Pedorthic systems

• US 7,640,680 B1
• Filed: 09/20/2005
• Issued: 01/05/2010
• Est. Priority Date: 09/20/2004
• Status: Active Grant

• Current Assignee: Arizona Afo, Inc. (Orthotic Holdings, Inc.)
• Original Assignee: Ergis Company LLC
• Inventors: Castro, Ernesto G.
• Primary Examiner(s): Snow; Bruce E
• Assistant Examiner(s): HOBAN, MELISSA A
• Application Number:
  US11/231,489
• Time in Patent Office: 1,568 Days
• Field of Search: 623/29, 623 53- 55, 361/40, 361/54, 36/88, 602/28
• US Class Current: 36/140
• CPC Class Codes: A43B 7/00 Footwear with health or hygienic arrangements
• CPC Class Codes: A43B 7/28 Adapting the inner sole or the side of the upper of the shoe to the sole of the foot
• CPC Class Codes: A61F 2/5046 for designing or making customized prostheses, e.g. using templates, finite-element analysis or CAD-CAM techniques
• CPC Class Codes: A61F 2/66 Feet; Ankle joints
• CPC Class Codes: A61F 2002/5052 Direct moulding or reforming to the stump
• CPC Class Codes: A61F 2002/6614 Feet
• CPC Class Codes: A61F 3/00 Lengthening pieces for natural legs
• CPC Class Codes: A61F 5/0111 for the feet or ankles
• CPC Class Codes: A61F 5/0195 Shoe-like orthopaedic devices for protecting the feet against injuries after operations

Abstract

The present invention provides improved pedorthic systems for patients having partial foot amputations or foot neuropathies. Custom-molded, custom-made pedorthics with leather linings and molded stiffeners are disclosed, along with methods of manufacture. Custom-molded, custom-made pedorthics and ankle-foot orthoses having solid, molded fillers to replace the volume of missing foot portions are also provided, along with methods of manufacture.

Claims

1. A pedorthic support system, relating to at least one pedorthic adapted to assist at least one patient requiring lower limb immobilization in order to walk, comprising:

a) at least one insole adapted to support at least one lower limb in such at least one pedorthic;

b) at least one inner lining;

c) wherein said at least one insole is positioned inward of said at least one inner lining;

d) at least one balancer adapted to balance such at least one pedorthic, wherein said at least one balancer underlies heel and arch portions of said at least one inner lining on the bottom of such at least one pedorthic;

e) at least one padding adapted to pad such at least one pedorthic;

f) wherein said at least one balancer, said at least one inner lining, and said at least one insole are positioned inward of said at least one padding;

g) at least one stiffener adapted to stiffly support the lower limb and the foot in such at least one pedorthic

i) wherein said at least one padding, said at least one balancer, said at least one inner lining, and said at least one insole are positioned inward of said at least one stiffener, and

ii) wherein said at least one stiffener extends forward to the toe-end of such at least one pedorthic along the bottom of such at least one pedorthic;

h) at least one spring adapted to spring such at least one pedorthic, wherein said at least one spring underlies said at least one stiffener;

i) at least one outer lining, wherein said at least one outer lining covers the exterior surface of such at least one pedorthic; and

j) at least one closure adapted to close such at least one pedorthic.

2. The pedorthic support system, according to claim 1, further comprising at least one resilient unitary filler adapted to fill at least one void exterior to said at least one inner lining, and adapted to mold to the shape of such exterior of said at least one inner lining.

3. The pedorthic support system, according to claim 1, further comprising at least one sole, wherein said at least one sole substantially underlies said at least one spring on the bottom of such at least one pedorthic.

4. The pedorthic support system, according to claim 3, further comprising at least one midsole, wherein said at least one midsole substantially underlies said at least one spring on the bottom of such at least one pedorthic, and wherein said at least one sole substantially underlies said at least one midsole.

5. A pedorthic support system, relating to at least one pedorthic adapted to assist at least one patient requiring lower limb immobilization in order to walk, comprising:

a) at least one insole adapted to support at least one lower limb in such at least one pedorthic, wherein said at least one insole is custom-molded to the shape of the bottom of such at least one patient'"'"'s lower limb;

b) at least one inner lining

ii) wherein said at least one inner lining is custom shaped to fit around at least said at least one insole and at least one portion of such at least one patient'"'"'s lower limb;

c) wherein said at least one insole is positioned inward of said at least one inner lining;

d) at least one padding adapted to pad such at least one pedorthic;

e) wherein said at least one inner lining and said at least one insole are positioned inward of said at least one padding;

f) at least one stiffener adapted to stiffly support the lower limb in such at least one pedorthic

i) wherein said at least one padding is positioned inward of said at least one stiffener,

ii) wherein said at least one stiffener is custom-molded to the shape of the at least one underlying layer(s), and

iii) wherein said at least one stiffener extends forward to the toe-end of such at least one pedorthic along the bottom of such at least one pedorthic;

g) at least one balancer adapted to balance such at least one pedorthic, wherein said at least one balancer underlies heel and arch portions of said at least one stiffener on the bottom of said at least one inner lining;

h) at least one spring adapted to spring such at least one pedorthic, wherein said at least one spring underlies said at least one stiffener;

i) at least one outer lining, wherein said at least one outer lining covers the exterior surface of such at least one pedorthic; and

j) at least one closure adapted to close such at least one pedorthic.

6. The pedorthic support system, according to claim 5, further comprising at least one resilient unitary filler adapted to fill at least one void exterior to said at least one inner lining, and adapted to mold to the shape of such exterior of said at least one inner lining.

7. The pedorthic support system, according to claim 6, wherein said at least one resilient unitary filler comprises at least one polyurethane foam.

8. The pedorthic support system, according to claim 6, wherein said at least one resilient unitary filler comprises at least one tough, microcellular, flexible, two-component, polyurethane foam.

9. The pedorthic support system, according to claim 5, further comprising at least one sole, wherein said at least one sole substantially underlies said at least one spring on the bottom of such at least one pedorthic.

10. The pedorthic support system, according to claim 9, wherein said at least one sole comprises at least one leather.

11. The pedorthic support system, according to claim 9, wherein said at least one sole comprises at least one plastic.

12. The pedorthic support system, according to claim 9, further comprising at least one midsole, wherein said at least one midsole substantially underlies said at least one spring on the bottom of such at least one pedorthic, and wherein said at least one sole substantially underlies said at least one midsole.

13. The pedorthic support system, according to claim 5, wherein said at least one insole comprises at least one thermoplastic foam.

14. The pedorthic support system, according to claim 5, wherein said at least one inner lining comprises at least one leather.

15. The pedorthic support system, according to claim 5, wherein said at least one padding comprises at least one thermoplastic foam.

16. The pedorthic support system, according to claim 5, wherein said at least one stiffener substantially comprises at least one thermoformable polyethylene sheet material.

17. The pedorthic support system, according to claim 5, wherein said at least one balancer comprises cork in at least one thermoplastic matrix.

18. The pedorthic support system, according to claim 5, wherein said at least one spring comprises at least one carbon fiber plate.

19. The pedorthic support system, according to claim 18, wherein said at least one carbon fiber plate comprises at least one carbon-fiber laminate.

20. The pedorthic support system, according to claim 5, wherein said at least one outer lining comprises at least one leather.

21. A pedorthic support system, relating to at least one pedorthic adapted to assist at least one patient requiring lower limb immobilization in order to walk, comprising:

a) at least one insole adapted to support at least one lower limb in such at least one pedorthic, wherein said at least one insole is custom-molded to the shape of the bottom of such at least one patient'"'"'s lower limb;

b) at least one inner lining

ii) wherein said at least one inner lining is custom shaped to fit around at least said at least one insole and at least one portion of such at least one patient'"'"'s lower limb;

c) wherein said at least one insole is positioned inward of said at least one inner lining;

d) at least one balancer adapted to balance such at least one pedorthic, wherein said at least one balancer underlies heel and arch portions of said at least one inner lining on the bottom of such at least one pedorthic;

e) at least one padding adapted to pad such at least one pedorthic;

f) wherein said at least one balancer, said at least one inner lining, and said at least one insole are positioned inward of said at least one padding;

g) at least one stiffener adapted to stiffly support the lower limb in such at least one pedorthic

i) wherein said at least one padding, said at least one balancer, said at least one inner lining, and said at least one insole are positioned inward of said at least one stiffener substantially surrounds said at least one padding,

ii) wherein said at least one stiffener is custom-molded to the shape of the underlying layer(s), and

iii) wherein said at least one stiffener extends forward substantially to the toe-end of such at least one pedorthic along the bottom of such at least one pedorthic;

h) at least one spring, wherein said at least one spring underlies said at least one stiffener;

i) at least one outer lining, wherein said at least one outer lining covers the exterior surface of such at least one pedorthic;

j) at least one sole, wherein said at least one sole underlies said at least one spring on the bottom of such at least one pedorthic; and

k) at least one closure adapted to close such at least one pedorthic.

22. A pedorthic support system, relating to at least one pedorthic adapted to assist at least one patient requiring lower limb immobilization in order to walk, comprising:

a) at least one insole adapted to support at least one lower limb in such at least one pedorthic, wherein said at least one insole is custom-molded to the shape of the bottom of such at least one patient'"'"'s lower limb;

b) at least one inner lining

ii) wherein said at least one inner lining is custom shaped to fit around at least said at least one insole and at least one portion of such at least one patient'"'"'s lower limb;

c) wherein said at least one insole is positioned inward of said at least one inner lining;

d) at least one balancer adapted to balance such at least one pedorthic, wherein said at least one balancer underlies heel and arch portions of said at least one inner lining on the bottom of such at least one pedorthic;

e) at least one padding adapted to pad such at least one pedorthic;

f) wherein said at least one balancer, said at least one inner lining, and said at least one insole are positioned inward of said at least one padding;

g) at least one stiffener adapted to stiffly support the lower limb in such at least one pedorthic

i) wherein said at least one padding, said at least one balancer, said at least one inner lining, and said at least one insole are positioned inward of said at least one stiffener,

ii) wherein said at least one stiffener is custom-molded to the shape of the underlying layers,

iii) wherein said at least one stiffener extends forward to the toe-end of such at least one pedorthic along the bottom of such at least one pedorthic, and

iv) wherein said at least one stiffener extends upward at least to the top edge of said at least one insole at the toe-end of such at least one pedorthic;

h) at least one spring adapted to spring such at least one pedorthic, wherein said at least one spring underlies said at least one stiffener;

i) at least one outer lining, wherein said at least one outer lining covers the exterior surface of such at least one pedorthic;

j) at least one sole, wherein said at least one sole underlies said at least one spring on the bottom of such at least one pedorthic; and

k) at least one closure adapted to close such at least one pedorthic;

l) wherein such at least one pedorthic is substantially open over such at least one patient'"'"'s toes.

23. A pedorthic support system, relating to at least one pedorthic adapted to assist at least one patient requiring lower limb immobilization in order to walk, comprising:

a) at least one insole adapted to support at least one lower limb in such at least one pedorthic, wherein said at least one insole is custom-molded to the shape of the bottom of such at least one patient'"'"'s lower limb;

i) at least one inner lining, and

ii) wherein said at least one insole is positioned inward of said at least one inner lining;

iii) wherein said at least one inner lining is custom shaped to fit around at least said at least one insole and at least one portion of such at least one patient'"'"'s lower limb;

b) at least one resilient unitary filler adapted to fill at least one void exterior to said at least one inner lining, and adapted to mold to the shape of such exterior of said at least one inner lining;

c) at least one balancer adapted to balance such at least one pedorthic, wherein said at least one balancer underlies heel and arch portions of said at least one inner lining on the bottom of such at least one pedorthic;

d) at least one padding adapted to pad such at least one pedorthic;

e) wherein said at least one balancer, said at least one inner lining, and said at least one insole are positioned inward of said at least one padding;

f) at least one stiffener adapted to stiffly support the lower limb in such at least one pedorthic

i) wherein said at least one padding, said at least one balancer, said at least one inner lining, and said at least one insole are positioned inward of said at least one stiffener,

ii) wherein said at least one stiffener is custom-molded to the shape of the underlying layers, and

iii) wherein said at least one stiffener extends forward to the toe-end of such at least one pedorthic along the bottom of such at least one pedorthic;

g) at least one spring adapted to spring such at least one pedorthic, wherein said at least one spring underlies said at least one stiffener;

h) at least one outer lining, wherein said at least one outer lining covers the exterior surface of such at least one pedorthic;

i) at least one sole, wherein said at least one sole underlies said at least one spring on the bottom of such at least one pedorthic; and

j) at least one closure adapted to close such at least one pedorthic.

24. The pedorthic support system, according to claim 23, wherein such at least one pedorthic is sized and shaped to fit into at least one non-custom shoe purchased by the patient.