Custom-fitted prosthetic socket devices and methods for producing same

Abstract

Methods of producing a custom fitted prosthetic socket device for a residual limb include covering the distal end thereof with a liner, positioning the covered end within a socket cup to maintain a spaced relationship between the exterior of the liner and the interior of the socket cup, introducing an expandable, hardenable filler material into the socket cup, expanding the material to fill the volume between the liner and the socket cup, hardening the material, and removing the socket cup, hardened filler material, and liner, from the residual limb. Some methods include a filler material that hardens into a flexible solid foam cushioning layer, which may optionally form a bond between the socket cup and the liner, embedding the liner in the cushioning layer. Some methods include selecting a socket cup from a plurality of sized socket cups, and/or providing the plurality of sized socket cups.

1 . A prosthetic socket device for coupling a prosthetic device to a residual limb, the prosthetic socket device being custom-fittable to the residual limb and comprising:
 a socket cup configured to receive at least a portion of a distal end of the residual limb covered with a limb liner, the socket cup having a floor and a wall, a top edge of the wall forming an opening at a top end of the socket cup,   wherein the socket cup is sized to receive the residual limb covered with a limb liner to define an annular space between an interior surface of the socket cup and an exterior surface of the limb liner sufficient to receive an expandable, hardenable material in the annular space.   
     
     
         2 . The prosthetic socket device of  claim 1 , further comprising a support plate having a first face and a second face, the support plate being coupled to the floor of the socket cup so that the first face of the support plate contacts the exterior surface of the floor of the socket cup. 
     
     
         3 . The prosthetic socket device of  claim 2 , wherein the support plate is coupled to the floor of the socket cup via fastening components inserted through aligned holes in the support plate and the floor of the socket cup. 
     
     
         4 . The prosthetic socket device of  claim 2 , wherein the prosthetic device has a first end and a second end, the first end being proximal to the socket cup, and
 the second face of the support plate is coupled to the first end of the prosthetic device.   
     
     
         5 . The prosthetic socket device of  claim 4 , wherein the second face is secured directly to and is continuous with the prosthetic device. 
     
     
         6 . The prosthetic socket device of  claim 1 , wherein the expandable, hardenable material is expandable and hardenable to create a foam cushioning layer around the distal end of the residual limb covered with the limb liner, the foam cushioning layer being the disposed inside of the socket cup and bonded to the interior surface of the socket cup. 
     
     
         7 . The prosthetic socket device of  claim 6 , wherein the foam cushioning layer is complimentarily configured to the distal end of the residual limb covered with the limb liner. 
     
     
         8 . The prosthetic socket device of  claim 6 , wherein the foam cushioning layer is further bonded to an exterior surface of the limb liner. 
     
     
         9 . The prosthetic socket device of  claim 8 , wherein the prosthetic device is attachable to the residual limb via friction-fit between the interior surface of the limb liner and skin of the residual limb. 
     
     
         10 . The prosthetic socket device of  claim 1 , wherein the expandable, hardenable material is polyeurethane foam. 
     
     
         11 . The prosthetic socket device of  claim 1 , wherein the socket cup is comprised of a rigid material. 
     
     
         12 . A prosthetic socket device for a residual limb, the prosthetic socket device being custom-fitted to the residual limb, the prosthetic socket device comprising:
 a socket cup having a floor and a wall, top edge of the wall forming an opening at a top end of the socket cup;   a limb liner configured to receive the residual limb;   a foam cushioning layer, the foam cushioning layer being disposed between and bonded to an interior surface of the socket cup and an exterior surface of the limb liner; and   a prosthetic device, the prosthetic device having a first end and a second end, the first end being proximal to the socket cup.   
     
     
         13 . The prosthetic device of  claim 12 , further comprising a support plate having a first face and a second face, the support plate being coupled to the floor of the socket cup so that the first face of the support plate contacts the exterior surface of the floor of the socket cup. 
     
     
         14 . The prosthetic device of  claim 13 , wherein the support plate is coupled to the floor of the socket cup via fastening components inserted through aligned holes in the support plate and the floor of the socket cup. 
     
     
         15 . The prosthetic device of  claim 13 , wherein the second face of the support plate is coupled to the first end of the prosthetic device. 
     
     
         16 . The prosthetic device of  claim 12 , wherein the foam cushioning layer is formed from an expandable, hardenable material that is insertable into the socket cup between a portion of a distal end of the residual limb covered with the limb liner and the interior surface of the socket cup. 
     
     
         17 . The prosthetic device of  claim 12 , wherein the prosthetic device is attachable to the residual limb via friction-fit between the interior surface of the limb liner and skin of the residual limb. 
     
     
         18 . The prosthetic device of  claim 12 , wherein the foam cushioning layer is expanded and hardened polyeurethane foam. 
     
     
         19 . The prosthetic device of  claim 12 , wherein the socket cup is comprised of a rigid material. 
     
     
         20 . A prosthetic socket device for a residual limb, the prosthetic socket device being custom-fitted to the residual limb, the prosthetic socket device comprising:
 a socket cup having a floor and a wall, a top edge of the wall forming an opening at a top end of the socket cup;   a limb liner configured to receive the residual limb;   a foam cushioning layer, the foam cushioning layer being disposed between and bonded to an interior surface of the socket cup and an exterior surface of the limb liner;   a prosthetic device, the prosthetic device having a first end and a second end, the first end being proximal to the socket cup; and   a support plate having a first face and a second face, the support plate being coupled to the floor of the socket cup so that the first face of the support plate contacts the exterior surface of the floor of the socket cup, the second face of the support plate being coupled to the first end of the prosthetic device,   wherein the foam cushioning layer is formed from an expandable, hardenable material that is insertable into the socket cup between a portion of a distal end of the residual limb covered with the limb liner and the interior surface of the socket cup, and   wherein the prosthetic device is attachable to the residual limb via friction-fit between the interior surface of the limb liner and skin of the residual limb.