Modular prosthetic sockets and methods for making same

Abstract

The invention relates to a prosthetic socket for a residual limb of the lower extremity or upper extremity of an individual person. The residual limb has particular dimensions and anatomical contours; the prosthetic socket has dimensions and contours that fit the dimensions and contours of the residual limb. The prosthetic socket may also fit in a manner that is biomechanically particularly appropriate for the individual. The prosthetic socket is an assembly of components from groups of components that include (a) struts arranged longitudinally with respect to the residual limb, (b) proximal brim members arranged proximally to the struts and connected thereto; and (c) distal socket members disposed at the distal base of the prosthetic socket. The socket components within these groups may be modular in that they can vary with respect to dimensions and/or contours, and yet have common connecting features that permit assembly of the components together to form the prosthetic socket.

What is claimed is: 
     
         1 . A modular prosthetic socket device for a lower extremity residual limb of a patient, the device comprising:
 a distal base;   four longitudinal struts, each of the struts having a distal end and a proximal end, and each of the struts connected at its distal end to the distal base;   one or more proximal brim members, each brim member fitted over the proximal end of at least one of the four longitudinal struts; and   an ischial seat extension coupled with at least one of the proximal end of one of the four longitudinal struts or the one or more proximal brim members, wherein the ischial seat extension is configured to bear weight by fitting under an ischial tuberosity of the patient,   wherein at least one of the distal base, the four longitudinal struts, the at least one proximal brim member, or the ischial seat extension is selected from a distal base inventory of multiple distal bases, a strut inventory of multiple longitudinal struts, a proximal brim inventory of multiple proximal brim members, or an ischial seat extension inventory, respectively, wherein each of the inventories includes components with at least one of different sizes or shapes, and wherein the distal bases, struts, proximal brims and ischial seat extensions of the respective inventories comprise common connecting features that allow assembly of the differently sized or shaped components to form the modular prosthetic socket.   
     
     
         2 . A device as in  claim 1 , wherein the one or more proximal brim members comprise:
 an anterior-medial brim member fitted over and surrounding the proximal end of one of the four longitudinal struts and having a shape formed to match an anterior-medial aspect of the residual limb; and   at least a first lateral brim member, fitted over and surrounding the proximal end of another of the four longitudinal struts and having a curved inner surface formed to match a lateral aspect of the residual limb.   
     
     
         3 . A device as in  claim 2 , further comprising a second lateral brim member, fitted over and surrounding the proximal end of another of the four longitudinal struts and having a curved inner surface formed to match a lateral aspect of the residual limb. 
     
     
         4 . A device as in  claim 2 , further comprising an ischial brim member, fitted over and surrounding the proximal end of another of the four longitudinal struts and having a surface formed to match an ischial aspect of the residual limb. 
     
     
         5 . A device as in  claim 1 , wherein the one or more proximal brim members comprise multiple brim members, and wherein at least one of the multiple brim members is configured to fit over the proximal ends of more than one of the four longitudinal struts. 
     
     
         6 . A device as in  claim 1 , further comprising a distal cup positioned on top of the distal base and on an interior aspect of the four longitudinal struts. 
     
     
         7 . A device as in  claim 1 , wherein the distal base is configured to couple with the struts at multiple different angles. 
     
     
         8 . A device as in  claim 1 , wherein the strut inventory comprises struts having at least one different characteristic selected from the group consisting of cross-sectional shapes, lengths and widths. 
     
     
         9 . A device as in  claim 1 , wherein the distal base includes four connection features disposed at spaced apart locations around a circumference of the base, wherein each connection feature is configured for coupling one strut with the base, such that, when the socket is assembled, the socket does not have a continuous surface around the circumference of the base. 
     
     
         10 . A device as in  claim 1 , further comprising a flexible liner arranged on an interior aspect of the socket. 
     
     
         11 . A device as in  claim 1 , wherein the four struts are removably attached to the distal base. 
     
     
         12 . A device as in  claim 1 , wherein the one or more proximal brim members are removably fitted over the proximal ends of the four longitudinal struts. 
     
     
         13 . A device as in  claim 1 , wherein at least one of the struts comprises a reformed strut that was reformed from an initial shape to a reformed shape to better fit the residual limb of the patient. 
     
     
         14 . A device as in  claim 13 , wherein the at least one reformed strut comprises a strut that was reformed by applying heat to the strut. 
     
     
         15 . A device as in  claim 14 , wherein the at least one reformed strut comprises a strut that was reformed by directly molding the strut in its initial shape against the residual limb of the patient to reform the strut into the reformed shape. 
     
     
         16 . A device as in  claim 1 , further comprising an encircling band coupled with the one or more proximal brim members and encircling the four longitudinal struts for tightening or loosening the socket device relative to the residual limb without removing any parts from the encircling band. 
     
     
         17 . A device as in  claim 16 , further comprising:
 at least one additional encircling band attached to the struts around at least one of an outer surface or an inner surface of the struts; and   at least one adjustment member coupled with the at least one additional encircling band, to allow a user to adjust spacing between the struts and thus adjust an overall circumference of the socket device.   
     
     
         18 . A device as in  claim 1 , wherein each of the four longitudinal struts comprises a telescoping mechanism for adjusting the strut to a desired height. 
     
     
         19 . A device as in  claim 1 , wherein the ischial seat extension comprises an extension of the proximal end of one of the four longitudinal struts. 
     
     
         20 . A device as in  claim 19 , wherein the ischial seat extension is attached to the one of the four longitudinal struts via screws. 
     
     
         21 . A device as in  claim 1 , wherein the ischial seat extension comprises a shock absorbing silicone pad.