Abstract
A self-adjusting adapter for a prosthetic leg having a foot and a leg socket has a low stiffness spring having a central opening, a high stiffness spring that has a central opening and is adjacent the low stiffness spring, a shaft or a bolt passing through the central opening in the low stiffness spring and the central opening in the high stiffness spring and a spring stiffener configured and positioned to restrain movement of the high stiffness spring relative to the low stiffness spring in a direction parallel to the low-stiffness spring. A connector for attaching the adapter to a leg socket is connected to the bolt or shaft and is capable of pivoting about an axis through the bolt or shaft. The adapter can be used an add-on component for existing prosthetic legs, or it can be integrated with foot design for the ankle-foot product category.
Claims
1. A self-adjusting adapter for a prosthetic leg having a foot and a leg socket, the self-adjusting comprising: a low stiffness spring, having a central opening; a high stiffness spring adjacent the low stiffness spring having a central opening, one of a shaft and a bolt passing through the central opening in the low stiffness spring and the central opening in the high stiffness spring; a spring stiffener configured and positioned to restrain movement of the high stiffness spring relative to the low stiffness spring in a direction parallel to the low-stiffness spring; and a connector having a hole through which one of the shaft and the bolt passes the connector being capable of pivoting about an axis through the hole of the connector.
2. The self-adjusting adapter of claim 1 wherein at least one of the low-stiffness spring and the high stiffness spring has a spiral opening about the central opening of that spring.
3. The self-adjusting adapter of claim 1 wherein the low stiffness spring is C-shaped having a mouth and central cavity, the high stiffness spring is within the cavity and the spring stiffener covers at least a portion of the mouth.
4. The self-adjusting adapter of claim 1 wherein the low stiffness spring is an integral portion of a foot.
5. The self-adjusting adapter of claim 1 wherein the spring stiffener is comprised of a plurality of wires.
6. The self-adjusting adapter of claim 1 wherein the high stiffness spring is an integral portion of a foot.
7. The self-adjusting adapter of claim 1 wherein the high stiffness spring is an integral portion of a foot and the low stiffness spring is an integral portion of the foot.
8. The self-adjusting adapter of claim 1 wherein the high stiffness spring and the low stiffness spring have been made by 3D printing.
9. The self-adjusting adapter of claim 1 wherein the high stiffness spring and the low stiffness spring are comprised of a material selected from the group consisting of aluminum alloys, titanium alloys and carbon fiber composites.
10. The self-adjusting adapter of claim 1 also comprising a core rod through which one of the bolt and the shaft passes.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIGS. 1a and 1b show examples of angular misalignment in a conventional prosthetic leg.
[0037] FIGS. 1c and 1d show examples of linear misalignment in the same conventional prosthetic leg.
[0038] FIG. 2a is a graph of the gait cycle showing three phases (heel, ankle and fore-foot rocker) in healthy humans.
[0039] FIG. 2b is a graph in which the solid line shows ankle angle vs. ankle torque or moment in healthy humans with diamond marked data showing performance of the adapter of this invention.
[0040] FIG. 3 shows a present preferred embodiment of our adapter (as an add-on component) connected between a prosthetic leg socket and a foot.
[0041] FIG. 4 is a perspective view of the embodiment of our adapter shown in FIG. 3.
[0042] FIG. 5 is an end view thereof.
[0043] FIG. 6 is an exploded view thereof.
[0044] FIG. 7 is a top plan view of a present preferred embodiment of a 6 degree of freedom planar compliant structure (before loading).
[0045] FIG. 8 is a top plan view of another present preferred embodiment of a 6 degree of planar compliant structure (before loading).
[0046] FIG. 9 is a top plan view of a present preferred embodiment of a 6 degree of freedom planar compliant structure that demonstrates linear motion of the planar compliant structure.
[0047] FIG. 10 is a side view of the embodiment shown in FIG. 9.
[0048] FIG. 11 is a top plan view of a present preferred embodiment of a 6 degree of freedom planar compliant structure that demonstrates rotational motion of the planar compliant structure.
[0049] FIG. 12 is a side view of the embodiment shown in FIG. 9.
[0050] FIG. 13 is a side view of the embodiment of our self-aligning adapter shown in FIGS. 2 through 6 after it is attached to a foot and is in no-load condition.
[0051] FIG. 14 is a side view of the embodiment shown in FIG. 13 at the end of the heel-rocker phase (planter-flexion).
[0052] FIG. 15 is a side view of the embodiment shown in FIG. 13 at the end of the heel-rocker phase (dorsi-flexion).
[0053] FIGS. 16a and 16b are front views of the embodiment shown in FIGS. 13 through 15 showing how our self-aligning adapter provides rotational alignment in the coronal plane.
[0054] FIGS. 16c and 16d are top plan views of the embodiment shown in FIGS. 13 through 15 showing how our self-aligning adapter provides rotational alignment in the transverse plane.
[0055] FIG. 17 is an exploded view of a second present preferred embodiment of our self-aligning adapter.
[0056] FIG. 18 is an end view of the embodiment shown in FIG. 17.
[0057] FIG. 19 is a perspective view of a third embodiment where the claimed invention of a planar compliant 6 dof spring (FIG. 7 or FIG. 8) is integrated with a foot, thereby falling in the category of ankle-foot.
[0058] FIG. 20 is a perspective view of the ankle-foot embodiment shown in FIG. 19 from another perspective viewing angle.
[0059] FIG. 21 is a right side view of the ankle-foot shown in FIGS. 19 and 20.
[0060] FIG. 22 is an exploded view of a fourth embodiment of our self-aligning adapter integrated to a foot.
[0061] FIG. 23 is a perspective view of the embodiment shown in FIG. 22.
[0062] FIG. 24 is an exploded view of a fifth embodiment of our self-aligning adapter integrated to a foot.
[0063] FIG. 25 is a perspective view of the embodiment shown in FIG. 24.
[0064] FIG. 26 is exploded perspective view of a sixth embodiment in which the heel part of the foot is modified to act like a 3 degrees of freedom spring having low stiffness.
[0065] FIG. 27 is a right side view of the embodiment shown in FIG. 26.
[0066] FIG. 28 is an exploded view of a seventh present preferred embodiment of our self-aligning adapter. This embodiment has the same functionality as the embodiment shown in FIG. 6.
[0067] FIG. 29 is a perspective view of the embodiment shown in FIG. 28.
DESCRIPTION OF PRESENT PREFERRED EMBODIMENTS
[0068] To explain the product function, we provide some background of the gait cycle in FIG. 2a. The human gait cycle starts with the heel rocker phase, where the ankle provides up to 5 of plantarflexion angle and the moment is about 5 N-m. Our adapter achieves similar rotational and linear compliance in this phase to perform the self-alignment because a natural leg does the same. Interestingly, none of the existing alignment adapters function in this phase, because they are manually setup by the prosthetist even before walking. Our product acts in real time not only during this phase, but also in the second phase.
[0069] The second phase of gait is called the ankle-rocker, where the rotational stiffness in the sagittal plane becomes abruptly high and the direction of ankle rotation reverses from plantarflexion to dorsiflexion. The rotational stiffness must increase highly non-linearly to allow the body propulsion forwards. The ankle angle versus ankle torque (moment) diagram is given in FIG. 2b. Such abrupt reversal or angle and increase of rotational stiffness is the key challenge our invention handles very efficiently.
[0070] FIG. 2b shows how the present product functions using the diamond shaped data markers as compared to natural ankle function shown in solid line. The present product function is shown during two phases. The first phase is between points A and B while the second phase is between points B and C. The third phase, between points C and D, is called fore-foot rocker and is not an ankle-activity. The products disclosed and claimed herein can mimic the natural ankle for the first two phases.
[0071] Referring to FIG. 3, a present preferred embodiment of our self-aligning adapter 10 is connected between a prosthetic socket 6 and a foot 8 in a prosthetic leg 1. The embodiment shown in FIGS. 3 through 6 is an add-on component (a self-aligning adapter) that is mounted on a foot 8 and connected to a pylon 2 or socket 6. In FIG. 4, we show a low stiffness spring 11 which is essentially a 6 dof planar compliant spring shown in FIG. 7 or FIG. 8. FIG. 5 shows how the low stiffness spring 11 is cut out of the structural frame 18. This frame 18 also accommodates a high stiffness spring 12 inside its cavity. Like spring 11, spring 12 is also a 6 dof planar compliant spring, except is stiffer. A spring stiffener 15 is attached to the structural frame 18, which acts as mechanical stop to the spring 11 as well as spring 12, thereby effectively non-linearly stiffening them. A top adapter connector 14 is connected to the structural frame 18 by screw 13 by bolt 16 and nut 17. An unthreaded shaft may be used in place of the bolt. The leg socket 6 or pylon 2 is connected to the top adapter connector 14. FIG. 6 shows the physical connections of the components using an exploded view. The self-aligning adapter can be connected to prosthetic legs with existing socket and foot components.
[0072] Our product exploits the planar (spiral, elliptical or other possible shapes) compliant structures shown in FIGS. 6 and 7, each as 6 degrees of freedom springs. It employs two such springs physically connected by a core rod and a housing in a unique way to act as non-linear stiffener for the springs. The physical connection of the two springs are uniquely designed so that during the heel-rocker phase, only the low stiffness spring engages. At the end of this phase, the amputee has the foot flat on the ground and the second phase (ankle-rocker) begins. In the second phase, the two springs become parallel connected, making high stiffness spring the dominant one. The resulting moment vs ankle angle values are shown in FIG. 2b using diamond shaped data markers. The overall result demonstrates the biomimicry of a natural ankle by the invention in the sagittal plane.
[0073] A unique component of the present invention is the planar compliant structure that passively senses the various values of applied moment (negative for heel-rocker phase and positive for ankle-rocker phase). Or in other words, it can sense the various phases of walking and can soften or stiffen itself to produce self-aligning features in heel-rocker and propulsion ankle-rocker. This happens in real time in all three planes of motion and not just the sagittal plane. This is obtained naturally by the compliant structures because they have 6 degrees of freedom (3 linear and 3 rotational). This arises naturally because the geometric symmetry of the structure. FIGS. 7 and 8 show two possible embodiments of these planar structures. The first embodiment 100 (in FIG. 7) has a cylindrical disc shaped body 110 with center opening 111 through which the mounting bolt may pass and a circular spiral opening 112 around the center opening. The spiral can be circular or elliptical depending of the desired stiffness and the available space. The second embodiment 114 (in FIG. 8) has cylindrical body 116 with center opening 111 through which the mounting bolt may pass and an elliptical spiral opening 118 around the center opening. FIGS. 9 and 10 show the change in shape of the first embodiment 100 during linear motion, while FIGS. 11 and 12 show the change in shape of the first embodiment 100 during rotational motion. In a typical assembly, the body 110 or 116 is held rigidly while the load is applied through the core (111). The location around the core is essentially a 6 dof spring because it can experience linear and rotational motion in three axes. The stiffness of these springs is determined by the geometry of the spiral (112 or 118) and thickness of the disc shaped bodies 100 or 114.
[0074] It is important to note that these planar compliant structures have nonlinear stiffness. As shown in FIGS. 9 and 11, the various facets of the structures make contact with each other upon deformation. These contact points are shown with arrows. Upon this contact, the structures stiffen up. Such change is stiffness is non-linear. Another way the stiffness can be non-linear is if the structures are nested with rigid structures (stiffeners). Here, upon initial deformation, the structures are blocked by the stiffeners and the resultant is non-linear stiffness increase.
[0075] In addition to the 6 degrees of freedom of motion, the non-linear stiffness changing capability is of tremendous significance for the present invention. Human gait phases require time and position dependent nonlinear changes in stiffness. For example, the end of the heel rocker and ankle rocker phases require significant stiffening of the low and high stiffness springs.
[0076] Finite element analysis (FEA) was performed on a detailed product model of the embodiment shown in FIG. 4. The numerical results are shown in FIG. 2b. As previously described, that figure provides a visualization from the finite element simulation for the two different phases of the gait cycle. In the first phase, from A to B in FIG. 2b, the ankle moves from 0 to 5 with very low ankle rotational stiffness. This is shown schematically in FIGS. 13 and 14. The torque value at the end of this phase shown in FIG. 14 is only 2-5 N-m as the ground reaction force reached the maximum value. For able bodied persons it is about 120% of the body weight. For amputees, it could be as low as 80%. This suggests that low stiffness is the key to alignment of the foot before the entire body weight is applied. FIG. 13 shows our adapter 10 attached to a foot 8 in its neutral or no-load condition. FIG. 14 shows the adapter 10 at the end of heel-rocker phase (point B in FIG. 2b). Finite element results show only low stiffness spring being activated. Finite element simulation also shows that depending on the misalignment and the applied load, the self-aligning adapter can translate in the x-y plane as well as the vertical (z) plane. Such translation in the 3D space minimizes linear misalignment in the prosthetic leg. In addition, the low torque spring can also perform rotation along all 3 axes to minimize rotational misalignment.
[0077] In the second phase, between points B and C in FIG. 2b, the foot 8 remains flat on the ground as the ankle rotates from 5 to +10 (plantar to dorsiflexion) with very high rotational stiffness. FIG. 15 shows the self-aligned adapter 10 at the ankle-rocker phase (dorsi-flexion). As the adapter starts rotating from plantar to dorsi flexion, there is an abrupt and large change in stiffness, shown in FIG. 2b. This is achieved by the self-aligning adapter, where the unique assembly of the two springs and the rigid constraint (identified in FIG. 4 as spring stiffener 15) shift the load towards the high torque spring 12. At the end of this phase, the motion of this spring becomes completely blocked by the rigid constraints at both ends, which helps the adapter 10 to achieve the very high torque (>100 N-m) without excessive ankle rotation. It is important to note that existing passive prosthetic legs use roll over of the foot on the ground and this takes place without any real rotation in the ankle area. In comparison, the present invention is passive, but it acts like a natural human ankle.
[0078] While FIGS. 13, 14 and 15 show the self-alignment capability of our adapter in the sagittal plane, the 6 degrees of freedom nature of the planar compliant structures allow the adapter to show similar behavior in the two other (coronal and transverse) planes of motion. FIGS. 16a (level with no rotation) and 16b (rotated by about 5 degrees angle) show our self-aligning adapter allowing rotational alignment in the coronal plane. FIGS. 16c (level and neutral) and 16d (about 5 degrees of rotation) show our self-aligning adapter allowing rotational alignment in the transverse plane. During walking on uneven terrain or walking on turns, the coronal and transverse plane moments increase and their alignment becomes important for balance and comfort.
[0079] A unique feature of the innovation is that it can be 3D printed. This is a one-piece, no assembly manufacturing technique. It can also be machined with conventional machine shop manufacturing tools. Finally, the product can also be manufactured with carbon fiber composites, a material known for superior strength to weight ratio. Carbon fiber is a very popular material in the prosthetic foot industry.
[0080] The first embodiment of our self-aligning adapter shown in FIGS. 3 through 6 is an add-on component. This is a self-aligning adapter that can be mounted on any commercially available foot. Essentially, the adapter is a combination of two planar compliant 6 degrees of freedom springs with unique assembly that allows them to behave non-linearly compliant during heel-rocker and stiff during ankle-rocker phases of the gait. However, other different embodiments of the same core design philosophy are possible. Also, these embodiments can involve different materials (such as aluminum alloys, titanium alloys, carbon fiber composites to name a few).
[0081] A different embodiment of our self-aligning adapter 10 is configuration 20 shown in FIGS. 17 and 18. FIG. 17 shows an exploded view, while FIG. 18 is an end view. This embodiment is made stiffer by modifying spiral geometry and employing a different material thereby rendering the use of stiffener 15 unnecessary.
[0082] The embodiments shown so far are for the product category of add-on component. These are known as adapters that are mounted on prosthetic components such as socket, pylon or foot. A second product category is the ankle-foot, where the embodiment is integrated with a foot or in other words, the same design philosophy for our self-aligning adapter is integrated as an ankle to a foot structure, hence the name ankle-foot. There can be several ways to achieve this, based on the location of the claimed innovation of the 6 dof planar compliant spring (FIG. 6 or FIG. 7) in the heel (31) or keel (32) component of an ankle-foot.
[0083] One such embodiment 30 is shown in FIGS. 19, 20 and 21. This embodiment has heel spring 31 similar to low stiffness spring 11 and a keel 32 which is functionally similar to high stiffness spring 12. This embodiment has a different connector 33 on the top to connect to the pylon 6 or socket 2.
[0084] Another embodiment of our self-aligning adapter 10, integrated to an ankle-foot is configuration 40, shown in FIGS. 22 and 23. Another embodiment 50 is shown in FIGS. 24 and 25. These embodiments have two planar springs 41 and 42 or 51 and 52 that look different but have the same functionality. One spring 41, 51 is a low stiffness spring. The other spring 42, 52 is a high stiffness spring. The spring stiffener 45, 55 is shown in each of these embodiments as wire-like structures to reduce weight, but solid structures like spring stiffener 15 shown in FIG. 4 can also be used. All these embodiments utilize the connector 14 as well as bolt 16 and nut 17 that are in the first embodiment.
[0085] Another possible embodiment 60 is shown in FIGS. 26 and 27 where the heel part of the foot is modified to function as the low stiffness spring 61 and another part of the foot act as the high stiffness spring 62. A non-linear stiffener 65 is connected between the two springs 61 and 62. There is a different connector 66 that is used to attach this embodiment to a pylon or leg socket. In this embodiment the foot keel (top plate) itself works as the high stiffness spring 62. The heel part of the foot is attached to it through a planar compliant structure. This low stiffness 6 degree of freedom spring allows the heel to produce the biomimetic heel-rocker region. After that, the wire-like spring stiffeners 45 become taut, and the foot keel starts to deform to produce the ankle rocker phase. This design can be a one-piece (no assembly) product, hence no exploded view is shown.
[0086] In another possible embodiment 70 shown in FIGS. 28 and 29 the relative position of the two 6 degrees of freedom planar compliant mechanisms are changed. In the first embodiment 10 shown in FIG. 4 the low stiffness spring 11 is located above the high stiffness spring 12. For this embodiment 70 the relative position of the low stiffness spring 71 and the high stiffness spring 72 is exactly opposite. The overall geometry of the product is changed to accommodate the non-linear stiffening mechanisms. A core rod 73 is provided through which bolt 16 passes. The core rod acts as a spacer between connector plate 74 and the high stiffness spring to accommodate the spring stiffener 75 in the assembled structure shown in FIG. 29.
[0087] Although we have described and shown certain present preferred embodiments of our self-adjusting adapter it should be distinctly understood that our invention is not limited thereto but may be variously embodied within the scope of the following claims.
