Modular Prosthetic Sockets and Method for Making Same

Abstract

A prosthetic socket for a residual limb of the lower extremity or upper extremity of an individual person is provided. 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 appropriate for the individual. The prosthetic socket may be an assembly 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 method of assembling a modular prosthetic socket for a residual limb of an amputee, the modular socket for use with a modular endoskeletal distal component, the method comprising:
 a) providing a plurality of longitudinal struts, each of the struts having a non-circular cross-sectional shape, each of the struts defining an interior side and an exterior side, proximal and distal ends, and a first thickness extending in dimension between the interior and exterior sides, and a first width transverse to the first thickness;   b) providing a distal base having a proximal aspect and a distal aspect, the base adapted to couple relative to the modular endoskeletal distal component;   c) providing a plurality of separable elements adapted to be received on at least an interior side of the proximal end of the struts, the separable elements having a second width greater than the first width of the struts;   d) securing the spatial relationship of the struts in relation to the base; and   e) coupling the plurality of separable elements to cover at least the interior side of the proximal end of the struts.   
     
     
         2 . The method of  claim 1 , wherein:
 the struts are provided from a strut inventory that includes struts of multiple sizes or multiple shapes.   
     
     
         3 . The method of  claim 1 , wherein:
 the separable elements are proximal brims provided from an inventory of brims that includes brims of multiple sizes or multiple shapes.   
     
     
         4 . The method of  claim 1 , wherein:
 the separable elements are softer than the struts.   
     
     
         5 . The method of  claim 1 , wherein:
 the struts are fixed in spatial relationship to extend vertically upwards relative to a periphery of the distal base.   
     
     
         6 . The method of  claim 1 , further comprising:
 positioning a distal cup having a rounded, concave interior at its distal end, the distal cup positioned over the proximal aspect of the base and facing the interior side of the struts, the distal cup adapted to receive the residual limb.   
     
     
         7 . The method of  claim 1 , further comprising:
 coupling an element to the base adapted to directly support a garment worn over the residual limb.   
     
     
         8 . The method of  claim 1 , further comprising:
 rotatably adjusting at least one of the struts relative to the other struts to angularly adjust the interior side of the at least one strut relative to the interior side of another strut.   
     
     
         9 . The method of  claim 1 , further comprising:
 adjusting a length of at least one of the struts.   
     
     
         10 . The method of  claim 1 , further comprising:
 adjusting a vertical extension of at least one of the struts relative to the base.   
     
     
         11 . The method of  claim 1 , wherein:
 the plurality of struts comprises exactly four struts.   
     
     
         12 . The method of  claim 1 , further comprising:
 adjusting a tension between at least two struts at a location vertically spaced apart from the distal base.   
     
     
         13 . The method of  claim 1 , further comprising:
 re-shaping one or more of the struts using heat.   
     
     
         14 . The method of  claim 1 , wherein:
 the provided longitudinal struts are custom molded or custom fabricated to the contours of the residual limb.   
     
     
         15 . The method of  claim 1 , further comprising
 providing a band; and   connecting the band between and/or around two struts.   
     
     
         16 . The method of  claim 15 , further comprising:
 adjusting a tension in the band.   
     
     
         17 . The method of  claim 15 , further comprising:
 providing at least one tensioning element and a mechanism,
 wherein the band has first and second portions and the at least one tensioning element couples the first and second portions together, and the mechanism is operated to loosen or tighten the tension in the at least one tensioning element to thereby adjust tension in the band. 
   
     
     
         18 . The method of  claim 1 , wherein:
 the modular endoskeletal distal component includes a prosthetic foot.   
     
     
         19 . The method of  claim 1 , further comprising:
 after the step of securing, adjusting the spatial relationship of the struts relative to each other.   
     
     
         20 . A method of assembling a modular prosthetic socket for a residual limb of an amputee, the modular socket for use with a modular endoskeletal distal component, the method comprising:
 a) custom-molding or custom-fabricating a plurality of longitudinal struts to correspond to contours of the residual limb, the struts having proximal and distal ends and interior and exterior sides;   b) providing a distal base having a proximal aspect and a distal aspect, the base adapted to couple relative to the modular endoskeletal distal component;   c) providing a plurality of separable elements adapted to be received on at least an interior side of the proximal end of the struts, the separable elements having a second width greater than the first width of the struts;   d) securing the spatial relationship of the struts in relation to the base; and   e) coupling the plurality of separable elements to cover at least the interior side of the proximal end of the struts.   
     
     
         21 . The method of  claim 20 , further comprising:
 providing a distal cup having a tapered, concave interior at its distal end, the distal end smaller than the base and adapted to receive the residual limb, providing the distal cup at the proximal aspect of the distal base.   
     
     
         22 . The method of  claim 20 , further comprising:
 providing a band;   connecting the band between and/or around two struts; and   adjusting a tension in the band.   
     
     
         23 . The method of  claim 20 , further comprising:
 attaching the modular endoskeletal distal component to the base, the modular endoskeletal distal component including a prosthetic foot.   
     
     
         24 . The method of  claim 20 , wherein:
 the struts comprise a thermoplastic material.   
     
     
         25 . The method of  claim 20 , further comprising:
 re-shaping one or more of the struts using heat.