PROSTHETIC FOOT

Abstract

A prosthetic foot is provided with a forefoot spring, a heel spring and a base spring. The base spring is connected to the heel spring and to the forefoot spring. The base spring has receiving means for the forefoot spring and the heel spring, into which receiving means the heel spring and the forefoot spring can be inserted. The heel spring is connected to the forefoot spring via a coupling element, and the coupling element extends forwards along the forefoot spring at least via one portion thereof.

Claims

1-73. (canceled)

74. A prosthetic foot comprising: a forefoot spring, a heel spring, and a base spring attached to or attachable to the forefoot spring and the heal spring, wherein the base spring comprising toe pockets, and wherein the forefoot spring is inserted into the toe pockets.

75. The prosthetic foot of claim 74 wherein the toe pockets are integrally molded with the base spring.

76. The prosthetic foot of claim 74 wherein the base spring comprises a heel spring pocket.

77. The prosthetic foot of claim 76 wherein the heel spring pocket is integrally molded with the base spring.

78. The prosthetic foot of claim 74 wherein the base spring comprises a composite midsection and molded ends.

79. The prosthetic foot of claim 74 wherein the base spring comprises recesses.

80. The prosthetic foot of claim 79 wherein the recesses are configured for accommodating screws.

81. The prosthetic foot of claim 74 wherein the base spring, heel spring, and forefoot spring are attachable together without fasteners or glue.

82. The prosthetic foot of claim 74 wherein the base spring, heel spring, and forefoot spring are attachable by plug in connections with each other.

83. The prosthetic foot of claim 74 wherein the toe pockets include a first toe pocket on a medial portion of the base spring and a second toe pocket on a lateral portion of the base spring.

84. The prosthetic foot of claim 83 wherein the base spring has a sandal toe on one end, and wherein the first and second pockets are on opposite sides of the sandal toe.

85. The prosthetic foot of claim 82 wherein the base spring has a sandal toe on one end which is injection molded.

86. The prosthetic foot according to claim 74, wherein the toe pocket are separated by a slit into a medial toe pocket and a lateral toe pocket.

87. The prosthetic foot according to claim 74, wherein the forefoot spring has a substantially straight forefoot portion which, towards the front, is oriented at a downward incline.

88. The prosthetic foot according to claim 74, wherein the toe pockets hold the forefoot spring with a form fit.

89. The prosthetic foot according to claim 74, wherein the pockets are of a closed design and have insertion openings.

90. The prosthetic foot according to claim 74, wherein the base spring has middle portion, which is adjoined at both ends by the toe pockets and a heel spring pocket.

91. The prosthetic foot according to claim 74, wherein a connecting means, provided for securing the prosthetic foot to a below-knee socket, is arranged on the proximal end of the prosthetic foot.

92. The prosthetic foot according to claim 91, wherein the connecting means has a shock absorber.

93. The prosthetic foot according to claim 91, wherein the forefoot spring is designed as a straight flat spring, the connecting means arranged at a rear portion of the forefoot spring.

94. The prosthetic foot according to claim 74, wherein the forefoot spring and the base spring have a slit.

95. The prosthetic foot according to claim 76, wherein the heel spring pocket holds the heel spring with a form fit.

96. The prosthetic foot according to claim 76, wherein the heel spring pocket is of a closed design and have an insertion opening.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Illustrative embodiments of the invention are explained in more detail below with reference to the attached figures.

[0046] FIG. 1 shows a prosthetic foot in an exploded and perspective view;

[0047] FIG. 2a shows a side view of a prosthetic foot according to FIG. 1;

[0048] FIG. 2b shows a plan view of the prosthetic foot according to FIG. 1;

[0049] FIG. 3 shows an exploded side view of the prosthetic foot according to FIG. 2a;

[0050] FIGS. 3a, 3b show variants of the FIG. 3 embodiment;

[0051] FIGS. 4a, 4b show a base spring in two perspective views;

[0052] FIG. 5a shows a side view of an alternative embodiment of the prosthetic foot;

[0053] FIG. 5b shows an exploded and perspective view of the prosthetic foot according to FIG. 5a;

[0054] FIG. 6a shows a side view of a further alternative embodiment of the prosthetic foot with a shock absorber,

[0055] FIG. 6b shows an exploded view of the foot according to FIG. 6a;

[0056] FIG. 7 shows an exploded and perspective view of a further embodiment of the invention;

[0057] FIG. 7a shows an exploded side view of the embodiment of FIG. 7;

[0058] FIG. 7b shows a side view of the assembled embodiment of FIG. 7;

[0059] FIG. 8 illustrates a modified base spring having cylindrical or frustro-conical receiving means for receiving ends of the forefoot spring; and

[0060] FIG. 9 illustrates a further variation of the caps shown in the FIG. 7 embodiment.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION

[0061] In FIG. 1, a prosthetic foot 1 comprising a forefoot spring 2, a heel spring 3 and a base spring 4 in form of a base spring is shown in an exploded and perspective view. The forefoot spring 2 has a substantially straight vertical portion 22 which, after a curvature, merges into a substantially straight forefoot portion 21. The forefoot portion 21 extends forwards at a downward incline and can have a further bend in the toe area, such that the toe area is oriented substantially horizontally or is curved slightly upwards. In the front end area of the forefoot portion 21, sleeves or caps 24 can be arranged which at least partially enclose the forefoot spring 2. The forefoot spring 2 can be made of a plastic or of a composite material, in particular a fibre-reinforced plastic. A connecting means 6 in the form of a conventional adapter is positioned on the vertical portion 22. It is secured by bolts 9, which are guided through a securing plate or reinforcement plate 8. The bolts 9 pass through the reinforcement plate 8, a coupling element 5 and the vertical portion 22 of the forefoot spring 2 and are screwed into the adapter 6.

[0062] By means of the bolts 9, the forefoot spring 2 is coupled mechanically to the coupling element 5 in the proximal area of the vertical portion 22. The coupling element 5 likewise has a vertical portion 51, which is adjoined by a forwardly directed portion 52. The transition between the vertical portion 51 and the front portion 52 is likewise effected via a bend, which is arranged in the area of the natural ankle. The coupling element is likewise designed as a spring and extends with the front portion 52 substantially parallel to the forefoot portion 21 of the forefoot spring 2.

[0063] A front area 521 of the coupling element 5 is provided with bores through which screws 10 are guided. In the front area 521 of the coupling element 5, the screws 10 provide a mechanical connection to the front end area 31 of the heel spring. The front end area 31 of the heel spring 3 is likewise provided with bores or recesses through which the screws 10 extend, and the screws 10 are fixed in sleeves 11.

[0064] The heel spring 3 is designed with a slight curve and slopes gently downwards in the front end area, whereas the curvature extends in the opposite direction at the rear end 32 of the heel spring, such that there is a substantially horizontal orientation in the rear end 32. A spring element 7 in the form of an elastomer component is arranged between the heel spring 3 and the ankle area of the coupling element 5.

[0065] The rear end 32 of the heel spring 3 can likewise be lined with a sleeve or cap 34, which can be inserted into a rear receiving means 43 of the base spring 4.

[0066] The receiving means 43 of the one-piece base spring 4 is designed as a pocket, which forms a closed cap. The base spring 4 is arched slightly upwards and also has, at the front end, receiving means 42 for receiving the forefoot spring 2. The design of the forefoot spring 2 and also of the base spring 4 is explained in more detail below.

[0067] FIG. 2a shows the prosthetic foot 1 in the assembled state. It will be noted that the bolts 9 extend through both the coupling element 5 and also the forefoot spring 2 and engage in threads in the adapter element 6. The vertical portions 22, 51 of the forefoot spring 2 and of the coupling element 5 extend parallel to each other and substantially vertically, both vertical portions 22, 51 being adjoined by a bent ankle area that has a curvature, for example a smooth curvature in the shape of a sector of a circle. The forwardly directed portion 52 of the coupling element 5 extends along part of the length of the forefoot portion 21, parallel to the forefoot portion 21, and can either bear on the underside of the forefoot portion 21 or have a small gap between itself and the forefoot portion 21. A wedge 12 in the ankle area of the coupling element 5 has a straight underside, such that, after the start of the curvature in the ankle area, there is a rectilinear continuation for supporting the spring element 7.

[0068] It will also be seen from FIG. 2a that the screws 10 end flush on the upper face of the front area 521 of the coupling element 5 and extend through both the coupling element 5 and also the heel spring 3. The heel spring 3 has an upwardly curved profile and extends rearward beyond the vertical portion 22, 51 of the forefoot spring 2 and of the coupling element 5. The rear end 32 is received in the receiving means 43 of the base spring 4. The base spring 4 has a slight upward curvature so as to be able to lengthen at heel strike, in order to provide an additional spring action. The front end of the base spring 4 is likewise provided with a receiving means 42, into which the front end of the forefoot area 21 of the forefoot spring 2 engages with a form fit.

[0069] In the assembled state shown, the front end of the forefoot spring 2 and the rear end 32 of the heel spring 3 press in different directions against the receiving means 42, 43 designed as pockets, such that the forefoot spring 2 and the heel spring 3 are tensioned against each other. This has the effect that the base spring 4 is under tensile stress, such that the upwardly directed arch tends to be pressed down. The tension between the heel spring 3 and the forefoot spring 2 is applied and maintained via the resilient coupling element 5. It will be seen from the plan view in FIG. 2b that both the base spring 4 and also the forefoot spring 2 have a slit 46, 26 that extends along approximately the first third of the forefoot spring 2. By means of the slits 26, 46, it is possible to permit and to compensate for different loading in the medial-lateral direction in the forefoot area.

[0070] FIG. 3 shows an exploded and perspective side view of the prosthetic foot 1. The figure clearly shows the forefoot spring 2 with the vertical portion 22, the curved ankle portion 23 in the shape of a sector of a circle, the forefoot area 21 and the sleeves 24 for insertion into the front receiving means of the base spring 4. The adapter 6 with the pyramid connector for connection to the other components of a prosthesis is mechanically secured, together with the coupling element 5, on the vertical portion 22 of the forefoot spring 2 by means of the bolts 9 and the reinforcement plate 8. The coupling element 5, which can also be designated as a securing spring, also has a vertical portion 51, a forwardly inclined front portion 52 and an ankle portion 53, which is designed corresponding to the ankle portion 23 of the forefoot spring 2. Arranged on the outer side of the curve is the wedge 12, which is provided as a continuation and bearing for an additional spring element 7. Instead of a spring element 7, it is also possible to provide a wedge-shaped spring element 7, as shown in FIGS. 3a and 3b, that prevents or restricts relative movement between the ankle area 53 and the wedge 12 to the rear end of the heel spring 3.

[0071] FIGS. 3a and 3b show a variant of the embodiment according to FIG. 3 in an assembled state. In FIGS. 3a and 3b, the spring element 7 has been replaced with a wedge-shaped spring element 7. In FIG. 3a the spring element 7 is not inserted. The prosthetic foot can be used without the spring element 7, if the patient prefers a soft heel. For fixing the spring element 7 a retainer element 57 in form of a protrusion is provided at the coupling element 5. The wedge-shaped spring element 7 is inserted or slid in the tapered gap between the coupling element 5 and the heel spring 3 and is held there form-fittingly by the retainer element 57. The assembled state is shown in the FIG. 3b. With such an installed spring element 7 it is possible to vary the stiffness of the heel. With an installed spring element 7 a stiffer heel is provided than without the spring element 7. Various different stiffnesses of the spring element 7 can be provided to adopt the stiffness of the prosthetic foot to the preferences of the patient during the tread.

[0072] FIGS. 4a and 4b show different views of a base spring 4. The base spring 4 has front and rear receiving means 42, 43 with insertion openings 421, 431, such that the respective portions 24, 34 of the forefoot spring 2 and of the heel spring 3 can be inserted and held with a form fit in the receiving means 42, 43. The slit 46, which is formed almost to the halfway point of the base spring 4, permits a medially/laterally directed compensating movement. In the middle portion 44 of the base spring, an arch is provided which is directed upwards in order to make available an additional spring action. Locking elements, tensioning elements or form-fit elements can be arranged in the receiving means 42, 43 so as to be able to hold the springs 2, 3 securely in the receiving means 42, 43. These locking elements can be designed as projections, for example, and the pretensioning means can likewise be designed as springs or elastomer elements that are arranged in and/or on the receiving means 42, 43. Because of the arrangement of the slit 46 in the base spring 4, two receiving means 42 are provided in the forefoot area of the base spring 4. In a design of the forefoot spring without a slit, only one receiving means 42 is provided and needed. The base spring 4 can be made from an injection moulded part and be designed in one piece. It is also possible for a reinforcing element, for example a curved and fibre-reinforced plastic spring, to be placed in an injection mould and then encapsulated with a plastic, such that the receiving means 42, 43 are formed integrally on the base spring. It is also possible in principle for the base spring 4 to be designed in several pieces, such that the receiving means 42, 43 are secured on the middle portion 44, for example by screwing, adhesive bonding, welding or some other way.

[0073] FIGS. 5a and 5b show an alternative embodiment of the invention. The basic structure of the prosthetic foot 1 corresponds to that shown in FIGS. 1 to 4. Identical reference signs designate identical structural parts. In contrast to the design according to FIGS. 1 to 4, the prosthetic foot 1 according to FIGS. 5a and 5b does not have a vertical portion 22, 51 on the forefoot spring 2 and the coupling element 5. The forefoot spring 2 and the coupling element 5 are thus designed as substantially straight springs, and the adapter 6 is once again secured by screws that pass through the coupling element 5 and the forefoot spring 2. Such a prosthetic foot is of advantage when there is a considerable below-knee length and when, as a result, the upper attachment point of the prosthetic foot 1 cannot be moved upwards to the desired extent. In addition, the adapter 6, at the surface facing the forefoot spring 2, is rounded or has a haunch so that there is no edge or rim facing to the upper surface of the forefoot spring. If a rim or edge is acting on the upper surface of the forefoot spring 2 and the adapter 6 is moved relatively to the forefoot spring, very high stress is applied to the forefoot spring, which is usually made of fiber composite material. By pressing a rim or edge onto the surface of the spring, a very small indentation is made, which may lead to a weakening of the material and to wear of the forefoot spring. With a rounded and smooth surface of the adapter 6, a kind of wedge is created in which an elastomer can be integrated.

[0074] FIGS. 6a and 6b show an alternative embodiment of the invention. The basic structure of the prosthetic foot 1 corresponds to that in FIGS. 1 to 4. In addition to the customary adapter 6, a shock absorber 61 is also provided that is able to take up axial loads and torques about the vertical axis. The shock absorber 61 serves to further increase the comfort level and affords further possibilities of adjustment, to ensure that the rollover can be adapted to the wishes of the prosthetic foot user. The stiffness can be adjusted by exchanging the absorption element for one with greater stiffness or by increasing the pretensioning in the absorption element of the shock absorber 61. The shock absorber 61 can also comprise a vacuum pump.

[0075] The base spring 4 is easy to produce and can be easily exchanged. It is thus possible to adapt the prosthetic foot 1 to the requirements of the particular user. It is set up in a simple way, by inserting the front ends of the forefoot spring 2 with the caps 24 into the front receiving means 42 and by inserting the rear end of the heel spring 3, if appropriate with a cap, into the rear receiving means 43, such that the base spring 4 is held securely on the prosthetic foot 1 as a result of the tension between the front and rear ends of the forefoot spring 2 and heel spring 3. At heel strike, the force is transferred at least partially to the forefoot spring 2, by means of the arch, in the middle area 44, stretching until the base spring 4 transfers tensile forces without deformation directly to the receiving means 42, which then in turn transfers forces to the forefoot spring 2. It is thus possible for all of the spring elements, namely the forefoot spring 2, the coupling element 5, the heel spring 3 and the base spring 4, to be utilized at heel strike in order to store and then deliver kinetic energy. This has the effect that all of the individual spring elements 2, 3, 4, 5 are coupled to one another and contributes to storing energy, such that each individual spring element 2, 3, 4, 5 can be made smaller than would be the case if it had to perform only partial functions in isolation.

[0076] The prosthetic foot 1 according to the invention has five main components, namely the forefoot spring 2, the coupling element 5, which is secured on the forefoot spring 2, the heel spring 3, which is secured on the coupling element 5, the base spring 4, which connects the front end 21 of the forefoot spring 2 to the rear end 32 of the heel spring 3, and the fifth component, the adapter element 6, which is designed as a conventional pyramid adapter with elements for securing to other components of a prosthetic leg. The springs 2, 3, 4, 5 are preferably made from fibre-reinforced plastic materials, in particular carbon-fibre-reinforced plastics, which are configured as so-called composite materials. The cross section of the springs 2, 3, 4, 5 is preferably rectangular or almost rectangular, a bend or deformation being effected preferably only in one plane. At the end areas, caps 24, 34 or protective elements can be provided for the springs. The base spring 4 can contain a core made of composite material. The base spring 4 with an upwardly directed arch, i.e. oriented towards the adapter 6, is moved or forced into a straight shape by application of a tensile force or of a bending moment. A spring action is achieved in this way. Such a base spring 4 provides a smooth rollover movement during mid-stance, on account of a plantar flexion of the toe area during loading of the heel, since the front end 21 of the forefoot spring 2 is drawn down when the heel strike occurs. The base spring 4 increases the energy return, both of the forefoot spring 2 and also of the heel spring 3, and thus provides a satisfying sensation when walking, because of the additional spring resistance. This is achieved by the excursion of the springs on account of the uniform load distribution resulting from the connection of the base spring 4 both to the forefoot spring 2 and also to the heel spring 3. As has already been discussed, the base spring 4 also increases the stability of the prosthetic foot 1, because the applied loads are divided up between the four spring components 2, 3, 4, 5. Overall, this has the effect that the prosthetic foot 1 has the features of an ankle joint, without having to accept any of the disadvantages of a traditional ankle joint, such as wear, complex construction, costs and maintenance.

[0077] The coupling element 5 has a number of advantages, for example the fact that the length of the heel support is extended, which leads overall to increased flexibility. The coupling element 5 reduces the load in the area of the attachment to the heel spring 3, which again leads to increased stability. The coupling element 5 further serves as an overload spring if unusually high loads occur. In the event of unusually high loads, the coupling element 5 can come into contact with the forefoot spring 2 in the front area or with the base spring 4, depending on the nature of the load that is applied. In this way, the direction in which the load is introduced is changed, which leads to an increased load-hearing capacity of the entire prosthetic foot 1.

[0078] The slit base spring 4 and the slit forefoot spring 2, with the orientation of the slit 26, 46 in the anterior-posterior direction, permit increased medial-lateral mobility of the prosthetic foot 1, which in turn leads to improved adaptability of the tread surface on the ground. The improved adaptability to the ground surface increases the comfort and stability experienced by the person using the prosthetic foot 1.

[0079] With the prosthetic foot 1, various configurations of the springs with different degrees of stiffness can be used, so as to be able to adapt to different weight categories for a defined size of the prosthetic foot 1. The modular, reversible mode of construction allows the prosthetic foot 1 to be dismantled for maintenance purposes, such that defective individual parts can be replaced and such that the prosthetic foot 1 can be adapted to a change of weight, to a change of loads, to a change in the degree of mobility or to the individual requirements of the users. It can be adapted easily by using a spring with a different degree of stiffness. The modular, reversible design permits a simplified assembly procedure, since the individual components are screwed together or fitted into one another. Adhesive bonding of the individual components of the prosthetic foot is no longer necessary, although this can be carried out in the area of the receiving means 42, 43 in order to reduce wear.

[0080] Adapting the degree of stiffness of the prosthetic foot 1 is mainly achieved by changing the thickness of the individual springs 2, 3, 4. The thicker a spring is, the stiffer it is, unless changes are made. It has therefore proven advantageous that the receiving means 42, 43 in the base spring 4 have identical dimensions, which are preferably adapted to the maximum stiffness, and that adaptation to the respective spring dimension is effected using compensating elements that are fitted onto the springs, cast onto the springs or fitted into the receiving means or injected in before assembly.

[0081] FIG. 7 illustrates further refinements of the invention. As illustrated in FIG. 7, a friction element 71 is inserted between the forefoot spring 2 and the coupling element 5. The purpose of this friction element 71 is to eliminate or reduce noise. In addition, the forefoot spring has an elongated slit 26 which provides more flexibility in rollover. In the embodiment shown in FIG. 7, the bolts 9 attach to adapter 6 by means of threaded through holes 72. These holes are covered by a cover plate 73, made of any suitable material such as composite or metal. The cover plate 73 may be attached as a friction fit into grooves in the adapter 6 or by adhesive. Caps 74 are shown at the front end of the forefoot spring 2. In the embodiment shown in FIG. 7, the forefoot spring 2 is more or less flat and the caps 74 have corresponding receiving means. Because of the longitudinal slits in the forefoot spring 2 and the base spring 4, it is possible that the springs rotate relative to each other in a way that the inserted forefoot spring 2 is turned inside the receiving pockets 42 of the base spring 4. To minimize the torsional stress along the longitudinal axis of the forefoot spring 2, it is advantageous to allow a relative rotation movement between the caps 74 and the corresponding receiving pockets 42. To achieve this, a conical or cylindrical design is provided, so that the outer surface of the caps can rotate inside the receiving pockets. A stop can be implemented to set a limit for the turning movement.

[0082] FIGS. 7a and 7b are side views of the embodiment shown in FIG. 7 in an unassembled state and an assembled state, respectively.

[0083] FIG. 8 illustrates a modification of the base spring 4, similar to the embodiment in FIG. 4a but in which the receiving pockets 42 are provided with cylindrical or frusto-conical insertion openings 421 into which ends of the base spring 4 are inserted.

[0084] FIG. 9 shows a variation of the embodiment of FIG. 7 in which the caps 74 are cylindrical or frusto-conical.

[0085] While the invention has been described in terms of preferred embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the appended claims.