 above.

Assuming that the prosthetic devices1110,1130are made from the same material, that the portions are the same length, and that the same amount of force applied, then a ratio between the moment of inertia of the prosthetic device1110and the moment of inertia of the prosthetic device1130can be used to determine a comparison of the stiffness of the prosthetic devices1110,1130. Accordingly, in this example, the ratio

(IFIG.11AIFIG.11C=9⁢8⁢49⁢9⁢1≈0.9⁢93)
calculates to 0.993, indicating that the prosthetic devices1120are approximately the same stiffness.

The results of the foregoing stiffness comparison can be confirmed by deflection measurements. In particular, the deflection of the prosthetic device1110is 13 mm, while the deflection of the prosthetic device1130is 13 mm. A ratio of the deflections (13 mm/13 mm) also indicates that the prosthetic devices1110,1130are approximately the same stiffness. However, the ratio of areas

(AreaFIG.11CAreaFIG.11A=2⁢6⁢12⁢7⁢9≈0.94)
indicates that the prosthetic device1130(with the fin1132) allows for a 6% mass reduction, while retaining approximately the same stiffness as the prosthetic device1110.

FIGS.12A-12Eillustrate a perspective view, a bottom view, a top view, a side view, and a rotated perspective view, respectively, of an example of a prosthetic foot1200with a fin1216, in accordance with the present disclosure. The prosthetic foot1200includes a body1202having an anterior surface1210, a posterior surface1212opposite the anterior surface1210, and a fin1216on the posterior surface1212. It will be appreciated that the prosthetic foot1200can be an embodiment of any of the limb support devices described herein. Furthermore, the prosthetic foot1200represents an example prosthetic foot and other examples may use fewer, additional, or different components or arrangements.

The prosthetic foot1200can include a curved profile. For example, in some cases, as visible at least inFIG.12D, the body1202has C-shape. In other examples, the body1202may have a different shape, such as a J-shape. The curved profile can facilitate improved user performance. For example, vertical forces generated during ambulation can cause the prosthetic foot1200to flex and store energy. The energy can be translated into a linear motion and returned to the user when the prosthetic foot1200moves back from a flexed position (e.g., at push-off). In this way, the prosthetic foot1200can reduce the need for the user to actively push her body forward using the prosthetic foot1200, assists in taking a more equal stride length, and provides for a more natural gait and reduced walking effort. In some implementations, the prosthetic foot1200can be a sport foot (e.g., used for sprinting or running).

The prosthetic foot can be made of a composite material, such as carbon fiber, glass fiber, or a carbon-glass fiber composite. For example, the prosthetic foot1200can include carbon fiber layers including a plurality of fibers. The plurality of fibers may extend generally in the same direction. For example, the plurality of fibers can be parallel or collinear to each other, such as along the length or width of the body1202. In some cases, the prosthetic foot1200can be made of other suitable materials. In some instances, the prosthetic foot1200can include material (e.g., a composite material) that can flex to provide energy storage and return to the user during ambulation. For instance, a carbon fiber composite can allow more flexion than a rigid material, thereby offering increased energy storage (e.g., when a portion of the prosthetic foot1200is flexed under load) and energy release (e.g., when the prosthetic foot1200moves back from a flexed position responsive to a release of the applied load).

The prosthetic foot can be manufactured using either dry fiber composite materials or pre-impregnated fiber composite materials. Depending on what composite material is being used, a curing agent may or may not be added. For example, when using the dry fiber composite materials, a curing agent may be added to the mold (e.g., mold50inFIGS.3A-3B). Alternatively, when using pre-impregnated fiber composite materials, a curing agent may not be needed since the curing agent may already present. In some implementations, depending on what composite material is being used, heat may or may not be applied during the curing process. For example, when using the dry fiber composite materials (e.g., in addition to a curing agent), additional heat may be applied during the curing process (e.g., depending on the dry fiber composite and curing agent used), or the addition of a curing agent may initiate an exothermic chemical reaction that can provide heat during the curing process (e.g., making it unnecessary for additional heat to be applied during the curing process). In some implementations, when using pre-impregnated (prepreg) fiber composite material, heat is applied to initiate the curing process.

In some implementations, pressure (e.g., vacuum or low pressure) can be applied during the curing process to cause the mold to be completely filled out and/or ensure that any air present or formed in the mold is sucked or pressed out. This may lead to stronger chemical bonds generated within the cured composite material and/or the curing agent.

The prosthetic foot1200can include a fin1216, which can be an embodiment of any of the fins described herein, such as fin1122. As described herein, the fin1216increases the stiffness of the structure in which is implemented. Accordingly, in this example, the fin1216increases the stiffness of the body1202of the prosthetic foot1200(e.g., relative to the prosthetic foot1200without the fin1216). As described herein, the fin1216can include a ridge or protrusion that extends outwardly from the body1202of the prosthetic foot (e.g., outwardly relative to portions of the posterior surface1212adjacent the fin1216). In the illustrated example ofFIGS.12A-12E, the fin1216is located on the posterior surface1212of the body1202. However, in some cases, the fin1216can alternatively or additionally be located on the anterior surface1210of the body1202, or can alternatively or additionally be located on one or more sides of the body1202. Further still, in some implementations, the prosthetic foot1200includes multiple ribs1216, which may be located on the posterior surface1212and/or the anterior surface1210.

The fin1216can extend along a longitudinal axis of prosthetic foot1200. In some cases, the fin1216extends along a majority of a length of the prosthetic foot1200, such as extending approximately 60%, 70%, 80%, or 90% of the length of the prosthetic foot1200. In other instances, the fin1216extends along approximately half the length of the prosthetic foot1200. Further still, in some cases, the fin1216extends along a minority of the length of the prosthetic foot1200, such as extending approximately 10%, 20%, 30%, or 40% of the length of the prosthetic foot1200.

In some cases, the fin1216does not extend to the end of the distal portion1206. For example, as illustrated byFIG.12B, in some cases, there is some distance, D1, between the end (e.g., a distal end) of the fin1216and the end of the distal portion1206. The distance, D1, can vary across implementations. Furthermore, in some cases, the fin1216extends to the end of the distal portion1206, such that D1is zero. Similarly, in some cases, the fin1216does not extend to the end of the proximal portion1204. For example, as illustrated byFIG.12C, in some cases, there is some distance, D2, between the end (e.g., a proximal end) of the fin1216and the end of the proximal portion1204. The distance, D2, can vary across implementations. Furthermore, in some cases, the fin1216extends to the end of the proximal portion1204, such that D2is zero.

As illustrated, the fin1216can extend along a centerline the prosthetic foot1200. As another example, the fin1216can extend along an axis that is parallel to and offset from the centerline of the prosthetic foot1200, such as along a left or right side of the prosthetic foot1200. In addition or alternatively, the fin1216can extend along an axis that is not parallel to the centerline of the prosthetic foot1200. For example, the fin1216may extend at an angle with respect to the centerline of the prosthetic foot1200. The particular angle between the fin1216and the centerline of the prosthetic foot1200may vary across implementations. For example, the angle between the fin1200and the centerline of the prosthetic foot1200may be 5, 10, 20, 30, 45, or 60 degrees (+/−a few degrees). In some implementations, the fin1216can extend at an angle with respect to the centerline of the prosthetic foot1200to help guide the rollover of the prosthetic foot1200during use.

In some cases, the body1202has a varying width along its length. For example, as illustrated inFIGS.12B and12C, the proximal portion1204and/or the central portion (e.g., curved portion)1208of the of the prosthetic foot1200may be narrower (e.g., have a smaller width (W1) transverse to the longitudinal axis of the body1202viewed from the anterior surface1210) than the width (W2) of the distal portion1206. In some examples, the central portion1208can be narrower than the distal portion1206so that the width of the distal portion1206flares outward (e.g., gradually flares outward starting at location1209) from the central portion1208to the distal portion1206.

A narrowed proximal portion1204and/or the central portion1208can advantageously reduce drag on the prosthetic foot1200, for example by reducing the amount of surface area of the prosthetic foot1200that faces airflow during use. Furthermore, a narrowed proximal portion1204and/or the central portion1208advantageously reduces a mass and/or weight of prosthetic foot1200. Further still, a narrowed proximal portion1204and/or the central portion1208can also advantageously enhance energy return or flexure (e.g., reduced resistance to flexion) of the prosthetic foot1200in use, while the increases thickness from the fin1216advantageously increases the stiffness.

FIGS.13A-13Cillustrate a perspective view, a back view, and a bottom view, respectively, of an example of a prosthetic foot1300with a fin1324, in accordance with the present disclosure. The prosthetic foot1300can include a first footplate1302, a second footplate1304, a third footplate1306, a spacer1340, and a fin1324. It will be appreciated that the prosthetic foot1300represents an example prosthetic foot and other examples may use fewer, additional, or different components or arrangements. For example, the prosthetic foot1300may not include the third footplate1306and/or the spacer1340. Furthermore, it will be understood that the prosthetic foot1300can be an implementation of, or include one or more features of, the prosthetic foot1100ofFIGS.11A-11E, the prosthetic foot1200ofFIGS.12A-12E, and/or any of the limb support devices described herein.

The first footplate1302can include a proximal portion1312and a distal portion1310. During ambulation, the proximal portion1312and a distal portion1310of the first footplate1302can operatively engage a support surface. For example, during ambulation, a bottom surface of the proximal portion1312and a distal portion1310of the first footplate1302can operatively engage a walking surface, such as the ground.

The second footplate1304can include a proximal portion1314and a distal portion1316. The distal portion1316of the second footplate1304can be coupled (e.g., with fasteners, such as bolts) to the first footplate1302at an intermediate location between the proximal portion1312and a distal portion1310of the first footplate1302. Furthermore, the second footplate1304can include an anterior surface1320, a posterior surface1322opposite the anterior surface, and a fin1324on the posterior surface1322. In some cases, the second footplate1304has transverse cross-section with a linear anterior edge and a posterior edge that defines a curved ridge (e.g., of the fin1324) that extends from linear sides. As described herein, a spacer1340can be positioned on the second footplate1304and coupled to the curved ridge (e.g., curved side edges of the second footplate1304).

The second footplate1304can be generally L-shaped. The L-shape can facilitate improved user performance. For example, vertical forces generated during ambulation cause the second footplate1304to flex and store energy. The energy can be translated into a linear motion and returned to the user when the second footplate1304moves back from a flexed position (e.g., at push-off).

The second footplate1304can include a slot1326that extends along at least a portion of the length of the second footplate1304and can define separate blades of the second footplate1304. In some cases, the slot1326may not extend across the fin1324. In some cases, the slot1326can extend across an end or a portion of the fin1324. In other implementations, the second footplate1304can exclude the slot1326.

The third footplate1306can include a proximal portion1332and a distal portion1334. The third footplate1306can be arranged adjacent to the anterior surface1320of the second footplate1304along at least a portion of the third footplate1306. As described in more detail herein, the distal portion1334of third footplate1306can be spaced apart from the second footplate1304when the prosthetic foot1300is in stance phase (or between heel strike and stance phase). Furthermore, the distal portion1334of third footplate1306can operatively engage the anterior surface1320of the distal portion1310of the second footplate1304in dorsi-flexion (e.g., up to and including toe-off).

The spacer1340can be positioned between the second footplate1304and the third footplate1306. In some cases, the spacer1340includes side edges that engage at least a portion of side edges of the second footplate1304. In some cases, the spacer1340includes a groove on a bottom along longitudinal axis of the spacer1340, as further discussed below.

FIG.13Dillustrates an example of a prosthetic foot1350, which is an implementation of the prosthetic foot1300, and to which the same description above forFIGS.13A-13Capplies. The prosthetic foot1350can include a first footplate1302, a second footplate1304, a third footplate1306, a spacer1340, and a fin1324. In this example, the prosthetic foot1350has a shorter height than the prosthetic foot1300. The prosthetic foot1300can include an adapter1350, which is attached to an anterior surface1342of the third footplate1306. Furthermore, the prosthetic foot1350can optionally include a pyramid connector1344for connection to another prosthetic device (e.g., pylon). It will be appreciated that the prosthetic foot1350represents an example prosthetic foot and other examples may use fewer, additional, or different components or arrangements, such as any of the components or arrangements described herein.

FIG.14Aillustrates a perspective view of a footplate1404of an example prosthetic foot1400. The footplate1404can be an implementation of, or at least partially similar to, the second footplate1304ofFIGS.13A-13C, and to which the description above applies except as discussed below. The footplate1404can be generally Z-shaped (e.g., the footplate1404changes direction in at least two locations) and can include an anterior surface1420and a posterior surface1422opposite the anterior surface. Additionally, the footplate1404can include a linear proximal portion1414and a curved distal portion1416. The distal portion1416can curve rearward at transition section1415(e.g., at ankle region), and then can extend forwardly toward a front end and transition at transition section1417(e.g., proximate toe region) into a portion1419that folds under another portion1421of the footplate1404.

FIG.14Billustrates a perspective view of an example of a prosthetic foot1400. The prosthetic foot1400can include a first footplate1402, a second footplate1404, a third footplate1406, and a spacer1440, which can be implementations of, or at least partially similar to, the first footplate1302, the second footplate1304, the third footplate1306, and/or the spacer1340, respectively, ofFIGS.13A-13C. The spacer1440can be disposed between the second footplate1404and third footplate1406but not extend about side edges of the third footplate1406. It will be appreciated that the prosthetic foot1400represents an example prosthetic foot and other examples may use fewer, additional, or different components or arrangements. Furthermore, it will be understood that the prosthetic foot1400can be an implementation of, or include one or more features of, any of the limb support devices described herein.

In the illustrated example ofFIG.14B, the distal portion1416of the second footplate1404has a bottom portion1419that folds under another portion1421of the second footplate1404. Furthermore, a posterior surface of the bottom portion1417can be coupled to (e.g., with fasteners, such as bolts) an anterior surface1411of the first footplate1402. In this example, the second footplate1404is generally Z-shaped (e.g., changes direction in at least two locations).

FIGS.15A-15Billustrate the spacer1340of the prosthetic foot1300ofFIGS.13A-13C. Optionally, the spacer1340can be implemented in the prosthetic foot1400ofFIG.14. With reference toFIGS.13A-13C, the spacer1340can be positioned between the second footplate1304and the third footplate1306. The spacer1340may be removable or fixed to the second footplate1304. In some cases, the spacer1340includes side edges1502that engage and/or disposed proximate or adjacent at least a portion of side edges of the third footplate1306. In some cases, the spacer1340includes a groove1504on a bottom1506of the spacer1340, such as along a longitudinal axis of the spacer1340. In some cases, the shape, edges1502, and/or groove1504facilitate production. For example, the spacer1340can steer or position itself on the blade for gluing, and the spacer1340can reduce a likelihood that a user sees glue on the edges of the third footplate1306, and/or that glue flows out between the spacer and the edges of the third footplate1306. In some cases, the spacer1340does not hug the sides of the third footplate1306, but instead is positioned entirely between the second footplate1304and the third footplate1306.

In some cases, the spacer1340is made of foam or other resilient and/or compressible materials. In some cases, the spacer1340can inhibit (e.g., prevent) or reduce the amount of noise generated during use of the prosthetic foot1300(e.g., due to interaction between the second and third footplates1304,1306). For example, the spacer1340can reduce the likelihood of sand or dirt from being caught between the blades, creating noise. In some cases, the spacer1340can limit vibration/kick felt by a user during use. Furthermore, in some cases, the spacer1340can facilitate a smooth rollover.

FIGS.16A-16Billustrate example implementations of slots in a footplate of a prosthetic foot, which can correspond to the second footplate1304of prosthetic foot1300described above. The features of the footplate inFIGS.16A-16Bcan also be incorporated into the second footplate1404of the prosthetic foot1400described above. As shown inFIG.16A, in some cases, the slot1602can extend along a minority of the length of the footplate. Alternatively, in some cases, the slot1602can extends along a majority of the length of the footplate. Furthermore, the slot1602can define separate blades1612,1614of the footplate. As shown inFIG.16A, in some cases, the slot1602can extend across an end or a portion of the fin1604. Alternatively, as shown inFIG.16B, in some cases, the slot1622may not extend across an end or a portion of the fin1624.

FIG.17illustrates an example prosthetic foot1702overlaid on an image of a sound limb1704. The prosthetic foot1702can be an implementation of any of the prosthetic devices described herein (e.g., prosthetic foot1300,1400). As shown, in some cases, the prosthetic foot1702can have an angular lean, x, where x is the angular offset from 90 degrees (e.g., from vertical). The angular lean, x, can vary across implementations. For example, x can be 1, 2, 3, 4, 5, 6, 7, 9, or 10 degrees, less than 15 degrees, greater than 2 degrees, between 3 and 10 degrees, etc. In some cases, the angular lean eases the prosthetic foot alignment when the foot is cut for different build heights.

FIGS.18A and18Billustrate an example prosthetic foot1800at various stages of a gait cycle. In this example, the prosthetic foot1800can be an implementation of, or include one or more features of, the prosthetic foot1300ofFIGS.13A-13C. For example, the prosthetic foot1800can include a first footplate1802, a second footplate1804, and a third footplate1806.

FIG.18Aillustrates the prosthetic foot1800at the heel contact stage of the gait cycle. As indicated by the space1807between the second footplate1804and the third footplate1806, at heel contact, the top blade (that is, third footplate1806) is not active (e.g., not engaged with the second footplate1804). Rather, at heel contact, only the main blade (second footplate1804) is active (e.g., flexing, storing energy).FIG.18Billustrates the prosthetic foot1800in a dorsi-flexed stage of the gait cycle. As indicated by the contact1809between the second footplate1804and the third footplate1806, at mid stance, the top blade (third footplate1806) is active (e.g., flexing, storing energy). Furthermore, there is progressive stiffening of the foot from mid stance to toe-off, when the top blade supports the main blade.

Example Embodiments

The following are numbered example embodiments of various embodiments of the limb support device, the modular sole apparatus, the prosthetic device, the composite articles, and any other features disclosed herein. Any of the below Examples 1-49, or any other examples disclosed herein, may be combined in whole or in part. Elements of the examples disclosed herein are not limiting.

Example 1: A composite article manufactured from layers of composite material, the composite article comprising a first portion having a first width, a second portion, a transition portion, a plurality of layers of fibrous material, and a first polymer. The second portion is distally positioned from the first portion and having a second width different than the first width. The transition portion is located between the first portion and the second portion, the transition portion having at least a first contour transitioning between the first width and the second width. The plurality of layers of fibrous material extends and is continuous between the first portion and the second portion. The first polymer is impregnated with the plurality of layers of fibrous material and polymerized during a curing process, the first polymer causing the plurality of layers of fibrous material to realign to a shape substantially similar to the first contour during the curing process.

Example 2: The composite article of any of the Examples 1-8 or any other embodiment described herein, wherein the composite article is one of a prosthetic foot and a crutch blade.

Example 3: The composite article of any of the Examples 1-8 or any other embodiment described herein, wherein the first portion is located at a first end of the composite article, and wherein the second portion is located at a second end of the composite article.

Example 4: The composite article of any of the Examples 1-8 or any other embodiment described herein, wherein the first polymer is impregnated with the plurality of layers after the plurality of layers are placed into a mold having a desired shape comprising at least the first contour.

Example 5: The composite article of any of the Examples 1-8 or any other embodiment described herein, wherein the composite article comprises a fin, the fin formed on a rear surface of the composite article and extending along at least a portion of a length of the composite article.

Example 6: The composite article of any of the Examples 1-8 or any other embodiment described herein, wherein the fin increases stiffness of the composite article.

Example 7: The composite article of any of the Examples 1-8 or any other embodiment described herein, wherein the fin allows the composite article to maintain same level of stiffness with less material.

Example 8: The composite article of any of the Examples 1-8 or any other embodiment described herein, wherein the fin comprises at least a portion of the plurality of layers of fibrous material.

Example 9: A limb support device comprising a body. The body comprising a proximal portion with a first width, a distal portion with a second width greater than the first width, a transition portion between the proximal portion and the distal portion, the transition portion with a tapered width that transitions from the first width to the second width, and a plurality of layers of fibrous material having a plurality of fibers, each of the plurality of fibers extending linearly and continuously along each of the proximal portion, the transition portion, and the distal portion, the plurality of fibers generally parallel to each other and to outer edges of the proximal portion, the distal portion, and the transition portion.

Example 10: The limb support device of any of the Examples 9-17 or any other embodiment described herein, wherein the limb support device is a prosthetic foot.

Example 11: The limb support device of any of the Examples 9-17 or any other embodiment described herein, wherein the limb support device is a blade of a crutch.

Example 12: The limb support device of any of the Examples 9-17 or any other embodiment described herein, wherein one or more of the proximal portion, the distal portion, and the transition portion comprises a non-rectangular cross-section.

Example 13: The limb support device of any of the Examples 9-17 or any other embodiment described herein, wherein one or more of the proximal portion, the distal portion, and the transition portion comprises one or more fins on a surface thereof, the one or more fins having a greater thickness than adjacent portions of the body.

Example 14: The limb support device of any of the Examples 9-17 or any other embodiment described herein, wherein the one or more fins are in the proximal portion.

Example 15: The limb support device of any of the Examples 9-17 or any other embodiment described herein, wherein the one or more fins extend generally along an axial centerline of the body.

Example 16: The limb support device of any of the Examples 9-17 or any other embodiment described herein, wherein the one or more fins extend on a rear surface of the body.

Example 17: The limb support device of any of the Examples 9-17 or any other embodiment described herein, wherein one or more of the proximal portion, the distal portion, and the transition portion comprises a cross-section comprising a front surface and a rear surface, the front surface and the rear surface generally parallel to each other, a left edge and a right edge, the left edge and the right edge generally parallel to each other, a first chamfer between the left edge and either one of the rear surface or the front surface, and a second chamfer between the right edge and either one of the rear surface or the front surface.

Example 18: A limb support device comprising a first portion, a second portion, a plurality of layers of fibrous material, and a first polymer. The first portion having a first dimension along a first axis, the second portion having a second dimension along the first axis, the plurality of layers of fibrous material extending and continuous between the first portion and the second portion, and the first polymer impregnating the plurality of layers of fibrous material and polymerized during a curing process, the first polymer causing the plurality of layer of fibrous material to realign to a shape corresponding to a contour of an intermediate portion of the composite article between the first portion and the second portion during the curing process.

Example 19: A prosthetic foot comprising a continuous body extending from a proximal end to a distal end, the body comprising an anterior surface, a posterior surface opposite the anterior surface, and a fin on the posterior surface.

Example 20: The prosthetic foot of any of the Examples 19-30 or any other embodiment described herein, wherein the body has a C-shape.

Example 21: The prosthetic foot of any of the Examples 19-30 or any other embodiment described herein, wherein the body has a J-shape.

Example 22: The prosthetic foot of any of the Examples 19-30 or any other embodiment described herein, wherein the fin extends along a longitudinal axis of the prosthetic foot.

Example 23: The prosthetic foot of any of the Examples 19-30 or any other embodiment described herein, wherein the fin extends along a majority of a length of the prosthetic foot.

Example 24: The prosthetic foot of any of the Examples 19-30 or any other embodiment described herein, wherein the fin is defined on the posterior surface within a center portion of the prosthetic foot between a proximal portion and a distal portion.

Example 25: The prosthetic foot of any of the Examples 19-30 or any other embodiment described herein, wherein the fin protrudes relative to the posterior surface sections adjacent to fin.

Example 26: The prosthetic foot of any of the Examples 19-30 or any other embodiment described herein, wherein the fin defines a ridge on the posterior surface.

Example 27: The prosthetic foot of any of the Examples 19-30 or any other embodiment described herein, wherein the fin increases a stiffness of the body.

Example 28: The prosthetic foot of any of the Examples 19-30 or any other embodiment described herein, wherein the body comprises carbon fiber layers including a plurality of fibers.

Example 29: The prosthetic foot of any of the Examples 19-30 or any other embodiment described herein, wherein the each of the plurality of fibers extends parallel to each other along a length of the body.

Example 30: The prosthetic foot of any of the Examples 19-30 or any other embodiment described herein, wherein the body has a proximal portion with a first width transverse to a longitudinal axis of the prosthetic foot, wherein the body has a distal portion with a second width transverse to the longitudinal axis of the prosthetic foot, wherein the second width is greater than the first width.

Example 31: A prosthetic foot comprising a first footplate extending between a proximal portion and a distal portion, the proximal and distal portions configured to operatively engage a support surface during ambulation, and a second footplate extending between a proximal portion and a distal portion, the distal portion coupled to the first footplate at an intermediate location between the proximal and distal portions of the first footplate, the second footplate having an anterior surface, a posterior surface opposite the anterior surface, and a fin on the posterior surface.

Example 32: The prosthetic foot of any of the Examples 31-42 or any other embodiment described herein, further comprising a third footplate extending between a proximal portion and a distal portion and arranged adjacent the anterior surface of the second footplate along at least a portion of the third footplate.

Example 33: The prosthetic foot of any of the Examples 31-42 or any other embodiment described herein, wherein the distal portion of third footplate is spaced from the second footplate when the prosthetic foot is in stance, and configured to operatively engage the second footplate in dorsi-flexion.

Example 34: The prosthetic foot of any of the Examples 31-42 or any other embodiment described herein, further comprising a spacer between second and third footplate.

Example 35: The prosthetic foot of any of the Examples 31-42 or any other embodiment described herein, wherein the spacer has side edges proximate at least a portion of side edges of the second footplate.

Example 36: The prosthetic foot of any of the Examples 31-42 or any other embodiment described herein, wherein the spacer has groove on bottom along longitudinal axis of spacer.

Example 37: The prosthetic foot of any of the Examples 31-42 or any other embodiment described herein, wherein the second footplate is generally L-shaped.

Example 38: The prosthetic foot of any of the Examples 31-42 or any other embodiment described herein, wherein the distal portion of second footplate has a bottom portion that folds under another portion of the second footplate, the bottom portion coupled to the first footplate.

Example 39: The prosthetic foot of any of the Examples 31-42 or any other embodiment described herein, wherein the second footplate is generally Z-shaped.

Example 40: The prosthetic foot of any of the Examples 31-42 or any other embodiment described herein, wherein the second footplate has a slot that extends along at least a portion of a length of the second footplate and defines separate blades of the second footplate.

Example 41: The prosthetic foot of any of the Examples 31-42 or any other embodiment described herein, wherein the slot extends across an end of the fin.

Example 42: The prosthetic foot of any of the Examples 31-42 or any other embodiment described herein, wherein the second footplate has transverse cross-section with a linear anterior edge and a posterior edge that defines a curved ridge that extends from linear sides.

Example 43: A sole for a limb support device comprising a body. The body comprising a support surface configured to receive thereon a body portion of the limb support device, side supports extending upwards from side edges of the support surface, a slot at a distal end of the body that is configured to receive a distal end of the body portion of the limb support device, and an attachment mechanism configured to releasably engage the limb support device to inhibit decoupling of the body from the limb support device.

Example 44: The sole of any of the Examples 43-48 or any other embodiment described herein, wherein the body comprises an engagement surface opposite from the support surface and configured to receive and engage the body portion of the limb support device.

Example 45: The sole of any of the Examples 43-48 or any other embodiment described herein, wherein the attachment mechanism comprises a recess formed on the engagement surface, the recess configured to engage a corresponding protrusion of the prosthetic device and secure the body to the prosthetic device.

Example 46: The sole of any of the Examples 43-48 or any other embodiment described herein, wherein the recess and the corresponding protrusion are at least partially coupled via a magnetic force therebetween, the magnetic force provided by one or more magnets or magnetic portions in or on the body that magnetically engage one or more magnets or magnetic portions in or on the body portion of the limb support device.

Example 47: The sole of any of the Examples 43-48 or any other embodiment described herein, wherein the attachment mechanism comprises a slit disposed about a proximal end of the engagement surface, the slit configured to receive the body portion of the limb support device therethrough.

Example 48: The sole of any of the Examples 43-48 or any other embodiment described herein, wherein the attachment mechanism comprises a retaining member configured to positioned about a neck of the prosthetic device and wrap around both the prosthetic device and the body.

Example 49: The sole for a limb support device comprising a sole body, an intermediate device coupled to the body, and an attachment mechanism. The intermediate device comprising a support surface configured to receive thereon a body portion of a limb support device during use, and a slot positioned at a distal end of the intermediate device, the slot configured to receive a distal end of the body portion of the limb support device and having a opening corresponding to a shape of a distal portion of the foot portion of the limb support device. The attachment mechanism configured to couple the intermediate device to the limb support device, the attachment mechanism configured to draw one or both of the sole body and the intermediate device proximally relative to the limb support device to securely fit to the limb support device.

Terminology

Although this disclosure has been described in the context of certain embodiments and examples, it will be understood by those skilled in the art that the disclosure extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses and obvious modifications and equivalents thereof. In addition, while several variations of the embodiments of the disclosure have been shown and described in detail, other modifications, which are within the scope of this disclosure, will be readily apparent to those of skill in the art. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments may be made and still fall within the scope of the disclosure. For example, features described above in connection with one embodiment may be used with a different embodiment described herein and the combination still fall within the scope of the disclosure. It should be understood that various features and aspects of the disclosed embodiments may be combined with, or substituted for, one another in order to form varying modes of the embodiments of the disclosure. Thus, it is intended that the scope of the disclosure herein should not be limited by the particular embodiments described above. Accordingly, unless otherwise stated, or unless clearly incompatible, each embodiment of this invention may comprise, additional to its essential features described herein, one or more features as described herein from each other embodiment of the invention disclosed herein.

Features, materials, characteristics, or groups described in conjunction with a particular aspect, embodiment, or example are to be understood to be applicable to any other aspect, embodiment or example described in this section or elsewhere in this specification unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The protection is not restricted to the details of any foregoing embodiments. The protection extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Furthermore, certain features that are described in this disclosure in the context of separate implementations may also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation may also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations, one or more features from a claimed combination may, in some cases, be excised from the combination, and the combination may be claimed as a subcombination or variation of a sub combination.

Moreover, while operations may be depicted in the drawings or described in the specification in a particular order, such operations need not be performed in the particular order shown or in sequential order, or that all operations be performed, to achieve desirable results. Other operations that are not depicted or described may be incorporated in the example methods and processes. For example, one or more additional operations may be performed before, after, simultaneously, or between any of the described operations. Further, the operations may be rearranged or reordered in other implementations. Those skilled in the art will appreciate that in some embodiments, the actual steps taken in the processes illustrated and/or disclosed may differ from those shown in the figures. Depending on the embodiment, certain of the steps described above may be removed, others may be added. Furthermore, the features and attributes of the specific embodiments disclosed above may be combined in different ways to form additional embodiments, all of which fall within the scope of the present disclosure. Also, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems may generally be integrated together in a single product or packaged into multiple products.

For purposes of this disclosure, certain aspects, advantages, and novel features are described herein. Not necessarily all such advantages may be achieved in accordance with any particular embodiment. Thus, for example, those skilled in the art will recognize that the disclosure may be embodied or carried out in a manner that achieves one advantage or a group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.

Conditional language, such as “may,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements, and/or steps are included or are to be performed in any particular embodiment.

Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain embodiments require the presence of at least one of X, at least one of Y, and at least one of Z.

Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately”, “about”, “generally,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of the stated amount.

The scope of the present disclosure is not intended to be limited by the specific disclosures of preferred embodiments in this section or elsewhere in this specification, and may be defined by claims as presented in this section or elsewhere in this specification or as presented in the future. The language of the claims is to be interpreted broadly based on the language employed in the claims and not limited to the examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive.