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 modular prosthetic socket for a residual limb of a human extremity for use with a modular endoskeletal distal component, the socket comprising:
 a) at least two longitudinal struts, each of the struts having a non-circular cross-sectional shape, each strut having proximal and distal ends;   b) a distal base having a proximal aspect and a distal aspect, the base assembled in fixed relation to the struts and adapted to couple the struts to the modular endoskeletal distal component; and   c) a distal cup positioned at the proximal aspect of the base, the 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.   
     
     
         2 . The modular prosthetic socket of  claim 1 , wherein:
 the struts have an interior aspect facing radially inward and an exterior aspect facing radially outward, and the struts are rotatable relative to the base such that the interior aspect may be angularly displaced.   
     
     
         3 . The modular prosthetic socket of  claim 1 , wherein:
 the struts have an interior aspect facing radially inward and an exterior aspect facing radially outward, a portion of the interior aspect of the struts facing the distal cup.   
     
     
         4 . The modular prosthetic socket of  claim 1 , wherein:
 at least one of the struts is adjustable in length.   
     
     
         5 . The modular prosthetic socket of  claim 1 , wherein:
 all of the struts are attached to the base.   
     
     
         6 . The modular prosthetic socket of  claim 1 , wherein:
 the at least two struts consists of four struts.   
     
     
         7 . The modular prosthetic socket of  claim 1 , further comprising:
 a shock absorbing material, wherein the struts have an interior aspect facing radially inward and an exterior aspect facing radially outward and the shock absorbing material is provided to the interior aspect of one or more struts.   
     
     
         8 . The modular prosthetic socket of  claim 1 , further comprising:
 a plurality of separable brims coupled over proximal ends of at least two of the struts.   
     
     
         9 . The modular prosthetic socket of  claim 8 , further comprising:
 a flexible band extending between and/or around at least two brims.   
     
     
         10 . The modular prosthetic socket of  claim 1 , further comprising:
 a flexible band extending between and/or around at least two struts.   
     
     
         11 . The modular prosthetic socket of  claim 1 , wherein:
 the at least two struts have a common attachment mechanism to fix the struts relative to the base, but the struts have variations in dimension and/or shape from each other.   
     
     
         12 . The modular prosthetic socket of  claim 1 , wherein:
 the struts are made of a moldable thermoplastic material.   
     
     
         13 . The modular prosthetic socket of  claim 1 , wherein:
 the struts are made of a thermoplastic resin and carbon fibers.   
     
     
         14 . A modular prosthetic socket for a residual limb of an amputee, the socket for use with a modular endoskeletal distal component, the socket comprising:
 a) at least two longitudinal struts, each of the struts having a non-circular cross-section and proximal and distal ends;   b) a distal base coupling the distal ends of the struts relative to the modular endoskeletal distal component; and   c) an element coupled to the base to directly support a garment worn by the amputee over the residual limb.   
     
     
         15 . The modular prosthetic socket of  claim 14 , wherein:
 at least one of the struts is adjustable in length.   
     
     
         16 . The modular prosthetic socket of  claim 14 , further comprising:
 a flexible band extending between and/or around at least two struts.   
     
     
         17 . The modular prosthetic socket of  claim 14 , wherein:
 the struts are made of a moldable thermoplastic material and optionally carbon fibers.   
     
     
         18 . A modular prosthetic socket for a residual limb of an amputee, the socket for use with a modular endoskeletal distal component, the socket comprising:
 a) a plurality of longitudinal struts, each of the struts having a non-circular cross-section and proximal and distal ends;   b) a distal base for coupling to the modular endoskeletal distal component, at least two of the struts fixed in relation to the base to define an interior aspect and an exterior aspect; and   c) at least one first element positioned on at least the interior aspect of the proximal end of the at least two struts, the at least one element softer than the struts.   
     
     
         19 . The modular prosthetic socket of  claim 18 , further comprising:
 a second element coupled to the base to directly support a garment worn by the amputee over the residual limb.   
     
     
         20 . The modular prosthetic socket of  claim 18 , wherein:
 at least one of the struts is adjustable in height relative to the distal base.   
     
     
         21 . The modular prosthetic socket of  claim 18 , further comprising:
 a first band extending between and/or around at least two struts.   
     
     
         22 . The modular prosthetic socket of  claim 21 , wherein:
 the first band includes:
 a first portion, 
 a second portion, 
 at least one tensioning element that couples the first and second portions together, and 
 a mechanism that permits loosening or tightening of the at least one tensioning element to adjust tension in the first band. 
   
     
     
         23 . The modular prosthetic socket of  claim 18 , wherein:
 the at least one first element comprises brim members removably fitted onto the struts.   
     
     
         24 . The modular prosthetic socket of  claim 23 , further comprising:
 a second band extending between and/or around at least two brim members.   
     
     
         25 . The modular prosthetic socket of  claim 18 , wherein:
 the struts are made of a moldable thermoplastic material and optionally carbon fibers.   
     
     
         26 . A kit for assembly of a modular prosthetic socket for use on a residual limb of an amputee, the socket for use with a modular endoskeletal distal component, the kit comprising:
 a) a plurality of longitudinal heat-moldable struts;   b) a distal base having structure for coupling to the modular endoskeletal distal component, the plurality of struts couplable in fixed relationship relative to a periphery of the distal base;   c) a plurality of first elements positionable on at least the interior aspect of the proximal end of the struts, the first elements provided in multiple sizes and/or shapes, the first elements softer than the struts; and   d) at least one banding element for extension between and/or around the plurality of longitudinal struts when the struts are in the fixed relationship relative to the periphery of the distal base.   
     
     
         27 . The kit according to  claim 26 , wherein:
 at least one strut is length-adjustable.   
     
     
         28 . The kit according to  claim 26 , wherein:
 each of the struts has a non-circular cross-section and proximal and distal ends, a length extending between the proximal and distal ends, and a width, and   the first elements are wider than the width of the struts.   
     
     
         29 . The kit according to  claim 26 , wherein:
 the plurality of struts are in at least two different lengths.   
     
     
         30 . The kit according to  claim 26 , further comprising:
 a distal cup positioned at a proximal aspect of the base, the 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.