Bionic prosthetic system reinforced with natural fibers

Abstract

Bionic prosthetic system reinforced with natural fibers, consisting of: a prosthetic structural body formed from a composite material comprising natural fibers and a polymer resin matrix; the natural fibers include pineapple leaf fibers (PALF) treated with an alkaline solution to improve the binding properties; wherein the polymer resin matrix comprises epoxy resin or an equivalent thermally curable polymer; the prosthetic system is configured to offer joint mobility of up to 180°, a load-bearing capacity of up to 100 kilograms and a lifespan of 5 to 7 years; The system is manufactured using a hand-laying process followed by oven curing, resulting in a lightweight and durable prosthesis with improved mechanical strength and environmental sustainability.

Description

[0001] The present invention relates to the field of biomedical engineering and biomechanics, in particular to prosthetic systems and devices for limb rehabilitation. Specifically, the invention relates to a bionic prosthetic system reinforced with natural fibers such as pineapple leaf fibers (PALF) and combined with polymer resins to produce lightweight, durable, and environmentally friendly prosthetic components.

[0002] Prosthetic systems are artificial devices designed to replace missing body parts and restore partial or full functionality to amputees. Over the years, advances in materials and manufacturing processes have led to a wide variety of prosthetic solutions, ranging from simple mechanical limbs to sophisticated bionic and myoelectric prostheses. However, most of these systems remain unaffordable, technologically complex, or environmentally unsustainable, limiting their accessibility to a significant portion of the world's population, particularly in developing regions. Conventional prostheses are often based on synthetic materials such as carbon fiber, fiberglass, or thermoplastic polymers, which, while offering good mechanical performance, contribute to high manufacturing costs and limited biodegradability.On the other hand, while inexpensive 3D-printed prostheses are affordable, they typically lack long-term durability and load-bearing capacity, making them unsuitable for extended use. Similarly, osseointegrated prostheses, which require invasive surgical fixation, are expensive and can lead to discomfort or postoperative complications. Existing bionic prostheses feature motorized and neural control mechanisms that offer improved mobility and functionality, but these come with extremely high production and maintenance costs. As a result, economically disadvantaged amputees are often forced to choose between affordability and performance, leading to a reduced quality of life and limited mobility.Therefore, there is an urgent need for a prosthetic system that combines affordability, mechanical strength, and environmental sustainability without compromising comfort or ease of use. The present invention fills this gap by introducing a bionic prosthetic system reinforced with natural fibers, in particular pineapple leaf fibers (PALF), in combination with epoxy resin to produce a lightweight, durable, and environmentally friendly prosthesis. The system offers high tensile strength, improved wear resistance, and easy scalability through a simple, repeatable manufacturing process, thus providing an economically and ecologically sustainable alternative to current prosthetic technologies.

[0003] To solve this problem, the present invention offers a bionic prosthetic system reinforced with natural fibers.

[0004] The system is affordable, durable, lightweight and environmentally friendly, and is suitable for people from low-income backgrounds.

[0005] The system improves the mechanical strength and wear resistance of the prosthesis while preserving its biodegradability and low cost.

[0006] The system aims to overcome the limitations of conventional prostheses by integrating natural fiber reinforcements, particularly pineapple leaf fibers (PALF), with epoxy resin, thus achieving a balance between cost-efficiency and performance suitable for large-scale, cost-effective production.

[0007] The system is characterized by high tensile strength, excellent wear resistance and a low weight-to-strength ratio, while keeping production costs low.

[0008] The system promotes environmentally friendly design and circular manufacturing processes while ensuring high durability, load-bearing capacity and a long service life for the prosthesis wearer.

[0009] In one embodiment, the present invention provides a natural fiber-reinforced bionic prosthetic system that overcomes the limitations of conventional prostheses in terms of cost, sustainability, and performance. The invention integrates pineapple leaf fibers (PALF), a renewable and biodegradable material, with epoxy resin to form a high-strength composite structure suitable for use in prostheses. The system comprises a mechanically optimized prosthetic framework that is fabricated by a hand lay-up process and subsequently oven-cured to achieve a uniform bond and improved structural integrity. The treated PALF reinforcement imparts excellent tensile strength, impact resistance, and stiffness to the system while maintaining a lightweight configuration for improved comfort and wearability.The prosthetic system can also include adjustable socket padding (5-10 mm), an adjustable length (20-40 cm), and joint mobility of up to 180°, allowing for natural limb movement and adaptability to different users. The invention can support a load-bearing capacity of up to 100 kg and has a lifespan of 5-7 years under normal use. By using natural fiber composites, the invention reduces production costs and environmental impact while ensuring mechanical reliability comparable to existing high-performance prostheses. The simplified manufacturing process enables mass production and easy repair or recycling, making the invention particularly suitable for use in developing regions and rural rehabilitation programs.Essentially, the invention offers an environmentally friendly, cost-effective and functionally robust bionic prosthetic system that bridges the gap between advanced bionic technologies and affordability, thereby improving the quality of life and mobility of amputees. The invention will be explained again below.

[0010] The present invention relates to a bionic prosthetic system reinforced with natural fibers, designed as a lightweight, durable, cost-effective, and environmentally friendly alternative to conventional synthetic prostheses. The system integrates natural fiber composites into the prosthetic structure to achieve excellent mechanical properties while ensuring affordability and ease of manufacture, making it suitable for amputees in both urban and rural areas. According to the invention, the prosthetic system consists of a composite material comprising natural fibers, preferably pineapple leaf fibers (PALF), and a polymer resin matrix such as epoxy resin. Pineapple leaf fibers are selected for their high tensile strength, low density, and renewable nature, providing an environmentally friendly alternative to synthetic fibers such as carbon or glass fibers.The resin serves as a binding matrix, ensuring effective load transfer and uniform stress distribution throughout the composite structure.

[0011] The fiber-to-resin ratio can be varied within a range that optimizes strength, stiffness, and flexibility depending on the application requirements. Before being incorporated into the composite material, the natural fibers undergo an alkaline treatment to improve interfacial adhesion with the resin matrix. In this treatment, the fibers are immersed in a sodium hydroxide (NaOH) solution, preferably with a concentration of about 5%, for approximately four to six hours. This process removes surface impurities, lignin, and hemicellulose, thereby roughening the fiber surface and improving adhesion properties.After alkali treatment, the fibers are thoroughly washed with distilled water until a neutral pH is reached, then dried at ambient conditions, and subsequently oven-dried at temperatures between 60°C and 80°C to remove residual moisture. The prosthetic component is manufactured using a hand lay-up process that is simple, economical, and suitable for small-batch production. In this process, a mold with the desired prosthetic shape, such as a forearm, foot, or leg, is made of metal or polymer material. To prevent sticking, a release agent such as polyvinyl alcohol (PVA) is applied to the mold surface. The treated and dried fibers are arranged in layers within the mold, and an epoxy resin mixed with a hardener in a weight ratio of approximately 10:1 is applied evenly between the fiber layers.The layers are compacted to remove trapped air and ensure uniform resin distribution. The composite material is then cured in an oven at a temperature of 60°C to 80°C for two to three hours to achieve complete polymerization and structural integrity. After curing, the component is demolded, trimmed, and machined to the desired dimensions. The resulting prosthetic component is characterized by a high strength-to-weight ratio and improved fatigue resistance. The composite structure offers a tensile strength in the range of 200 to 500 MPa and a flexural strength between 150 and 250 MPa, with a service life of approximately five to seven years under normal usage conditions.The weight of the prosthesis is significantly reduced compared to conventional metal or carbon fiber prostheses, thus improving user comfort and reducing energy expenditure during use. The prosthetic system can include a socket section designed to conform to the user's residual limb. The inner surface of the socket is lined with soft padding between 5 mm and 10 mm thick to enhance comfort and distribute pressure evenly. The system also includes a joint section that allows for up to 180 degrees of movement, enabling natural motion and flexibility during locomotion. The prosthesis's structural body is configured to withstand loads of up to 100 kilograms, making it suitable for daily use and physical activities.Depending on the user's needs, the distal end of the prosthesis can be equipped with various attachments, including mechanical footplates, artificial hands, or gripping mechanisms. In certain configurations, the prosthetic system can also incorporate electromechanical components such as sensors, servomotors, and microcontrollers, enabling bionic or myoelectric control. Such configurations allow the user to operate the prosthesis using biosignals, thus restoring more natural limb function.

Claims

[1] Bionic prosthetic system reinforced with natural fibers, consisting of: a prosthetic structural body formed from a composite material comprising natural fibers and a polymer resin matrix; the natural fibers include pineapple leaf fibers (PALF) treated with an alkaline solution to improve the binding properties; wherein the polymer resin matrix comprises epoxy resin or an equivalent thermally curable polymer; the prosthetic system is configured to offer joint mobility of up to 180°, a load-bearing capacity of up to 100 kilograms and a lifespan of 5 to 7 years; The system is manufactured using a hand-laying process followed by oven curing, resulting in a lightweight and durable prosthesis with improved mechanical strength and environmental sustainability. [2] The bionic prosthesis system according to claim 1, wherein the proportion of natural fibers is between 30 and 50 percent by weight of the total composite material. [3] The bionic prosthetic system according to claim 1, wherein the alkaline treatment of the pineapple leaf fiber comprises immersion in a 5% sodium hydroxide (NaOH) solution for 4 to 6 hours, followed by washing and drying to remove lignin and impurities. [4] The bionic prosthetic system according to claim 1, wherein the hand lay-up method comprises the sequential placement of layers of treated fiber and resin mixture into a mold, the application of pressure and subsequent curing in an oven at 60 to 80 °C to achieve a uniform bond. [5] The bionic prosthesis system according to claim 1, wherein the prosthesis comprises an adaptable shaft shape with a pad thickness between 5 mm and 10 mm to ensure comfort and secure attachment to the stump. [6] The bionic prosthetic system according to claim 1, wherein the dimensions of the stump are adjustable between 20 cm and 40 cm depending on the anatomical requirements of the user. [7] The bionic prosthesis system according to claim 1, wherein the composite material has a tensile strength in the range of 200 to 500 MPa, thereby ensuring a mechanical durability comparable to conventional carbon fiber prostheses. [8] The bionic prosthetic system according to claim 1, wherein the system is lightweight, biodegradable and cost-effective, making it suitable for mass production and use in resource-constrained environments.