Prosthetic foot with tunable performance and improved vertical load/shock absorption

• US 7,578,852 B2
• Filed: 03/31/2003
• Issued: 08/25/2009
• Est. Priority Date: 03/30/2001
• Status: Expired due to Fees

• Current Assignee: BioQuest Prosthetics LLC
• Original Assignee: BioQuest Prosthetics LLC
• Inventors: Townsend, Barry W., Claudino, Byron Kent
• Primary Examiner(s): Stewart; Alvin J
• Application Number:
  US10/551,420
• Publication Number:
  US 20060178754A1
• Time in Patent Office: 2,339 Days
• Field of Search: 623/46, 623/42, 623 47- 56
• US Class Current: 623/55
• CPC Class Codes: A61F 2/60 Artificial legs or feet or parts thereof
• CPC Class Codes: A61F 2/66 Feet; Ankle joints
• CPC Class Codes: A61F 2/6607 Ankle joints
• CPC Class Codes: A61F 2/74 fluid , i.e. hydraulic or pneumatic
• CPC Class Codes: A61F 2/76 Means for assembling, fitting or testing prostheses, e.g. for measuring or balancing, e.g. alignment means
• CPC Class Codes: A61F 2002/30433 using additional screws, bolts, dowels, rivets or washers e.g. connecting screws
• CPC Class Codes: A61F 2002/30462 retained or tied with a rope, string, thread, wire or cable
• CPC Class Codes: A61F 2002/5001 Cosmetic coverings
• CPC Class Codes: A61F 2002/5003 having damping means, e.g. shock absorbers
• CPC Class Codes: A61F 2002/5006 Dampers, e.g. hydraulic damper
• CPC Class Codes: A61F 2002/5007 having elastic means different from springs, e.g. including an elastomeric insert
• CPC Class Codes: A61F 2002/5009 having two or more elastomeric blocks
• CPC Class Codes: A61F 2002/503 for adjusting elasticity, flexibility, spring rate or mechanical tension
• CPC Class Codes: A61F 2002/5032 for adjusting fluid pressure
• CPC Class Codes: A61F 2002/5033 for adjusting damping
• CPC Class Codes: A61F 2002/5075 Multiple spring systems including two or more helical springs
• CPC Class Codes: A61F 2002/5079 Leaf springs A61F2002/6657 takes precedence
• CPC Class Codes: A61F 2002/5083 modular
• CPC Class Codes: A61F 2002/607 Lower legs
• CPC Class Codes: A61F 2002/6614 Feet
• CPC Class Codes: A61F 2002/6621 : Toes
• CPC Class Codes: A61F 2002/6628 : Big toes
• CPC Class Codes: A61F 2002/6635 : Metatarsals
• CPC Class Codes: A61F 2002/6642 : Heels
• CPC Class Codes: A61F 2002/665 : Soles
• CPC Class Codes: A61F 2002/6657 : having a plate-like or strip-like spring element, e.g. an energy-storing cantilever spring keel
• CPC Class Codes: A61F 2002/6664 : Dual structures made of two connected cantilevered leaf springs
• CPC Class Codes: A61F 2002/6671 : C-shaped
• CPC Class Codes: A61F 2002/6678 : L-shaped
• CPC Class Codes: A61F 2002/6685 : S-shaped
• CPC Class Codes: A61F 2002/704 : computer-controlled, e.g. robotic control
• CPC Class Codes: A61F 2002/7615 : Measuring means
• CPC Class Codes: A61F 2220/0041 : using additional screws, bolts, dowels or rivets, e.g. connecting screws
• CPC Class Codes: A61F 2220/0075 : sutured, ligatured or stitched, retained or tied with a rope, string, thread, wire or cable
• CPC Class Codes: A61K 9/4816 : Wall or shell material

Abstract

A prosthetic foot (64) incorporates a foot keel (65) and a calf shank (73) connected to the foot keel to form an ankle joint area (74) of the prosthetic foot. The foot keel has forefoot and hindfoot portions (67, 66) and a relatively long midfoot portion (68) extending between and upwardly arched from the forefoot and midfoot portions. The calf shank includes a downward convexly curved lower end which is attached at a portion thereof to the keel midfoot portion by way of an adjustable fastener arrangement (75). The adjustable fastener arrangement permits adjustment of the alignment of the calf shank and the foot keel with respect to one another in the longitudinal direction of the foot keel for tuning the performance of the prosthetic foot. The upwardly arched midportion of the foot keel, in addition to absorbing energy from vertical loading by expansion, can be formed with a coiled spring (69) which is compressed to absorb and expanded to return vertical load during use of the prosthetic in wide range of activities from walking to running and jumping.

Claims

1. A longitudinally extending foot keel for a prosthetic foot, the foot keel comprising:

a hindfoot portion having a posterior plantar surface weight bearing area, a forefoot portion having an anterior plantar surface weight bearing area and an upwardly arched midfoot portion monolithically formed with the forefoot portion and extending between the forefoot and hindfoot portions,

wherein a posterior end of the upwardly arched midfoot portion is monolithically formed with a single coil extending downwardly with a posterior facing convexly curved surface from the upwardly arched midfoot portion and extending anteriorly with a downward facing convexly curved surface to form a coiled spring which terminates in a free end, the coiled spring being compressed to absorb and expanded to return vertical load during use of the foot keel in a prosthetic foot, and

wherein an anterior end of the hindfoot portion includes an expansion joint hole extending through said hindfoot portion of the foot keel between dorsal and plantar surfaces thereof with an expansion joint extending posteriorly from said expansion joint hole to a posterior edge of the foot keel to form plural expansion struts which create improved biplanar motion capability of the posterior weight bearing area in the prosthetic foot in gait.

2. The foot keel according to claim 1, wherein the hindfoot portion of the foot keel is connected to the upwardly arched midfoot portion by way of the coiled spring.

3. The foot keel according to claim 1, further comprising an attachment fitting mounted on a dorsal surface of the posterior end of the upwardly arched midfoot portion for connecting the foot keel to a supporting structure attached to a leg stump of a person.

4. The foot keel according to claim 1, wherein each of the hindfoot and forefoot portions of the foot keel are upward concavely curved.

5. The foot keel according to claim 1, further comprising a fastening arrangement on a dorsal, posterior surface of the upwardly arched midfoot portion for connecting the lower end of a calf shank to the foot keel.

6. The foot keel according to claim 5, wherein the longitudinal position of the fastening arrangement on the midfoot portion is adjustable.

7. The foot keel according to claim 1, wherein a dorsal aspect of said midfoot portion and the forefoot portion is formed with an upwardly facing concavity, said concavity having a longitudinal axis which is oriented parallel to the frontal plane of the foot keel.

8. The foot keel according to claim 1, wherein the anterior end of said forefoot portion is shaped in an upwardly curved arc to simulate the human toes being dorsiflexed in the heel rise toe off position of the late stance phase of gait.

9. The foot keel according to claim 1, wherein the posterior end of the hindfoot portion is shaped in an upwardly curved arc that reacts to ground reaction forces during heel strike by compressing for shock absorption.

10. A prosthetic foot comprising:

a longitudinally extending foot keel including a hindfoot portion having a posterior plantar surface weight bearing area, a forefoot portion having an anterior plantar surface weight bearing area and an upwardly arched midfoot portion monolithically formed with the forefoot portion and extending between the forefoot and hindfoot portions,

wherein a posterior end of the upwardly arched midfoot portion is monolithically formed with a single coil extending downwardly with a posterior facing convexly curved surface from the upwardly arched midfoot portion and extending anteriorly with a downward facing convexly curved surface to form a coiled spring which terminates in a free end, the coiled spring being compressed to absorb and expanded to return vertical load during use of the prosthetic foot, and

wherein an anterior end of the hindfoot portion includes an expansion joint hole extending through said hindfoot portion of the foot keel between dorsal and plantar surfaces thereof with an expansion joint extending posteriorly from said expansion joint hole to a posterior end of the foot keel to form plural expansion struts which create improved biplanar motion capability of the posterior weight bearing area in the prosthetic foot in gait.

11. The prosthetic foot according to claim 10, further comprising a resilient, upstanding calf shank having a downward, anteriorly facing convexly curved lower end coupled to the foot keel to form an ankle joint area of the prosthetic foot, the calf shank extending upward to form a lower, prosthetic part of a leg above the ankle joint area for connection with a supporting structure on a person'"'"'s leg stump.

12. The prosthetic foot according to claim 11, further comprising a fastening arrangement coupling the calf shank to the foot keel, the fastening arrangement being adjustable to permit adjustment of the alignment of the calf shank and foot keel with respect to one another is the longitudinal direction of the foot keel.

13. The prosthetic foot according to claim 11, wherein the calf shank forming the lower, prosthetic part of a leg extends upward in a substantially curvilinear manner so as to be expandable and compressible in response to ground reaction forces therein during gait for storing and releasing energy to improve dynamic response of the prosthetic foot in gait.

14. The prosthetic foot according to claim 10, wherein the posterior plantar surface weight bearing area of the hindfoot portion of the foot keel is connected to the upwardly arched midfoot portion by way of the coiled spring.

15. The prosthetic foot according to claim 10, further comprising a coupling element mounted on a dorsal surface of the posterior end of the upwardly arched midfoot portion for connecting the foot to a supporting structure attached to a leg stump of a person.

16. The prosthetic foot according to claim 10, wherein each of the hindfoot and forefoot portion of the foot keel are upward concavely curved.

17. A prosthetic foot comprising:

a longitudinally extending foot keel including posterior and anterior plantar surface weight bearing areas and a non-weight bearing arch shaped midportion extending between the weight bearing areas,

wherein the midportion is formed with a coiled spring which is compressed to absorb and expanded to return vertical load during use of the prosthetic foot,

the prosthetic foot further comprising a resilient, upstanding calf shank having a downward, anteriorly facing convexly curved lower end coupled to the foot keel to form an ankle joint area of the prosthetic foot, the calf shank extending upward to form a lower, prosthetic part of a leg above the ankle joint area for connection with a supporting structure on a person'"'"'s leg stump,

wherein the calf shank above the ankle joint area is also anteriorly facing convexly curved, and

wherein an anterior of the posterior weight bearing includes an expansion joint hole extending through said foot keel between dorsal and plantar surfaces thereof with an expansion joint extending posteriorly from said expansion joint hole to a posterior edge of the foot keel to form plural expansion struts which create improved biplanar motion capability of the posterior weight bearing area in the prosthetic foot in gait.

18. A prosthetic foot comprising:

a longitudinally extending foot keel including posterior and anterior plantar surface weight bearing areas and a non-weight bearing arch shaped midportion extending between the weight bearing areas,

wherein the midportion is formed with a coiled spring which is compressed to absorb and expanded to return vertical load during use of the prosthetic foot,

the prosthetic foot further comprising a resilient, upstanding calf shank having a downward, anteriorly facing convexly curved lower end coupled to the foot keel to form an ankle joint area of the prosthetic foot, the calf shank extending upward to form a lower, prosthetic part of a leg above the ankle joint area for connection with a supporting structure on a person'"'"'s leg stump,

a fastening arrangement coupling the calf shank to the foot keel, the fastening arrangement including means for adjusting the inclination at which the calf shank is coupled to the foot keel is the longitudinal direction of the foot keel, and

wherein an anterior of the posterior weight bearing includes an expansion joint hole extending through said foot keel between dorsal and plantar surfaces thereof with an expansion joint extending posteriorly from said expansion joint hole to a posterior edge of the foot keel to form plural expansion struts which create improved biplanar motion capability of the posterior weight bearing area in the prosthetic foot in gait.

19. A method of absorbing and returning vertical load in a prosthetic foot during varied activities, wherein the prosthetic foot has a foot keel with a hindfoot portion having a posterior plantar surface weight bearing area, a forefoot portion having an anterior plantar surface weight bearing area and an upwardly arched midfoot portion extending between the forefoot and hindfoot portions, wherein a posterior end of the upwardly arched midfoot portion is monolithically formed with a single coil extending downwardly with a posterior facing convexly curved surface from the upwardly arched midfoot portion and extending anteriorly with a downward facing convexly curved surface to form a coiled spring which terminates in a free end, and wherein an anterior end of the hindfoot portion includes an expansion joint hole extending through said hindfoot portion of the foot keel between dorsal and plantar surfaces thereof with an expansion joint extending posteriorly from said expansion joint hole to a posterior edge of the foot keel to form plural expansion struts which create improved biplanar motion capability of the posterior weight bearing area in the prosthetic foot in gait the method including:

elastically loading the upwardly arched midfoot portion by expansion and the coiled spring which terminates in a free end of the midfoot portion by compression in response to vertically directed forces on the prosthetic foot, and

returning energy stored by the upwardly arched midfoot portion and the compressed coiled spring of the midfoot portion upon lowering the vertically directed forces on the prosthetic foot.

20. The method according to claim 19, wherein each of said forefoot and hindfoot portions of the foot keel are upward concavely curved, and wherein the method further comprises absorbing and returning vertical load upon heel-toe ground contact of the prosthetic foot in gait by the respective compression and expansion of the curvatures of the forefoot and hindfoot portions of the foot keel.