PROSTHETIC FOOT DEVICE

Abstract

A prosthetic foot device having a longitudinal direction and a transverse direction and comprising a base spring blade, an ankle spring blade being made from a composite material comprising glass fibers and a heel spring blade, the base spring blade and the ankle spring blade being connected in a forefoot region of the prosthetic foot device, the base spring blade and the heel spring blade being connected in a heel region of the prosthetic foot device and the ankle spring blade and the heel spring blade being connected in an ankle region of the prosthetic foot device.

Claims

1. A prosthetic foot device having a longitudinal direction and a transverse direction and comprising a base spring blade, an ankle spring blade and a heel spring blade, said base spring blade and said ankle spring blade being connected in a forefoot region of said prosthetic foot device, said base spring blade and said heel spring blade being connected in a heel region of said prosthetic foot device and said ankle spring blade and said heel spring blade being connected in an ankle region of said prosthetic foot device, said ankle spring blade being made from a composite material comprising glass fibers, wherein said ankle spring blade comprises a forward section, a medial section and a rear section in said longitudinal direction of said prosthetic foot device, said forward section having a first thickness, said medial section having a second thickness and said rear section having a third thickness, wherein said first thickness is smaller than said second thickness and smaller than said third thickness and wherein said second thickness is smaller than said third thickness said ankle spring blade being divided into said forward section, said medial section and said rear section along dividing lines extending across said ankle spring blade from a first side edge to a second side edge of said ankle spring blade and wherein a change in thickness between said sections of said ankle spring blade takes place abruptly at said dividing lines.

2. The prosthetic foot device according to claim 1, wherein said first thickness is from 2-6 mm, said second thickness is from 3-9 mm, and said third thickness is from 5-10 mm.

3. The prosthetic foot device according to claim 1, wherein said dividing lines extend in said transverse direction, perpendicular to said longitudinal direction of said prosthetic foot device.

4. The prosthetic foot device according to claim 1, wherein said heel spring blade is made from a composite material comprising glass fibers and wherein said base spring blade is made from a composite material comprising carbon fibers.

5. (canceled)

6. The prosthetic foot device according to claim 1, wherein said forward section of said ankle spring blade comprises a widened toe portion, wherein a maximum width of said widened toe portion of said ankle spring blade is smaller than a maximum width of said base spring blade in said forefoot region of said prosthetic foot device.

7. (canceled)

8. The prosthetic foot device according to claim 1, wherein said medial section of said ankle spring blade has a width in said transverse direction of said prosthetic foot device, said width of said medial section of said ankle spring blade decreasing in a direction from said rear section of said ankle spring blade to said forward section of said ankle spring blade.

9. (canceled)

10. The prosthetic foot device according to claim 1, wherein said ankle spring blade comprises a laminate comprising stacked layers of glass fiber web material and binder material.

11. (canceled)

12. The prosthetic foot device according to claim 1, wherein said prosthetic foot device comprises a connecting device, said connecting device being attached to said ankle spring blade within said ankle region of said prosthetic foot device.

13. A prosthetic foot device having a longitudinal direction and a transverse direction and comprising a base spring blade, an ankle spring blade and a heel spring blade, said base spring blade and said ankle spring blade being connected in a forefoot region of said prosthetic foot device, said base spring blade and said heel spring blade being connected in a heel region of said prosthetic foot device and said ankle spring blade and said heel spring blade being connected in an ankle region of said prosthetic foot device, said ankle spring blade being made from a composite material comprising glass fibers, wherein said ankle spring blade comprises a forward section, a medial section and a rear section in said longitudinal direction of said prosthetic foot device, said forward section having a first thickness, said medial section having a second thickness and said rear section having a third thickness, wherein said first thickness is smaller than said second thickness and smaller than said third thickness and wherein said second thickness is smaller than said third thickness said ankle spring blade being divided into said forward section, said medial section and said rear section along dividing lines extending across said ankle spring blade from a first side edge to a second side edge of said ankle spring blade and wherein a change in thickness between said sections of said ankle spring blade takes place abruptly at said dividing lines, wherein said ankle spring blade and said heel spring blade are connected by a spacer element that is arranged between said ankle spring blade and said heel spring blade in said ankle region, and wherein the spacer element is formed of a fiber composite material.

14-19. (canceled)

20. A prosthetic foot device having a longitudinal direction and a transverse direction and comprising a base spring blade, only one ankle spring blade and only one heel spring blade, said base spring blade and said ankle spring blade being connected in a forefoot region of said prosthetic foot device, said base spring blade and said heel spring blade being connected in a heel region of said prosthetic foot device and said ankle spring blade and said heel spring blade being connected in an ankle region of said prosthetic foot device, said ankle spring blade being made from a composite material comprising glass fibers, wherein said ankle spring blade comprises a forward section, a medial section and a rear section in said longitudinal direction of said prosthetic foot device, said forward section having a first thickness, said medial section having a second thickness and said rear section having a third thickness, wherein said first thickness is smaller than said second thickness and smaller than said third thickness and wherein said second thickness is smaller than said third thickness said ankle spring blade being divided into said forward section, said medial section and said rear section along dividing lines extending across said ankle spring blade from a first side edge to a second side edge of said ankle spring blade and wherein a change in thickness between said sections of said ankle spring blade takes place abruptly at said dividing lines.

21. The prosthetic foot device according to claim 1, wherein the glass fibers are formed as woven or nonwoven webs.

22. The prosthetic foot device according to claim 21, wherein the webs have an adjustable fiber directionality to obtain a predetermined elasticity of the ankle spring blade.

23. The prosthetic foot device according to claim 1, wherein the glass fiber content in the composite material comprising glass fibers is at least 50% of a total volume of the composite material.

24. The prosthetic foot device according to claim 1, wherein the forefoot region is formed as a laminate of the ankle spring blade and the base spring blade.

25. The prosthetic foot device according to claim 1, wherein the ankle spring blade includes a slit.

26. The prosthetic foot device according to claim 25, wherein the slit extends in the longitudinal direction from a front end edge of the ankle spring blade through the forward section and into the medial section of the ankle spring blade.

27. The prosthetic foot device according to claim 26, wherein the slit extends through a full length of the medial section of the ankle spring blade and/or through the forefoot region of the base spring blade.

28. The prosthetic foot device according to claim 10, wherein the glass fiber web material is impregnated by or embedded in the binder material.

29. The prosthetic foot device according to claim 28, wherein the binder material is applied as coatings or layers between the stacked layers of glass fiber web material to form a consolidated composite material comprising the glass fiber web material and the binder material.

30. The prosthetic foot device according to claim 1, wherein a length of the front section is between 15% and 30% of a total length of the ankle spring blade, a length of the medial section is from 40% to 70% of the total length of the ankle spring blade, and a length of the rear section is from 15% to 35% of the total length of the ankle spring blade, wherein the rear section is longer than the front section.

31. The prosthetic foot device according to claim 1, wherein at least one of the medial section and the ankle spring blade has a tapered thickness.

32. The prosthetic foot device according to claim 1, wherein the ankle spring blade has a constant width along a full longitudinal extension of the ankle spring blade.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0044] The invention will be described in greater detail below with reference to the figures shown in the appended drawings. It should be understood that the figures are schematic illustrations and that they are not necessarily drawn to scale.

[0045] FIG. 1 shows a perspective view of a prosthetic foot device according to the invention;

[0046] FIG. 2 shows a top view of the prosthetic foot device in FIG. 1;

[0047] FIG. 3 shows a cross-sectional view of the prosthetic foot device taken along the line III-III in FIG. 2;

[0048] FIG. 4 shows an exploded perspective view of the prosthetic foot device in FIG. 1; and

[0049] FIGS. 5a and 5b show a side view of an ankle spring blade for use in a prosthetic foot device in accordance with the invention.

DETAILED DESCRIPTION

[0050] FIGS. 1-4 show a prosthetic foot device 1 comprising a base spring blade 2, an ankle spring blade 3 and a heel spring blade 4. The base spring blade 2 and the ankle spring blade 3 are connected in a forefoot region 5 of the prosthetic foot device 1 by means of a first adhesive 6 applied between the ankle spring blade 3 and the heel spring blade 4, as indicated in FIG. 3. The base spring blade 2 and the heel spring blade 4 are similarly connected in a heel region 7 of the prosthetic foot device 1 by means of a second adhesive 8 applied between the base spring blade 2 and the heel spring blade 4. The first and second adhesives may be of the same kind or may be adhesives with different properties. By way of example, the adhesive in the forefoot region 5 may be more elastic and/or flexible than the adhesive in the heel region 7 thereby providing a more flexible connection in the forefoot region 5 and a stiffer connection in the heel region 7. Optionally, the first adhesive 6 and/or the second adhesive 8 may be substituted with any other suitable type of connection means including mechanical connections means such as screws and rivets and welds. In such constructions it may be desirable to arrange a resiliently deformable member such as a resilient polymer layer between the spring blades. The ankle spring blade 3 and the heel spring blade 4 are connected with each other in an ankle region 9 of the prosthetic foot device 1. The connection between the ankle spring blade 3 and the heel spring blade 4 is an indirect connection involving a spacer element 10 which is arranged between the ankle spring blade 3 and the heel spring blade 4 in the ankle region 9. The spacer element 10 is shown in FIG. 4 as having generally the same shape as the ankle spring blade 3 and the heel spring blade 4 within the ankle region 9 and to have a length I.sub.s with a major component in the longitudinal direction L of the prosthetic foot device 1, which length I.sub.s corresponds to the length of the ankle region 9. Hence, the spacer element 10 is considerably shorter than both the ankle spring blade 3 and the heel spring blade 4.

[0051] A pair of attachment openings 11,12,13 are arranged through each of the ankle spring blade 3, the spacer element 10 and the heel spring blade 4 within the ankle region 9. 11,12,13. As shown in FIG. 4, the attachment openings 11,12,13 are arranged centrally in the longitudinal direction L of the prosthetic foot device 1. When the prosthetic foot device 1 is assembled, as shown in FIG. 1, the attachment openings 11,12,13 are aligned with each other and a screw bolt 14 is inserted through each attachment opening 11,12,13 and is secured in a connecting device 15, for connecting the prosthetic foot device 1 with a leg prosthesis and/or the stump of an amputee. It is to be understood that the design of the connecting device is not critical to the invention and that a connecting device may be secured to the heel region of the prosthetic foot device by other means than the two screw bolts shown in the drawings. Accordingly, the connection device may optionally be secured to the prosthetic foot device by any suitable means or combination of means such as by welding, gluing, or by any suitable type of mechanical fastening elements. Similarly, the connection between the ankle spring blade 3 and the heel spring blade 4 may be an adhesive connection, a welded connection or another type of mechanical connection than the connection shown in the figures, as well as combinations of different connection means. The spacer element 10 may be omitted or may be replaced by an adhesive applied between the ankle spring blade 3 and a heel spring blade 4 in the heel region 9.

[0052] The ankle spring blade 3 has a concave curve shape in the longitudinal direction L of the prosthetic foot device 1, and a generally planar shape in a transverse direction T of the prosthetic foot device 1, perpendicular to the longitudinal direction L. The ankle spring blade 3 has a generally elongated shape with two side edges 31, 32 extending in the longitudinal direction L between a forefoot end 33 and a rear end 34.

[0053] The ankle spring blade is made from a composite material comprising glass fibres. As is shown in FIG. 3, the ankle spring blade is made from a laminate comprising stacked layers of glass fibre web material and binder material. The ankle spring blade 3 comprises a forward section 35, a medial section 36 and a rear section 37 in the longitudinal direction L of the prosthetic foot device 1. As indicated in FIGS. 5a and 5b which show cross-sections of the ankle spring blade 3 in a flat configuration before mounting in a prosthetic foot device and in the bent configuration in which it appears when mounted in the prosthetic foot device 1, the forward section 35 has a first thickness t.sub.f, the medial section 36 has a second thickness t.sub.m and the rear section 37 has a third thickness t.sub.r, such that the first thickness t.sub.f is smaller than the second thickness t.sub.m and the third thickness t.sub.r and wherein the second thickness t.sub.m is smaller than the third thickness t.sub.r according to the relation:

t.sub.f<t.sub.m<t.sub.r

[0054] As schematically shown in FIGS. 5a and 5b, the ankle spring blade 3 comprises 1-5 bottom layers 38 of glass fibre web material. The bottom layers 38 extend the full length of the ankle spring blade 3 and define the longitudinal extension of the ankle spring blade 3. A lowermost bottom layer also forms an inner surface 38 of the ankle spring blade 3, which inner surface 39 is facing the base spring blade 2 in the forefoot region 5 and the heel spring blade 4 in the heel region 7. The inner surface 40 of the ankle spring blade 3 is opposite an outer surface 39 of the ankle spring blade 3, which outer surface faces away from the base spring blade 3 and the heel spring blade 4. The combined thickness of the bottom layers 38 of the ankle spring blade 3 corresponds to the first thickness ti of the forward section 35 of the ankle spring blade 3.

[0055] The ankle spring blade 3 further comprises 1-5 middle layers 41 of glass fibre web material, the middle layer or middle layers 41 extending only over the medial section 36 and the rear section 37 of the ankle spring blade and 1-5 top layers 42 of glass fibre web material, the top layer or top layers 42 extending only over the rear section of the ankle spring blade. The combined thickness of the bottom layers 38 and the middle layers 41 of the ankle spring blade 3 corresponds to the second thickness t.sub.m of the middle section 36 of the ankle spring blade 3 and the combined thickness of the bottom layers 38, the middle layers 41 and the top layers 42 of the ankle spring blade 3 corresponds to the third thickness t.sub.r of the rear section 37 of the ankle spring blade 3.

[0056] The length proportions between the different sections of an ankle spring blade as disclosed herein may be such that the front section is approximately 25% of the total length of the ankle spring blade, the length of the medial section is approximately 50% of the total length of the ankle spring blade and the length of the rear section is approximately 25% of the total length of the ankle spring blade. However, the length of the front section may be between 15% and 30% of the total length of the ankle spring blade, the length of the medial section may be from 40% to 70% of the total length of the ankle spring blade and the length of the rear section may be from 15% to 35% of the total length of the ankle spring blade. The rear section may be somewhat longer than the front section. The proportions between the different sections may vary depending on the size and weight of the intended user, and/or depending on the intended use situations as set out herein.

[0057] By way of example only, in a prosthetic foot device for an adult, an ankle spring blade having a total length of 215 millimeters, the front section may be 50 millimeters, the medial section may be 105 millimeters and the rear section may be 60 millimeters. For longer or shorter ankle spring blades, the measurements for the individual sections will, of course, be different.

[0058] The glass fibre web material may be a weft material and the binder material may be a resinous binder material such as an epoxy resin binder. The stacked glass fibre webs may be impregnated by or embedded in the binder material or the binder material may be applied as coatings or layers between the stacked layers of glass fibre web material to form a consolidated composite material comprising the glass fibre web material and the binder material. As set out herein, the composite spring blade material may comprise further components, such as pigments, printed/coloured webs or films, decorative objects, etc. and may be coated or laminated with an outer covering film or web on one or both of the outer surfaces of the fibre composite material.

[0059] The first thickness, i.e. the thickness of the forward section of the ankle spring blade 3 may be from 2-6 mm, preferably from 3-5.5 mm, the second thickness, i.e. the thickness of the medial section may be from 3-9 mm, preferably from 4-8 mm and the third thickness may be from 5-10 mm, preferably from 6-9 mm, taking into consideration that the thickness relation between the different sections as set out above should always apply.

[0060] The ankle spring blade is divided into the forward section 35, the medial section 36 and the rear section 37 along dividing lines 44, 46 extending across the ankle spring blade 3 from one side edge 31 to the other side edge 32 of the ankle spring blade 3. The change in thickness between the sections 35, 36, 37 of the ankle spring blade 3 is shown to take place abruptly at the dividing lines 44, 46, preferably within an area at each dividing line having an extension in the longitudinal direction of from 0 to 3 millimeters of the ankle spring blade 3. The abrupt thickness change can be obtained as illustrated in FIGS. 5a and 5b by stacking glass fibre webs 38, 41, 42 of different lengths on top of each other. The change in thickness will be visible as a stepped surface profile on the outer surface 40 of the ankle spring blade 3. Although the dividing lines 44, 46 may take on other shapes than the straight transverse lines shown in the figures, such as V-shapes, U-shapes, etc, as set out herein, it has been found that straight and distinct transverse dividing lines may be preferred over other types of dividing lines or dividing areas both for functional reasons and for production reasons. Without wishing to be bound by theory, a distinct border between the different sections 35, 36, 37 of the ankle spring blade 3, may promote a differentiation between the different functions of the different sections 35, 36, 37. Accordingly, the main function of the forward section 35 of the ankle spring blade 3 is to provide a connection surface for connecting the ankle spring blade 3 with the base spring blade 2 within the forefoot region 9, while making a minimum contribution to the stiffness of the forefoot region 9. The medial section 36 should have high capability of dynamically deforming by resiliently twisting and bending in response to varying loads, similar to the movements occurring in the metatarsal region of a natural foot. The rear section 37 should provide a stiff and firm anchoring site for the connecting device 15.

[0061] The ankle spring blade 3 is shown, e.g. in FIG. 2 with a hammerhead shape, which means that it has a widened toe portion 48 in the forward section 35 of the ankle spring blade 3 and a more narrow forwardly tapering medial portion 36. The widened toe portion 48 provides an enlarged connection surface for connecting the ankle spring blade 3 with the base spring blade 4 and the tapering medial portion 36 provides the requisite torsional and bending characteristics in the metatarsal part of the prosthetic foot device 1.

[0062] As is best seen in FIG. 2, the maximum width of the widened toe portion 48 of the ankle spring blade 3 is smaller than the maximum width of the base spring blade 2 in the forefoot region of the prosthetic foot device. In this way, side portions 50, 51 of the base spring blade 2 extend laterally outside the ankle spring blade 3 in the forefoot region 5. This means that the forefoot region 5 is more flexible within the area formed only by the side portions 50, 51 of the base spring blade 2 than in the part of the forefoot region 5 where the ankle spring blade 3 and the construction adhesive 6 are also present. A forefoot region 5 constructed in this manner will be less rigid and will have higher sideways flexibility than a forefoot region in which the ankle spring blade and the base spring blade have the same width.

[0063] As set out above, the medial section 36 of the ankle spring blade 3 has a tapering shape implying that the width of the ankle spring blade 3 in the transverse direction T decreases in a direction from the rear section 37 of the ankle spring blade 3 to the forward section 35 of the ankle spring blade 3. An ankle spring blade having a medial section 36 with a width profile of this kind will be less resistant to flexing and twisting at the front than at the rear.

[0064] It is to be understood that the tapering shape of the ankle spring blade, as well as the widened toe portion and different widths of the ankle spring blade and the base spring blade in the forefoot region are optional to the invention. Accordingly, the ankle spring blade may have the same width along its full longitudinal extension. Moreover, a widened toe portion may have the same maximum width as the base spring blade and/or may be combined with a straight or tapering medial section, as desired.

[0065] It is to be understood that the lateral shape of the ankle spring blade as well as the use of features such as sections of different thickness, a widened toe portion, etc. may be varied within the scope of the invention depending to suit particular user requirements. A prosthetic foot device may be designed to suit a particular individual and/or a particular use situation. By way of example, a heavier user may need an overall thicker ankle spring blade, a prosthetic foot device intended for high activity purposes may be designed to allow more flexing and bending than a prosthetic foot device intended for an every-day use, where a more rigid and stable prosthetic foot device may be preferred.

[0066] In the drawings, the prosthetic foot device 1, is shown with a slit 55 being arranged in the ankle spring blade 3 and extending in the longitudinal direction L from the front end edge 33 of the ankle spring blade 3 through the forward section 35 and a small distance into the medial section 36 of the ankle spring blade. The slit 55 is an optional feature of the invention and may be omitted, if desired. The slit 55 increases sideways flexibility in the forefoot region 5 of the prosthetic foot device 1 and if extended into the medial section 36 it will also decrease torsional resistance in the metatarsal part of the prosthetic foot device 1. If desired, the slit can extend through all of the medial section 36 of the ankle spring blade 3 and/or through the forefoot region 5 of the base spring blade 2.

[0067] As set out herein, the heel spring blade may be made from a composite material comprising carbon fibres or from a composite material comprising glass fibres, as desired.

[0068] Likewise, the base spring blade 2 may be made from a composite material comprising carbon fibres or from a composite material comprising glass fibres, as desired.