Method for computer aided orthotic inlay fabrication

• US 20010047246A1
• Filed: 03/13/2001
• Published: 11/29/2001
• Est. Priority Date: 03/13/2000
• Status: Active Grant

• Current Assignee: Fullen Systems, LLC
• Original Assignee: Fullen Systems, LLC
• Inventors: Fullen, George R., Fullen, Jeryl G.
• Granted Patent: US 6,804,571 B2
• Time in Patent Office: Days
• US Class Current: 702/33
• CPC Class Codes: A43D 1/025 comprising optical means, e.g. mirrors, photo-electric cells, for measuring or inspecting feet
• CPC Class Codes: A61B 5/1036 Measuring load distribution, e.g. podologic studies
• CPC Class Codes: G16H 10/60 for patient-specific data, e.g. for electronic patient records
• CPC Class Codes: G16H 40/63 for local operation
• CPC Class Codes: G16H 50/50 for simulation or modelling of medical disorders
• CPC Class Codes: G16Z 99/00 Subject matter not provided for in other main groups of this subclass

Abstract

The present invention relates to a process for determining the magnitude and distribution of forces on a foot during ambulation and utilizing this data in combination with a plurality of other factors to create an orthotic inlay with an automated inlay fabricating machine.

Claims

1. A process for making an orthotic inlay based on plantar surface force measurements taken during subject ambulation, comprising:

obtaining force data which is indicative of the magnitude and distribution of forces present on the plantar surface of a foot during ambulatory functions;

generating optimum orthotic shape inlay data based on said force data and a desired pressure distribution, and

fabricating said orthotic inlay using said orthotic inlay shape data.

2. The process of

claim 1

, further comprising utilizing data related to a footwear shape to generate said optimum orthotic shape inlay data.

3. The process of

claim 1

, wherein said obtaining force data step comprises downloading said force data to a data storage means.

4. The method of

claim 1

, wherein said fabricating step comprises cutting and shaping an orthotic inlay material on at least four distinct sides.

5. The method of

claim 1

, wherein said orthotic inlay material is comprised of a pliable material capable of being resiliently compressed.

6. The method of

claim 1

, wherein said fabricating step is automatically performed on an inlay fabrication machine receiving computer generated instructions which contain said optimum orthotic shape inlay data.

7. The process of

claim 1

, wherein said orthotic shape inlay data is further generated for a specific physical activity for each individual user.

8. The process of

claim 1

, wherein said generating optimum orthotic shape inlay data step further comprises considering the material characteristics of an orthotic inlay material prior to fabricating said orthotic inlay.

9. The process of

claim 1

, wherein said fabricating step further comprises determining an optimum thickness of an orthotic inlay material at a plurality of locations based on said obtaining force data step.

10. The process of

claim 1

, wherein said obtaining force data step further comprises determining a plurality of translational forces present on the plantar surface of the foot.

11. The process of

claim 1

, wherein said obtaining force data step comprises positioning a force sensor array inside a user'"'"'s footwear which is positioned below the plantar surface of a foot.

12. A method for fabricating an orthotic inlay using force data indicative of the magnitude and distribution of forces present on a foot, comprising:

providing an automated inlay fabrication apparatus with a means for holding an orthotic inlay material and at least one cutting instrument;

a memory means;

a central processing unit;

a data input means;

a communications means which allows the transmission of information and instructions between said central processing unit and said automated inlay fabrication apparatus;

providing a formable inlay material for use in said inlay fabrication apparatus;

obtaining the force data which is indicative of the magnitude and distribution of forces present on a plantar surface of a foot during ambulatory functions;

storing the force data in said memory means;

generating optimum shape inlay data with said central processing unit by utilizing the force data; and

fabricating said orthotic inlay using the force data and said inlay material positioned on said automated inlay fabrication apparatus.

13. The method of

claim 12

, wherein said automated inlay fabrication apparatus further comprises a visual display means such as a computer monitor.

14. The method of

claim 12

, wherein said memory means comprises a computer hard drive.

15. The method of

claim 12

, wherein said data input means comprises an operator interface such as a keyboard or a mouse.

16. The method of

claim 12

, wherein said communications means comprises a communications cable.

17. The method of

claim 12

, wherein said obtaining force data step comprises

positioning a foot sensor array between the plantar surface of the foot and an interior surface of a shoe, said foot sensor array having a plurality of row and column electrodes with intersections at a plurality of locations and which have a resistive material positioned between said rows and columns of electrodes at each of said intersections, wherein the magnitude, distribution and relative change of pressure applied at each of said intersections can be measured.

18. The method of

claim 12

, wherein said fabricating said orthotic inlay step comprises:

positioning said inlay material in said inlay fabrication apparatus in a predetermined position;

orienting said at least one cutting instrument with respect to said inlay material; and

cutting said inlay material on at least four distinct sides based on operating instructions generated from said optimum shape inlay data.

19. A process for a computed assisted fabrication of an orthotic inlay which is adapted for a user'"'"'s foot, comprising the steps of:

a) measuring the magnitude and distribution of forces on a plantar surface of a foot during ambulatory functions to obtain force distribution data;

b) utilizing said force distribution data in combination with information relating to a desired pressure distribution profile to create an optimum orthotic shape inlay data profile; and

c) fabricating an orthotic inlay comprised of a substantially resilient material by shaping said substantially resilient material into a predetermined shape on an automated inlay fabrication apparatus based on said orthotic shape inlay data profile.

20. The process of

claim 19

, wherein a thickness of said substantially resilient material for said orthotic inlay is determined at a plurality of locations based on said force distribution data and an intended purpose of use.

21. The process of

claim 19

, wherein said automated inlay fabrication apparatus is operated by a computer numeric control system in operable communication with a central processing unit.

22. The process of

claim 19

, wherein said automated inlay fabrication apparatus capable of shaping said substantially compressible material in three distinct directions.

23. The process of

claim 19

, wherein said substantially resilient material is compressible.