PROSTHETIC LIMB SLEEVE

Abstract

A sleeve for mounting a prosthetic unit on a limb is formed using a tripartite composite that includes a breathable woven fabric in combination with an elastic urethane middle layer and a soft perforated plastic inner layer. The middle layer can be a hyper-elastic polymer that is cured to a hemispherical shape to stretch and move while maintaining a shape memory that returns the polymer to its original shape once relieved of a stretching force. Moreover, the liner/prosthetic sleeve of the present invention's anatomical suspension works as an advantage to maintain its placement on the user's residual limb.

Claims

1. A sleeve for use in conjunction with mounting a prosthetic device on a limb, comprising: a hollow cylindrical sleeve having a closed first end and an open second end, the cylindrical sleeve formed of a unitary tripartite composite, comprising: an outer layer of a breathable elastic fabric formed with spaced apart holes; an intermediate layer formed in a honeycomb pattern of a flexible, thermoplastic polymer; and an innermost layer of a perforated plastic; wherein each of the layers are sealed together to form a unitary composite.

2. The sleeve of claim 1, wherein the intermediate layer is formed of a flexible thermoplastic urethane silicone.

3. The sleeve of claim 2, wherein a thickness of the intermediate layer is equal to a thickness of the innermost layer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] FIG. 1 is an elevated, perspective view of a first embodiment of the present invention;

[0006] FIG. 2 is an enlarged, perspective view in shadow of the sleeve of the present invention;

[0007] FIG. 3 is an enlarged, sectional view of the tripartite layers of the present invention;

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] FIG. 1 illustrates how an amputated leg fits inside of a prosthetic device. The prosthetic device 10 is hollow and the limb 15 is covered with a sleeve 20 that protects the limb from wear, friction, abrasion, and general discomfort from wearing the prosthetic for long periods of time. Such sleeves 20 are typically made of a soft material such as a sock that can easily be slipped over the limb, or a more protective material that offers more protection at the expense of comfort and breathability. The present invention offers both comfort and protection in a unique tripartite material composition. This design also allows the sleeve to become more breathable and to facilitate airflow from hot spots, with the hyper-elastic polymer material adding a waterproof and hygienic feature. The sleeve has the capability to support highly advanced fabrics to provide a supportive, breathable mesh on the inner and outer shell of the prosthetic liner.

[0009] FIG. 2 illustrates a hollow cylindrical sleeve 20 having a closed first end 22 and an open second end 24. The sleeve is sized to fit an amputated limb with some snugness, so it is designed to stretch around the limb for a close but not tight fit. The sleeve 20 has spaced apart holes over the entire surface of the sleeve for aerating the limb and for cooling purposes. In a first embodiment, the grooves are recessed and lead to air channels that line the inside wall. With this, air and moisture is able to travel both horizontally and vertically to escape through the outer surface. Channels and pathways built on the inner wall of the liner facilitate the movement, flow and circulation of air and moisture to cool the residual limb as well as allowing for hot air to escape. This allows for the liner to passively maintain and cool the residual limb as the user wears it.

[0010] FIG. 3 shows the three layers that make up the composition of the composite sleeve 20 of the present invention. The outer layer 30 is a breathable, elastic fabric that incorporates holes at regular intervals over the surface of the material. The outer layer 30 must be of a nature that it can bond with the intermediate layer, either through thermal bonding or some other bonding technique. The middle layer 32 is a flexible thermoplastic urethane silicone that forms a honeycomb structure with openings that permit moisture and heat to pass through. The flexible thermoplastic urethane silicone is stretchable in all directions and is sandwiched between the outer and inner layers. The inner layer 34 is a soft plastic material with perforations and has a thickness that is approximate to the middle layer 32. The inner layer is moisture wicking to extract perspiration and wick it to the outer layer while providing a soft and more comfortable interface with the patient's skin. The three layers are sealed together into a unitary composite and formed into the cylindrical or conical sleeve 20 as shown in FIG. 2.

[0011] The sleeve 20 of the present invention can be manufactured in multiple ways depending on the material used at the time of production. One manufacturing process involves the tooling of negative molds that are lined with the selected moisture wicking fabric to be joined with a urethane silicone polymer that is poured in and cured to the specified shape and design. There are multiple molds based on thickness and sizing to fit an array of individuals. These molds include the recessed air channels and pathways along with the holes to allow for additional air flow. Another method uses a prefabricated thermoformable cone made from a foam like material. After selecting and adjusting the material to a predetermined thickness, length and size, it is placed on a positive mold where it is then covered and placed in a vacuum forming and heating machine. After approximately 5-10 minutes it is removed and allowed to cool. The mold includes the positive indentations that emboss the design on the inner walls of the liner. The final step for both manufacturing process involves inspecting for imperfections, quality testing, and final adjustments to ensure efficacy.

[0012] While specific embodiments of the present invention have been described herein, the invention is not limited to the embodiments shown or described but rather the breadth of the invention includes non-described embodiments. A person of ordinary skill in the art would readily recognize various modifications, substitutions, and alterations to the above described embodiments, and the scope of the invention is intended to include all such modifications, substitutions, and alterations.