U.S. patent application number 17/448770 was filed with the patent office on 2022-03-17 for prosthetic feet and foot covers.
The applicant listed for this patent is Ossur Iceland ehf. Invention is credited to Bjarni Andresson, Rowan Patrick Robinson Cain, Arinbjorn Viggo Clausen, Ragnar Orn Gunnarsson, Larus Gunnsteinsson.
Application Number | 20220079781 17/448770 |
Document ID | / |
Family ID | 1000005990437 |
Filed Date | 2022-03-17 |
United States Patent
Application |
20220079781 |
Kind Code |
A1 |
Clausen; Arinbjorn Viggo ;
et al. |
March 17, 2022 |
PROSTHETIC FEET AND FOOT COVERS
Abstract
Prosthetic feet and foot covers that provide a more natural
appearance and improved performance are provided. A foot element
for a prosthetic foot can extend from a heel end to a toe end and
include a heel, arch, forefoot, and toe regions. The forefoot
region can be wider than the arch and heel regions. The toe region
can include a U-shaped cut out to define a big toe. Various
features of the foot element can guide rollover of the foot through
the big toe during use. A foot cover can be designed to receive a
prosthetic foot including such a foot element. The foot cover can
have a region of increased flexibility at a transition between the
forefoot region and toe region. The foot cover can also have a
padded area extending from the heel region across a lateral part of
the arch region and forefoot region.
Inventors: |
Clausen; Arinbjorn Viggo;
(Reyjavik, IS) ; Gunnarsson; Ragnar Orn;
(Reykjavik, IS) ; Andresson; Bjarni;
(Seltjarnarnes, IS) ; Gunnsteinsson; Larus;
(Reykjavik, IS) ; Cain; Rowan Patrick Robinson;
(Kopavogur, IS) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ossur Iceland ehf |
Reykjavik |
|
IS |
|
|
Family ID: |
1000005990437 |
Appl. No.: |
17/448770 |
Filed: |
September 24, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15985484 |
May 21, 2018 |
11147692 |
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17448770 |
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14755464 |
Jun 30, 2015 |
9999524 |
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15985484 |
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62019233 |
Jun 30, 2014 |
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62153387 |
Apr 27, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A61F 2002/5001 20130101;
A61F 2/66 20130101; A61F 2002/665 20130101; A61F 2002/6671
20130101; A61F 2002/6628 20130101; A61F 2002/6614 20130101; A61F
2002/6621 20130101 |
International
Class: |
A61F 2/66 20060101
A61F002/66 |
Claims
1.-12. (canceled)
13. A prosthetic foot comprising: an elongate foot element
extending from a heel end to a toe end, the foot element comprising
a generally U-shaped cut-out portion at the toe end that is
positioned toward a medial side of a longitudinal axis of the foot
element, the cut-out portion dividing the toe end into a medial toe
and a lateral toe portion, wherein the medial toe is angled toward
the U-shaped cut-out portion; and a cosmesis cover comprising a
body having an outer surface and an inner surface and surrounding
an inner cavity, the outer surface having the shape and contours of
a natural human foot, the inner cavity configured to removably
receive the foot element therein, wherein the cosmesis cover
comprises a toe region comprising a slot dividing the toe region
into a medial toe and a lateral toe portion and configured to be
disposed in the U-shaped cut-out portion of the foot element when
the foot element is disposed within the cosmesis cover, and
wherein, when the foot element is disposed in the cosmesis cover,
the angled medial toe of the foot element forces the medial toe of
the cosmesis cover toward the lateral toe portion of the cosmesis
cover to at least partially close the slot.
14. The prosthetic foot of claim 13, wherein a portion of the
medial toe of the cosmesis cover adjacent the slot has a thickness
greater than a thickness of surrounding areas of the body of the
cosmesis cover.
15. The prosthetic foot of claim 13, wherein the lateral toe
portion of the cosmesis cover defines a plurality of toes disposed
adjacent each other without intervening slots therebetween.
16. The prosthetic foot of claim 13, wherein the body comprises a
region of increased flexibility at a transition between the
forefoot region and the toe region.
17. The prosthetic foot of claim 13, wherein the body of the
cosmesis cover is monolithic.
18. The prosthetic foot of claim 16, wherein the region of
increased flexibility is thinner than a remainder of the body or
made of a different material than the remainder of the body.
19. The prosthetic foot of claim 16, wherein the region of
increased flexibility corresponds to a metatarsal joint of a
natural human foot.
20. The prosthetic foot of claim 16, wherein the body further
comprises other regions of increased flexibility at areas
corresponding to other joints between bones of toes in a natural
human foot.
21. The prosthetic foot of claim 13, wherein the cosmesis cover
further comprises a padded area extending from a heel region of the
cosmesis cover and across a lateral portion of an arch region and a
forefoot region of the cosmesis cover.
22. The prosthetic foot of claim 13, wherein a forefoot region of
the cosmesis cover is wider than a reminder of the cosmesis
cover.
23. The prosthetic foot of claim 13, wherein the body of the
cosmesis cover comprises a sole portion and a sidewall extending
upward from the sole portion, wherein an inner surface of the sole
portion comprises a plurality of dimples configured to reduce
distortion of the cosmesis cover during cooling during
manufacture.
24. The prosthetic foot of claim 13, wherein the body of the
cosmesis cover comprises a sidewall extending upward to
approximately the level of an ankle of a natural human foot.
25. The prosthetic foot of claim 13, wherein the body of the
cosmesis cover comprises a sidewall extending upward to a level
below the level of an ankle of a natural human foot.
26. The prosthetic foot of claim 13, wherein the body of the
cosmesis cover comprises a sidewall extending upward to a level
above the level of an ankle of a natural human foot.
27. The prosthetic foot of claim 13, wherein the inner cavity of
the body comprises an inner sole portion, wherein the foot element
is configured to be positioned on the inner sole portion, a
perimeter of the foot element substantially coinciding with a
perimeter of the inner sole portion.
28. The prosthetic foot of claim 13, the foot element further
comprises a lengthwise split, wherein a first portion of the split
runs substantially straight in an anterior to posterior direction
and a second portion curves in a medial direction and extends to a
base of the cut-out portion.
29. The prosthetic foot of claim 13, further comprising an upper
foot element coupled to the foot element via fasteners inserted
through one or more attachment holes in the elongate foot
element.
30. The prosthetic foot of claim 29, wherein a widest part of a
forefoot portion of the elongate foot element is distal to the one
or more attachment holes.
31. The prosthetic foot of claim 13, further comprising a forefoot
piece coupled to a bottom surface of at least a portion of a
forefoot portion and a toe portion of the foot element.
32. The prosthetic foot of claim 13, wherein the medial toe of the
foot element is longer and extends further distally than the
lateral toe portion of the foot element.
Description
INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS
[0001] Any and all applications for which a foreign or domestic
priority claim is identified in the Application Data Sheet as filed
with the present application are hereby incorporated by reference
under 37 CFR 1.57. This application is a continuation of U.S.
patent application Ser. No. 15/985,484, filed May 21, 2018, which
is a divisional of U.S. patent application Ser. No. 14/755,464,
filed Jun. 30, 2015, now U.S. Pat. No. 9,999,524, which claims the
priority benefit of U.S. Provisional Application Nos. 62/019,233,
filed Jun. 30, 2014, and 62/153,387, filed Apr. 27, 2015, the
entireties of which are hereby incorporated by reference herein and
should be considered part of this specification.
BACKGROUND
Field
[0002] The present disclosure relates generally to prosthetic feet
and foot covers for prosthetic feet. In some embodiments, the
present disclosure relates more specifically to prosthetic feet and
foot covers having characteristics that provide improved rollover
and/or performance.
Description of the Related Art
[0003] Various types of prosthetic foot and cosmesis devices are
available as substitutes for human feet. Many prosthetic devices
available today incorporate various features to try to better
approximate the functioning of natural feet. For example, some
prosthetic foot designs seek to provide improved foot rollover
during use.
SUMMARY
[0004] In some embodiments, a prosthetic foot includes an elongate
foot element extending from a heel end to a toe end and having an
arch portion therebetween. In some embodiments, a ratio of a width
of at least a portion of a forefoot portion of the foot element
relative to a length of the foot element is approximately 30%. The
foot element can further include a generally U-shaped cut-out
portion at the toe end. The cut-out portion is positioned toward a
medial side of a longitudinal axis of the foot element and divides
the toe end into a medial toe and a lateral toe portion. The medial
toe is longer and extends further distally than the lateral toe
portion. The foot element can also include a lengthwise split. A
first portion of the split runs substantially straight in an
anterior/posterior direction, and a second portion is curved. In
some embodiments, the second portion curves in a medial direction
and extends to a base of the cut-out portion. In some embodiments,
the second portion of the split curves in a medial direction and
extends to a medial edge of the foot element in the forefoot
portion. Alternatively, the second portion can curve in a lateral
direction and extend to a lateral edge of the foot element in the
forefoot portion.
[0005] In some embodiments, the split begins in a circular opening.
A ratio of the diameter of the opening to the width of the split
can be between 2:1 and 6:1. The foot element can also include an
upper foot element coupled to the foot element via fasteners
inserted through one or more attachment holes in the foot element.
The second portion of the split can begin distal to the attachment
holes. In some embodiments, the second portion of the split begins
at a transition between the arch region and forefoot portion. A
length of the split can be about 70% to about 90% of a total length
of the foot element.
[0006] In some embodiments, a cosmesis cover for a prosthetic foot
includes a body having an outer surface and surrounding an inner
cavity. The outer surface has the shape and contours of a natural
human foot, and the inner cavity is configured to removably receive
a prosthetic foot therein. The cosmesis has a heel region, arch
region, forefoot region, and toe region. The forefoot region is
wider than the heel region and the arch region. The body includes a
region of increased flexibility at a transition between the
forefoot region and the toe region.
[0007] In some embodiments, the region of increased flexibility is
thinner than a remainder of the body. A width of the forefoot
region relative to a length of the cosmesis cover can be about 30%.
In some embodiments, the cosmesis cover further includes a padded
area extending from the heel region and across a lateral region of
the arch region and the forefoot region.
[0008] In some embodiments, a prosthetic foot includes an elongate
foot element and a cosmesis cover. The foot element extends from a
heel end to a toe end, and a width of a forefoot portion of the
foot element is greater than a width of an arch region and a heel
region. The foot element can also include a generally U-shaped
cut-out portion at the toe end positioned toward a medial side of a
longitudinal axis of the foot element. The cut-out portion divides
the toe end into a medial toe and a lateral toe portion, and the
medial toe is longer and extends further distally than the lateral
toe portion. The cosmesis cover includes a body having an outer
surface and surrounding an inner cavity. The outer surface has the
shape and contours of a natural human foot, and the inner cavity is
configured to removably receive the foot element therein. The
cosmesis has a heel region, arch region, forefoot region, and toe
region. The forefoot region is wider than the heel region and the
arch region. The cosmesis has an inner sole portion and a sidewall
extending upward from the inner sole portion. A size and shape of
the inner sole portion and portion of the sidewall adjacent the
inner sole portion substantially corresponds to a size and shape of
the foot element.
[0009] In some embodiments, the toe region of the cosmesis further
includes a mating structure configured to engage the cut-out
portion of the foot element. In some embodiments, the sidewall
extends upward to approximately the level of an ankle of a natural
human foot. Alternatively, the sidewall can extend upward to a
level above or below the level of an ankle of a natural human foot.
In some embodiments, a width of the forefoot portion relative to a
length of the foot element is about 30%. A width of the forefoot
region relative to a length of the cosmesis cover can also be about
30%.
[0010] In some embodiments, a prosthetic foot includes an elongate
foot element and a forefoot piece. The elongate foot element
extends from a heel end to a toe end and has an arch portion, a
forefoot region, and a toe portion. The forefoot piece is coupled
to a bottom surface of at least a portion of the forefoot region
and the toe portion, and a bottom surface of the forefoot piece is
downwardly facing convex and comprises a curvature different than a
curvature of a bottom surface of a portion of the foot element
proximal to the forefoot piece.
[0011] In some embodiments a ratio of a width of at least a portion
of the forefoot region relative to a length of the foot element is
approximately 30%. In some embodiments, the foot element includes a
generally U-shaped cut-out portion at the toe end that is
positioned toward a medial side of a longitudinal axis of the foot
element such that the cut-out portion divides the toe end into a
medial toe and a lateral toe portion, and the forefoot piece
includes a generally U-shaped cut-out portion configured to
correspond in size and shape to the cut-out portion of the foot
element. In some embodiments, the foot element further includes a
lengthwise split, wherein a first portion of the split runs
substantially straight in an anterior/posterior direction and a
second portion of the split curves in a medial direction and
continues to a base of the cut-out portion.
[0012] In some embodiments, a prosthetic foot includes an elongate
foot element and a cosmesis cover. The elongate foot element
extends from a heel end to a toe end and includes a generally
U-shaped cut-out portion at the toe end that is positioned toward a
medial side of a longitudinal axis of the foot element such that
the cut-out portion divides the toe end into a medial toe and a
lateral toe portion. The medial toe is angled toward the U-shaped
cut-out portion. The cosmesis cover includes a body having an outer
surface and an inner surface and surrounding an inner cavity, the
outer surface has the shape and contours of a natural human foot,
and the inner cavity is configured to removably receive the foot
element therein. The cosmesis cover includes a toe region having a
slot that divides the toe region into a medial toe and a lateral
toe portion and is configured to be disposed in the U-shaped
cut-out portion when the foot element is disposed within the
cosmesis cover. When the foot element is disposed in the cosmesis
cover, the angled medial toe of the foot element forces the medial
toe of the cosmesis cover toward the lateral toe portion to at
least partially close the slot. In some embodiments, a portion of
the medial toe of the cosmesis cover adjacent the slot has a
thickness greater than a thickness of surrounding areas of the body
of the cosmesis cover.
[0013] In some embodiments, a cosmesis cover for a prosthetic foot
includes a body having an outer surface and surrounding an inner
cavity, the body has a top opening extending into the inner cavity,
the top opening is concave and a rim of the body surrounding the
top opening includes cavities configured to receive pins of an
attachment plate, the outer surface has the shape and contours of a
natural human foot, and the inner cavity is configured to removably
receive a prosthetic foot therein. In some embodiments, the
cosmesis cover further includes a generally straight attachment
plate including downwardly extending pins configured to be received
in the cavities in the rim of the cosmesis cover body.
[0014] In some embodiments, a cosmesis cover for a prosthetic foot
includes a body having an outer surface and surrounding an inner
cavity, the outer surface has the shape and contours of a natural
human foot, the inner cavity is configured to removably receive the
prosthetic foot therein, the cosmesis body has a sole portion and a
sidewall extending upward from the sole portion, and an inner
surface of the sole portion includes a plurality of dimples
configured to reduce distortion of the cosmesis cover during
cooling during manufacture.
[0015] All of these embodiments are intended to be within the scope
of the disclosure herein. These and other embodiments will become
readily apparent to those skilled in the art from the following
detailed description having reference to the attached figures, the
disclosure not being limited to any particular disclosed
embodiment(s).
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] These and other features, aspects, and advantages of the
present disclosure are described with reference to the drawings of
certain embodiments, which are intended to schematically illustrate
certain embodiments and not to limit the disclosure.
[0017] FIGS. 1A-1F illustrate example embodiments of prosthetic
feet;
[0018] FIGS. 2A-4C illustrate example embodiments of foot
elements;
[0019] FIG. 5 illustrates a scan of the center of pressure of a
sound foot and a prosthetic foot during rollover;
[0020] FIG. 6 illustrates an example embodiment of a prosthetic
foot incorporating the foot element of FIGS. 2A-2C and a top view
of an example embodiment of a foot cover configured to receive a
prosthetic foot;
[0021] FIG. 7 illustrates an example embodiment of a prosthetic
foot incorporating the foot element of FIGS. 2A-2C received in the
foot cover of FIG. 6;
[0022] FIG. 8 illustrates a bottom view of the foot cover of FIGS.
6-7;
[0023] FIG. 9 illustrates a partial cross-sectional view of a foot
element received in a foot cover;
[0024] FIG. 10 illustrates an example embodiment of a foot cover
and an attachment member;
[0025] FIGS. 11A-11B illustrate cross-sectional views of a foot
element including dimples in a sole portion;
[0026] FIGS. 12A-12E illustrate an example embodiment of a foot
element including a drop-toe portion; and
[0027] FIGS. 13A-13C illustrate example embodiments of prosthetic
feet disposed in an example embodiment of a foot cover.
DETAILED DESCRIPTION
[0028] Although certain embodiments and examples are described
below, those of skill in the art will appreciate that the
disclosure extends beyond the specifically disclosed embodiments
and/or uses and obvious modifications and equivalents thereof.
Thus, it is intended that the scope of the disclosure herein
disclosed should not be limited by any particular embodiments
described below.
[0029] FIGS. 1A-1F illustrate various example embodiments of
prosthetic feet 10a, 10b, 10c, 10d, 10e, 10f that can exhibit
improved rollover and/or other performance characteristics in use.
In some embodiments, prosthetic feet according to the present
disclosure, such as the feet shown in FIG. 1, include features that
allow the feet to resemble natural human feet more closely in
appearance and/or rollover performance than previously available
prosthetic feet. In some embodiments, a prosthetic foot 10a, 10b,
10c, 10d, 10e, 10f includes a foot element 100 (e.g., a lower foot
member) as shown in the example embodiments of FIG. 1. In the
illustrated embodiments, the foot element 100 is substantially
plate-like and has a generally rectangular or rectangular
cross-section along at least a portion of its length.
[0030] In some embodiments, the foot element 100 is constructed of
a resilient material capable of flexing in multiple directions. The
foot element 100 can include multiple layers or laminae. Examples
of possible materials for the foot element 100 include carbon, any
polymer material, and any composite of polymer and fiber. The
polymer can be thermoset or thermoplastic. In a composite, the
fiber reinforcement can be any type of fiber, such as carbon,
glass, or aramid. The fibers can be long and unidirectional, or
they can be chopped and randomly oriented.
[0031] The foot element 100 extends from a heel end 12 to a toe end
14. The foot element 100 includes an arch region 16 between the
heel end 12 and the toe end 14, for example, at approximately the
location of an arch of a natural human foot. The foot element 100
further includes a forefoot region 18 distal to the arch region 16
or between the arch region 16 and the toe end 14.
[0032] FIGS. 2A-4C illustrate example embodiments of foot elements
100a, 100b, 100c. In some embodiments, the forefoot region 18 of
the foot element 100a, 100b, 100c is wider than a remainder of the
foot element 100a, 100b, 100c, for example, wider than the arch
region 16 and/or a heel region 22. The forefoot region 18 can be
wider than a forefoot region of previously available prosthetic
feet. For example, in some previously available prosthetic feet,
the ratio of the width of the forefoot region to the length of the
foot element is about 25-26%. In some prosthetic feet according to
the present disclosure, the ratio of the width of the forefoot
region 18 to the length of the foot element is about 30%.
[0033] In some embodiments, a toe portion 20 of the foot element
100a, 100b, 100c includes a generally U-shaped cut-out portion,
slot or gap 24 extending inwardly from the toe end 14. In some
embodiments, the cut-out 24 is positioned toward a medial side of a
longitudinal axis of the foot element 100a, 100b, 100c, but is
spaced from a medial edge 31 of the foot element 100a, 100b, 100c
(e.g., the cut-out portion or gap 24 is defined between the
longitudinal axis and medial edge 31 of the foot element 100a,
100b, 100c). The cut-out 24 gives the foot element 100a, 100b, 100c
a "sandal toe" appearance and/or function and defines a structural
"big toe" 26. The cut out portion 24 can receive a strap of a
sandal. Because the forefoot region 18 is wider than a remainder of
the foot element and wider than previously available prosthetic
feet, the cut-out 24 and big toe 26 can be offset from the
longitudinal axis of the foot element to a greater extent. In the
illustrated embodiment, the big toe 26 is longer (e.g., extends
further distally) than the remaining "toes" or the remainder of the
toe portion 20.
[0034] In a healthy human foot, the center of mass travels
approximately through the big toe and second toe as the foot rolls
over from heel strike to toe off. The big toe 26 of the foot
element 100a, 100b, 100c is designed to be weight-bearing and
absorb load during rollover of the foot during use. In some
embodiments, the big toe 26 is thicker than the remainder of the
foot element 100a, 100b, 100c and/or than previously available
prosthetic feet to provide additional strength. In some
embodiments, the big toe 26 is formed of a particular material
layup that provides the big toe 26 with strength. As described
above, the big toe 26 is also longer than the remainder of the toe
portion 20 and is offset from the longitudinal axis of the foot
element to a greater extent than previously available prosthetic
feet. These features advantageously provide the foot element 100a,
100b, 100c with a full length toe lever and allow the foot element
100a, 100b, 100c to more closely approximate or mimic a natural
human foot during rollover. The outwardly bulging or curving
lateral edge 33 of the forefoot region 18 of the foot element 100a,
100b, 100c can help guide the travel of the foot's center of mass
toward the medial side during rollover so that the center of mass
travels through the big toe 26. The cut-out portion 24 can provide
the toe portion 20 of the foot element 100a, 100b, 100c with a
lesser stiffness on the medial side, which also helps guide the
center of mass toward the medial side during rollover. Any or all
of these features can advantageously improve the rollover
characteristics of the foot and provide the foot with a rollover
more similar to that of a healthy, natural human foot.
[0035] FIG. 5 illustrates a scan of the pressure applied by the
foot to a walking surface as the foot rolls over from heel strike
to toe off. The image on the left maps the pressure applied by a
sound or healthy human foot, and the image on the right maps the
pressure applied by a prosthetic foot including a foot element 100a
and a foot cover as described herein. The dots in each image follow
the path of the center of pressure as it travels through rollover.
The foot element 100a, 100b, 100c advantageously provides an
improved distribution of pressure in the forefoot and big toe
region that more closely approximates or mimics that of a natural
human foot. Additional details on prosthetic feet having features
that improve rollover can be found in U.S. Pat. No. 7,846,213,
entitled "Foot Prosthesis with Resilient Multi-Axial Ankle," the
entirety of which is hereby incorporated by reference and should be
considered a part of this specification.
[0036] In some embodiments, the foot element 100a, 100b, 100c
includes a split 30a, 30b, 30c that at least partially extends
substantially along the longitudinal axis of the foot. The split
30a, 30b, 30c provides a narrow gap between a medial portion 32a,
32b, 32c and a lateral portion 34a, 34b, 34c of the foot element
100a, 100b, 100c. In the illustrated embodiments, the split 30a,
30b, 30c does not extend to the heel end 12 of the foot element
100a, 100b, 100c. In some embodiments, the split 30a, 30b, 30c
begins in a rounded fillet, hole, or opening 36 that helps prevent
the formation of stress concentrations in that region. Although in
the illustrated embodiments, the opening 36 is circular, the
opening 36 can be any shape. In some such embodiments, the opening
36 is sized such that a ratio of the diameter of the opening 36 to
the width of the split 30a, 30b, 30c is between 2:1 to 6:1.
[0037] In the foot element 100a shown in FIGS. 2A-2C, the split 30a
extends substantially straight from the opening 36 through the arch
region 16, then curves medially in the forefoot region 18 or
approximately at a border between the arch region 16 and the
forefoot region 18. In the illustrated embodiment, the split 30a
extends to or toward the cut out 24. In the foot element 100b shown
in FIGS. 3A-3C, the split 30b similarly extends substantially
straight from the opening 36 and curves medially in the forefoot
region 18 or approximately at a border between the arch region 16
and the forefoot region 18. However, the split 30b of the foot
element 100b of FIGS. 3A-3C curves more sharply than the split 30a
of the foot element 100a of FIGS. 2A-2C and extends to or towards
the medial edge 31 of the foot element 100b in the forefoot region
18. In the foot element 100c shown in FIGS. 4A-4C, the split 30c
again extends substantially straight from the opening 36 and curves
in the forefoot region 18 or approximately at a border between the
arch region 16 and the forefoot region 18. However, the split 30c
of the foot element 100c of FIGS. 4A-4C curves more sharply
laterally and extends to or towards a lateral edge 33 of the foot
element 100c in the forefoot region 18. The asymmetric split 30a,
30b, 30c can advantageously provide a rollover that more closely
approximates or mimics that of a natural human foot. Although in
the illustrated embodiments the split 30a, 30b, 30c extends
substantially straight and parallel to a longitudinal axis of the
foot element 100a, 100b, 100c from the opening 36 to the curved
portion, in other embodiments, the split 30a, 30b, 30c can be
nonparallel (e.g., angled, askew, curved, or otherwise not straight
and/or not parallel to the longitudinal axis of the foot element
100a, 100b, 100c) along any portion between the opening 36 and
curved portion.
[0038] In the embodiment of FIGS. 2A-2C, the split 30a separates
the portion of the forefoot region 18 associated with the big toe
26 (e.g., the "ball" of the foot associated with the big toe) from
the remainder of the forefoot region 18. This can advantageously
allow the foot element 100a to more closely approximate or mimic a
natural human foot. In some embodiments, the foot element 100a,
100b, 100c includes attachment holes 38 as discussed in greater
detail herein. In some such embodiments, the curved portion of the
split 30a, 30b, 30c begins distal to (or closer to the toe end 14
than) the attachment holes 38. In some embodiments, the curved
portion of the split 30a, 30b, 30c begins proximal to (or closer to
the heel end 12 than) the forefoot region 18 or at or proximal to a
transition between the arch region 16 and the forefoot region
18.
[0039] In some embodiments, the portion of the foot element 100a,
100b, 100c that does not include the split 30a, 30b, 30c is between
about 10% and about 30% of the total length of the foot element
100a, 100b, 100c (i.e., the length of the split 30a, 30b, 30c is
between about 70% and about 90% of the length of the foot element
100a, 100b, 100c). In other words, the combined length of the
portions of the foot element 100a, 100b, 100c from the opening 36
to the heel end 12 and from the end of the split 30a, 30b, 30c to
the toe end 14 is no more than 30% and no less than 10% of the
total length of the foot element 100a, 100b, 100c.
[0040] FIGS. 12A-12E illustrate an example embodiment of a foot
element 400 that includes a drop-toe or vertically offset toe
portion. In the illustrated embodiment, a forefoot piece 410 is
coupled, either permanently or removably, to a bottom surface of at
least a portion of the forefoot region 418 and/or toe portion 420
of the foot element 400. In the illustrated embodiment, the foot
element 400 is similar to foot element 100a and includes a split
430 extending to a cut-out 424. However, in other embodiments,
other variations of foot elements, include foot elements 100b, 100c
shown and described herein, can include a forefoot piece and/or
features shown and described herein with respect to the embodiment
of FIGS. 12A-12E. As shown in the illustrated embodiment, the
bottom surface of the forefoot region 418 and toe portion 420 can
be flattened or straight (rather than curved) to accommodate a
forefoot piece 410 having a flat or straight upper surface. In
other embodiments, the bottom surface of the forefoot region 418
and toe portion can be curved or partially curved to accommodate a
forefoot piece 410 having a curved or partially curved upper
surface. As shown, the forefoot piece 410 is generally sized and
shaped to correspond to the forefoot region 418 and/or toe portion
420 of the foot element, and a distal end of the forefoot piece 410
can include a cut-out 425 that corresponds in shape and size to the
cut-out 424 of the foot element 400.
[0041] In the illustrated embodiment, a bottom surface of the
forefoot piece 410 is curved or downward-facing convex. In some
embodiments, the bottom surface of the forefoot piece 410 has a
curvature that is discontinuous relative to and/or different from
the curvature of the lower surface of the foot element 400 proximal
to the forefoot piece 410. The bottom surface of the forefoot piece
410 may therefore be downwardly vertically offset from a remainder
of the foot element 400 proximal to the forefoot piece 410. The
forefoot piece 410 can advantageously allow for the foot element
400 to be supported during stance at portions of the heel and toe
portion 420 rather than at the heel and fasteners that couple an
upper foot member to the foot element 400. This allows for enhanced
suspension and increased vertical displacement of the foot element
400 during stance because the fasteners are not in contact with the
ground.
[0042] In some alternative embodiments, the forefoot piece 410 can
be integrally formed with the foot element 400. In other words, the
bottom surface of the forefoot region 418 and/or toe portion 420 of
the foot element 400 itself can form or define a curvature that is
different than and/or discontinuous relative to the curvature of
the lower surface of the foot element 400 proximal to the forefoot
region 418 and/or toe portion 420. In some embodiments, an upper
surface of the forefoot region 418 and/or toe portion 420 can also
define a curvature that is different than and/or discontinuous
relative to the curvature of the upper surface of the foot element
400 proximal to the forefoot region 418 and/or toe portion 420.
Additional details regarding drop-toe or vertically offset toe
portions can be found in U.S. Publication No. 2013/0144403, the
entirety of which is hereby incorporated herein by reference.
[0043] Foot elements according to the present disclosure, for
example, foot elements 100a, 100b, 100c, can be incorporated into a
variety of prosthetic feet, for example as shown in FIGS. 1 and
6-7. In some embodiments, foot elements 100a, 100b, 100c include
attachment holes 38. An upper foot element, such as upper foot
elements 200a-200f of the prosthetic feet 10a-10f shown in FIG. 1,
can be coupled to the foot element 100a, 100b, 100c with fasteners,
e.g., screws, bolts, or the like 40, inserted through the
attachment holes 38. The upper foot elements 200a-200f can also
include attachment holes to receive the screws, bolts, or the like
40. Alternatively, an upper foot element can be coupled to a foot
element 100a, 100b, 100c with an adhesive or other suitable
mechanism. Upper foot elements 200a-200f can be made or constructed
with the same or similar materials and the same or similar
processes as described herein with respect to foot element 100a,
100b, 100c.
[0044] As shown, upper foot element 200b has a generally vertical
proximal portion and extends downwards and forwards to a generally
horizontal distal portion. The upper foot element 200b is coupled
to the foot element 100 via bolts, screws, or the like 40 proximate
a distal or anterior end of the upper foot element 200b. The upper
foot element 200b therefore extends forward approximately to a
transition area between the arch region 16 and the forefoot region
18. Upper foot element 200a is designed so that prosthetic foot 10a
has a lower profile than prosthetic foot 10b. Upper foot element
200f is similar to upper foot element 200a. However, in the
illustrated embodiment, upper foot element 200f has a tapered shape
such that a distal end of the upper foot element 200f is thicker
than a proximal end of the upper foot element 200f. The prosthetic
foot 10f of FIG. 1F can also include an upper flex plate 204f.
Additional details regarding prosthetic feet incorporating features
similar to prosthetic foot 10f can be found in U.S. Provisional
Application No. 62/153,406, filed Apr. 27, 2015, the entirety of
which is hereby incorporated by reference herein. Upper foot
element 200c has a C-shape, or has a relatively short
concave-forward portion at or near the proximal end, though it can
have other suitable shapes such as an L-shape or J-shape. In the
illustrated embodiment, upper foot element 200c extends farther
forward or anteriorly into the forefoot region 18 of the foot
element 100 than upper foot elements 200a, 200b, as also shown in
FIG. 6. In the illustrated embodiment, upper foot element 200c also
has a curved distal end, whereas upper foot elements 200a, 200b
have straight distal ends. Any of the upper and/or intermediate
foot elements described herein can have straight or curved distal
ends. Prosthetic foot 10c also includes an intermediate element
202c positioned between the upper foot element 200c and the foot
element 100. Prosthetic foot 10e similarly includes an upper foot
element 200e having a concave-forward portion at or near the
proximal end, although other shapes for upper foot element 200e are
also possible such as an L-shape or J-shape, and an intermediate
element 202e positioned between the upper foot element 200e and the
foot element 100. As shown in FIGS. 1C and 1E, the proximal ends of
the upper foot members 200c, 200e can be coupled to a front portion
212c, 212e of an ankle module 210c, 210e, and the proximal ends of
the intermediate elements 202c, 202e can be coupled to a rear
portion 214c, 214e of the ankle module 210c, 210e, which may be,
for example, a support member, actuator, or rod connector. FIGS. 1D
and 7 illustrate an example embodiment of a prosthetic foot 10d
having dual C-shaped upper foot elements 200d, 202d. The upper
and/or intermediate foot elements shown in FIGS. 1 and 6-7 can be
used with any foot element according to the present disclosure,
such as foot elements 100a, 100b, 100c. Additionally, foot elements
according to the present disclosure, such as foot elements 100a,
100b, 100c, can be used with other configurations of upper and/or
intermediate foot elements and can be incorporated into a variety
of prosthetic feet.
[0045] As shown in FIGS. 1A-1F, prosthetic feet incorporating foot
elements 100a, 100b, 100c, such as prosthetic feet 10a-10f, can
also include an adapter configured to couple the prosthetic foot to
a user, for example, to the user's residual limb, a pylon, or
another prosthetic component. For example, FIG. 1A illustrates an
example embodiment of an adapter 50a coupled to a proximal end of
upper foot member 200a of prosthetic foot 10a, and FIG. 1B
illustrates another example embodiment of an adapter 50b coupled to
a proximal end of upper foot member 200b of prosthetic foot 10b.
FIGS. 1C and 1E illustrate example embodiments of adapters 50c,
50e, respectively, coupled to proximal ends of ankle modules 210c,
210e, respectively. In the example embodiment of FIG. 1D, another
example embodiment of an adapter 50d is coupled to the proximal
ends of the dual upper foot elements 200d, 202d. FIG. 1F
illustrates an example embodiment of an adapter 50f coupled to the
proximal end of the upper flex plate 204f. Other configurations and
arrangements of adapters are also possible.
[0046] FIGS. 6-8 illustrate an example embodiment of a cosmesis or
foot cover 300 designed to receive a prosthetic foot, such as a
prosthetic foot as described herein. The foot cover 300 has the
shape of a natural human foot, which can advantageously improve the
aesthetic appeal of a prosthetic foot. The foot cover 300 is also
designed to enhance the performance of the prosthetic foot. In some
embodiments, the foot cover 300 is made of polyurethane or a
similar material, although other materials are also possible. The
foot cover 300 has an outer body 330 having an opening at a top end
and defining and surrounding an inner cavity 332 that removably
receives a prosthetic foot. The outer body 330 includes a sole
portion and sidewalls extending upward from the sole portion to
form sides and a top of the outer body 330. In some embodiments,
the sole portion and sidewalls are integrally formed such that the
outer body 330 is monolithic. An outer surface of the body
generally has the shape and contours of a natural human foot to
give the cosmesis the appearance of a natural human foot. In the
illustrated embodiment, the foot cover 300 is shallow; in other
words, the sidewalls are short and do not extend upward far beyond
a level of a foot when received in the foot cover 300 (e.g., the
sidewalls of the foot cover extend to a level below that
corresponding to the ankle in a natural human foot). In other
embodiments, the sidewalls extend to a level corresponding to that
of the ankle of a natural human foot, for example, as shown in
FIGS. 10 and 13A-13C. FIGS. 13A-13C illustrate prosthetic feet 10d,
10e, and 10f, respectively, disposed in the foot cover 300. In yet
other embodiments, the sidewalls can extend higher than the level
of the ankle. Additional details on foot covers can be found in
U.S. Pat. No. 8,128,709, entitled "Functional Foot Cover," and U.S.
Pat. No. 8,685,109, entitled "Smooth Rollover Insole for Prosthetic
Foot," the entireties of which are hereby incorporated by reference
and should be considered a part of this specification.
[0047] In some embodiments, the foot cover 300 includes areas
having relatively greater flexibility in a forefoot 318 and/or toe
region 320, for example as shown in FIG. 8. In some embodiments,
the areas of greater flexibility are formed by areas that are
thinner than the remainder of the foot cover 300. Additionally or
alternatively, the regions of greater flexibility can be made of a
different material than the remainder of the foot cover 300. In the
illustrated embodiment, the foot cover 300 includes a region 302 of
increased flexibility at a transition area between the forefoot or
ball of the foot region 318 and the toe region 320, for example, at
an area corresponding to the metatarsal joint of a natural human
foot. In the illustrated embodiment, the foot cover 300 also
includes regions 304 of increased flexibility in the toe region
320, for example, at areas corresponding to joints between bones of
the toes in a natural human foot. These areas of increased
flexibility can advantageously allow the toe portion 320 of the
foot cover 300 to articulate relative to the forefoot region 318 to
more closely resemble a natural human foot.
[0048] In some embodiments, an arch region 316 of the foot cover
300 is designed to more closely resemble that of a natural human
foot. In some embodiments, the foot cover 300 includes padded areas
or areas of increased build at or around a heel region 322, an
outer portion of the arch region 316, and/or the forefoot or ball
of the foot region 318, for example as shown in FIG. 8. In the
illustrated embodiment, the foot cover 300 includes a padded area
350 extending from the heel region 322, across an outer or lateral
portion of the arch region 316, to an outer or lateral portion of
the forefoot or ball of the foot region 318. In other embodiments,
the foot cover 300 can include padded areas at other locations of
the foot cover 300.
[0049] In some embodiments, the foot cover 300 is designed to be
used with a prosthetic foot including a foot element such as foot
elements 100a, 100b, 100c as described herein. For example, the
foot cover 300 can include a mating structure or slot 324 that
engages the cutout 24 of the foot element 100a, 100b, 100c as shown
in FIG. 7. The slot 324 can allow the foot cover 300 to more
closely resemble a human foot. The slot 324 can also receive a
strap of a sandal. The foot cover 300 can also or alternatively
define several toes disposed adjacent each other without
intervening slots therebetween. In some embodiments, the foot cover
300 and foot element 100a, 100b, 100c are designed to correspond in
size and shape to one another such that the foot cover 300 and foot
element 100a, 100b, 100c have an improved fit (e.g., the perimeter
of the foot plate substantially coincides with the perimeter of the
inner sole in the foot cover on which the foot plate is
positioned). With previously available prosthetic feet and foot
covers, the foot is usually not the same shape and/or size as the
foot cover, so there is often empty or extra space within the foot
cover (e.g., the perimeter of the foot plate does not coincide with
the perimeter of the inner sole in the foot cover on which the foot
plate is positioned), which can cause wear and tear in the foot
cover and/or suboptimal performance. With the foot elements 100a,
100b, 100c and foot cover 300 of the present disclosure, all or
substantially all of the sole portion of the foot cover 300
corresponds to a portion of the foot element 100a, 100b, 100c such
that any space between the foot plate and the foot cover is reduced
or minimized. This advantageously allows the foot element 100a,
100b, 100c and foot cover 300 to work together and improves or
optimizes the functionality of the foot cover 300.
[0050] In some embodiments, for example as shown in FIG. 9, an
inner surface 325 of a big toe portion 326 of the foot cover can
have a slightly different shape than the big toe 26 of the foot
element. The portion 327 of the wall of the big toe portion 326
adjacent the slot 324 can also have an increased thickness. As
shown in FIG. 9, the big toe 26 can angle slightly laterally (or
toward the cut-out 24). When the foot element is placed in the foot
cover, due to the angled big toe 26, shape of the inner surface
325, and/or increased thickness of the portion 327 of the wall of
the big toe portion 326, the big toe portion 326 of the foot cover
is pushed toward the remaining "toes" of the foot cover, which at
least partially closes the slot 324. This can advantageously help
hold a sandal strap in place and help inhibit the sandal from
falling off during gait, which is a problem users often face with
existing foot covers.
[0051] As shown in FIG. 10, in some embodiments, the top opening
331 of the foot cover 300 is curved or concave rather than
straight. The concave profile can advantageously provide for a more
secure attachment of a flat or straight attachment plate 360 to the
main body of the foot cover. The attachment plate 360 includes
downwardly extending teeth or pins 362 configured to fit into
cavities in the rim of the top opening 331. As the attachment plate
360 is coupled to the rim, the attachment plate 360 is bent or
curved to fit the curved opening, and the teeth or pins 362 spread
outwardly and upwardly. This can increase the holding strength of
the pins 362 in the cavities and increase the pull force needed to
detach the attachment plate 360 from the foot cover 300,
particularly, for example, at the front and rear portions of the
opening 331. The curved opening 331 can also improve the aesthetic
appearance of the foot cover 300 as the curve resembles the shape
of the opening of a shoe.
[0052] In some embodiments, the forefoot region 318 of the foot
cover 300 is wider than a remainder of the foot cover 300, for
example, wider than the arch region 316 and/or heel region 322, and
wider than previously available prosthetic feet and/or foot covers.
In some cases, conventional or previously available prosthetic feet
and foot covers have poor compliance with shoes designed for
natural human feet. The forefoot regions of such feet and/or foot
covers are often narrower than natural human feet, so there is
often a space between the foot cover and shoe. The space or gap
allows for movement between the foot or foot cover and shoe, which
can result in wear on the foot and/or foot cover. The wider
forefoot region 18 of the foot element 100a, 100b, 100c and the
corresponding wider forefoot region 318 of the foot cover 300 can
advantageously help reduce such wear. The wider forefoot region can
also improve the aesthetic appearance of the foot and/or foot cover
as it can resemble the size and/or shape of a natural human foot
more closely.
[0053] In some embodiments, for example as shown in FIGS. 11A-11B,
an inner surface of the sole portion of the foot cover 300 includes
dimples or perforations 370. The dimples 370 advantageously allow
for the creation of more even material thickness, particularly in
relatively thick portions of the sole portion. The dimples 370
allow the material to cool more quickly and evenly without
distortion during production of the foot cover 300. The dimples 370
also reduce the mass of the foot cover 370.
[0054] Although this disclosure has been described in the context
of certain embodiments and examples, it will be understood by those
skilled in the art that the disclosure extends beyond the
specifically disclosed embodiments to other alternative embodiments
and/or uses and obvious modifications and equivalents thereof. In
addition, while several variations of the embodiments of the
disclosure have been shown and described in detail, other
modifications, which are within the scope of this disclosure, will
be readily apparent to those of skill in the art. It is also
contemplated that various combinations or sub-combinations of the
specific features and aspects of the embodiments may be made and
still fall within the scope of the disclosure. For example,
features described above in connection with one embodiment can be
used with a different embodiment described herein and the
combination still fall within the scope of the disclosure. It
should be understood that various features and aspects of the
disclosed embodiments can be combined with, or substituted for, one
another in order to form varying modes of the embodiments of the
disclosure. Thus, it is intended that the scope of the disclosure
herein should not be limited by the particular embodiments
described above. Accordingly, unless otherwise stated, or unless
clearly incompatible, each embodiment of this invention may
comprise, additional to its essential features described herein,
one or more features as described herein from each other embodiment
of the invention disclosed herein.
[0055] Features, materials, characteristics, or groups described in
conjunction with a particular aspect, embodiment, or example are to
be understood to be applicable to any other aspect, embodiment or
example described in this section or elsewhere in this
specification unless incompatible therewith. All of the features
disclosed in this specification (including any accompanying claims,
abstract and drawings), and/or all of the steps of any method or
process so disclosed, may be combined in any combination, except
combinations where at least some of such features and/or steps are
mutually exclusive. The protection is not restricted to the details
of any foregoing embodiments. The protection extends to any novel
one, or any novel combination, of the features disclosed in this
specification (including any accompanying claims, abstract and
drawings), or to any novel one, or any novel combination, of the
steps of any method or process so disclosed.
[0056] Furthermore, certain features that are described in this
disclosure in the context of separate implementations can also be
implemented in combination in a single implementation. Conversely,
various features that are described in the context of a single
implementation can also be implemented in multiple implementations
separately or in any suitable subcombination. Moreover, although
features may be described above as acting in certain combinations,
one or more features from a claimed combination can, in some cases,
be excised from the combination, and the combination may be claimed
as a subcombination or variation of a subcombination.
[0057] Moreover, while operations may be depicted in the drawings
or described in the specification in a particular order, such
operations need not be performed in the particular order shown or
in sequential order, or that all operations be performed, to
achieve desirable results. Other operations that are not depicted
or described can be incorporated in the example methods and
processes. For example, one or more additional operations can be
performed before, after, simultaneously, or between any of the
described operations. Further, the operations may be rearranged or
reordered in other implementations. Those skilled in the art will
appreciate that in some embodiments, the actual steps taken in the
processes illustrated and/or disclosed may differ from those shown
in the figures. Depending on the embodiment, certain of the steps
described above may be removed, others may be added. Furthermore,
the features and attributes of the specific embodiments disclosed
above may be combined in different ways to form additional
embodiments, all of which fall within the scope of the present
disclosure. Also, the separation of various system components in
the implementations described above should not be understood as
requiring such separation in all implementations, and it should be
understood that the described components and systems can generally
be integrated together in a single product or packaged into
multiple products.
[0058] For purposes of this disclosure, certain aspects,
advantages, and novel features are described herein. Not
necessarily all such advantages may be achieved in accordance with
any particular embodiment. Thus, for example, those skilled in the
art will recognize that the disclosure may be embodied or carried
out in a manner that achieves one advantage or a group of
advantages as taught herein without necessarily achieving other
advantages as may be taught or suggested herein.
[0059] Conditional language, such as "can," "could," "might," or
"may," unless specifically stated otherwise, or otherwise
understood within the context as used, is generally intended to
convey that certain embodiments include, while other embodiments do
not include, certain features, elements, and/or steps. Thus, such
conditional language is not generally intended to imply that
features, elements, and/or steps are in any way required for one or
more embodiments or that one or more embodiments necessarily
include logic for deciding, with or without user input or
prompting, whether these features, elements, and/or steps are
included or are to be performed in any particular embodiment.
[0060] Conjunctive language such as the phrase "at least one of X,
Y, and Z," unless specifically stated otherwise, is otherwise
understood with the context as used in general to convey that an
item, term, etc. may be either X, Y, or Z. Thus, such conjunctive
language is not generally intended to imply that certain
embodiments require the presence of at least one of X, at least one
of Y, and at least one of Z.
[0061] Language of degree used herein, such as the terms
"approximately," "about," "generally," and "substantially" as used
herein represent a value, amount, or characteristic close to the
stated value, amount, or characteristic that still performs a
desired function or achieves a desired result. For example, the
terms "approximately", "about", "generally," and "substantially"
may refer to an amount that is within less than 10% of, within less
than 5% of, within less than 1% of, within less than 0.1% of, and
within less than 0.01% of the stated amount. As another example, in
certain embodiments, the terms "generally parallel" and
"substantially parallel" refer to a value, amount, or
characteristic that departs from exactly parallel by less than or
equal to 15 degrees, 10 degrees, 5 degrees, 3 degrees, 1 degree,
0.1 degree, or otherwise.
[0062] The scope of the present disclosure is not intended to be
limited by the specific disclosures of preferred embodiments in
this section or elsewhere in this specification, and may be defined
by claims as presented in this section or elsewhere in this
specification or as presented in the future. The language of the
claims is to be interpreted broadly based on the language employed
in the claims and not limited to the examples described in the
present specification or during the prosecution of the application,
which examples are to be construed as non-exclusive.
* * * * *