Mounting brackets for connecting the prosthetic limb to the prosthetic foot

Abstract

A mounting bracket for a prosthetic limb configured to attach to a residual limb includes an upper member, a lower member, and a compression-torsion joint. The upper member includes an upper flange, a mating post, and a mounting portion configured to attach to the residual limb. The lower member includes a mating portion, a lower flange, and a mounting portion configured to attach to the prosthetic limb. The compression-torsion joint connects the upper member to the lower member and is configured to limit vertical and torsional movement of the upper member relative to the lower member.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application Serial No. 63 / 078,748, filed September 15, 2020, and U.S. Provisional Application Serial No. 63 / 137,970, filed January 15, 2021, and is a continuation-in-part of U.S. Patent Application Serial No. 16 / 281,278, filed February 21, 2019, which is a continuation-in-part of U.S. Patent Application Serial No. 15 / 726,712, filed October 6, 2017 (now U.S. Patent No. 10,405,998), which is a continuation-in-part of U.S. Provisional ...13, 2016. No. 62 / 407,954, claims priority to U.S. Provisional Application Serial No. 62 / 451,870, filed January 30, 2017, and U.S. Provisional Application Serial No. 62 / 539,743, filed August 1, 2017, and is a continuation-in-part of U.S. Patent Application Serial No. 14 / 976,129, filed December 21, 2015, which is a continuation-in-part of U.S. Patent Application Serial No. 14 / 731,818, filed June 5, 2015, which is a continuation-in-part of U.S. Patent Application Serial No. 13 / 568,535, filed August 7, 2012. This application is also a continuation-in-part of U.S. Patent Application Serial No. 15 / 726,712, filed October 6, 2017 (now U.S. Patent No. 10,405,998), which is a continuation-in-part of U.S. Patent Application Serial No. 14 / 976,129, filed December 21, 2015, which is a continuation-in-part of U.S. Patent Application Serial No. 14 / 731,818, filed June 5, 2015, which is a continuation-in-part of U.S. Patent Application Serial No. 14 / 731,818, filed August 7, 2012. This application is a continuation-in-part of International Application Serial No. 13 / 568,535, which is a continuation-in-part of International Application No. PCT / US11 / 33319, filed April 20, 2011, which is a continuation-in-part of U.S. Patent Application Serial No. 12 / 799,215, filed April 20, 2010, which is a continuation-in-part of U.S. Patent Application Serial No. 11 / 901,845, filed September 19, 2007 (now U.S. Patent No. 8,048,173).This application is also a continuation-in-part of U.S. Patent Application Serial No. 15 / 726,712, filed October 6, 2017 (now U.S. Patent No. 10,405,998), which is a continuation-in-part of U.S. Patent Application Serial No. 14 / 976,129, filed December 21, 2015, which is a continuation-in-part of U.S. Patent Application Serial No. 13 / 568,535, filed August 7, 2012, which is a continuation-in-part of International Application No. PCT / US11 / 33319, filed April 20, 2011, which is a continuation-in-part of U.S. Patent Application Serial No. 12 / 799,215, filed April 20, 2010, which is a continuation-in-part of U.S. Patent Application Serial No. 11 / 901,845, filed September 19, 2007 (now U.S. Patent No. 8,048,173). This application is also a continuation-in-part of U.S. Patent Application Serial No. 14 / 731,771, filed June 5, 2015, which is a continuation-in-part of U.S. Patent Application Serial No. 13 / 642,501, filed November 27, 2012 (now U.S. Patent No. 9,078,773), which is the 371st National Phase application of International Application No. PCT / US11 / 33319, filed April 20, 2011, which is a continuation-in-part of U.S. Patent Application Serial No. 12 / 799,215, filed April 20, 2010, which is a continuation-in-part of U.S. Patent Application Serial No. 11 / 901,845, filed September 19, 2007 (now U.S. Patent No. 8,048,173), the disclosures of all of which are incorporated herein by reference. [Technical Field]

[0002] The present invention relates to prosthetics and orthotics, and more particularly to a prosthetic leg and mounting bracket for the prosthetic leg that, when used by an amputee, better replicates the motion of a natural leg and reduces the risk of injury to the amputee. [Background technology]

[0003] Prosthetic limbs are well known in the art. In use, such prosthetic limbs typically do not replicate the motion of a natural limb and can generate "kickback" or "kick-forward" responses, which increase the risk of injury to amputee users. Kickback refers to the backward movement of the prosthetic limb during the gait cycle. Kick-forward refers to the forward movement of the prosthetic limb during the gait cycle. Both movements can cause a user to feel unsteady by amplifying or restricting the intended motion. Additionally, many prior art prosthetic limbs generate vibrations that can travel through the user's leg and cause discomfort.

[0004] For amputee patients, the loss of bipedal walking can result in involuntary forward leaning and shifting, forcing them to constantly imbalance and rebalance their posture. Due to the amputation of the primary flexor and extensor muscles, amputee patients no longer have voluntary muscle control on the involved side. The primary anterior muscle responsible for dorsiflexion (sagittal plane movement) is the tibialis anterior. Dorsiflexion is the voluntary movement of the ankle that raises the foot upward, toward the midline of the body. The primary posterior muscle responsible for plantarflexion is the fundus muscle complex, which is made up of two muscles, the gastrocnemius and the soleus, working in tandem. Plantarflexion is the voluntary movement of the ankle that lowers the foot downward, away from the midline of the body. Therefore, it would be desirable to have a prosthetic foot configured to promote increased muscle activity and increased stability in amputee patients, and it would be desirable to provide an improved prosthetic foot that better mimics the action of a natural foot. Additionally, it would be desirable to provide an improved prosthetic foot that minimizes or eliminates "kickback" forces and reduces vibrations when the foot is utilized to walk over door jambs or other raised profile objects on the floor or ground.

[0005] In use, such prosthetic limbs are typically attached to either above-knee or below-knee amputees and are designed to mimic the user's natural gait. Different types of attachment systems may be utilized depending on the type of amputation. For example, if the amputation is above the knee, various suspension systems may be utilized in conjunction with the prosthetic limb to improve feel, fit, and function. For above-knee amputees, there is a large amount of space between the residual limb and the prosthetic limb, allowing for multiple options. For below-knee amputees, in some locations, there is less space between the user's residual limb and the prosthetic limb, allowing for a variety of attachment methods for the prosthetic limb. Summary of the Invention

[0006] An exemplary mounting bracket for a prosthetic limb may include an upper member, a lower member, and a torsion joint connecting the upper member to the lower member. The upper member may be configured to attach to a user's residual limb. The lower member may be configured to attach to a prosthetic limb.

[0007] Furthermore, in another embodiment, a prosthetic foot may include a resilient bottom member having a first bottom end and a second bottom end, and a resilient top member having a first top end and a second top end, the first top end being coupled to the first bottom end of the resilient bottom member, and the resilient top member being coupled to a mounting bracket and positioned on the resilient bottom member and facing the back of the prosthetic foot, and the prosthetic foot may also include a toe pad. The toe pad may include at least one spacer coupled between the first bottom end of the bottom member and the first top end of the top member to form a space therebetween, and adhesive bonding the first bottom end of the bottom member and the first top end of the top member, the adhesive commingling with the at least one spacer between the first bottom end and the first top end. [Brief explanation of the drawings]

[0008] These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description, appended claims, and accompanying drawings.

[0009] [Figure 1A] FIG. 1A is a perspective view illustrating a prosthetic foot configured in various embodiments. [Figure 1B] FIG. 1B is a perspective view illustrating a prosthetic foot configured in various embodiments. [Figure 2] FIG. 2 is a rear view further illustrating the prosthetic foot of FIGS. 1A and 1B. [Figure 3] FIG. 3 is a side view further illustrating the prosthetic foot of FIGS. 1A and 1B. [Figure 4A] FIG. 4A is a perspective view illustrating a prosthetic foot including a toe wrap. [Figure 4B] FIG. 4B is a perspective view illustrating a prosthetic foot including a toe wrap. [Figure 5A] FIG. 5A is a side view illustrating various embodiments of damper bar configurations. [Figure 5B] FIG. 5B is a side view illustrating various embodiments of damper bar configurations. [Figure 5C] FIG. 5C is a side view illustrating various embodiments of damper bar configurations. [Figure 6] FIG. 6 is a side view illustrating an exemplary prosthetic leg used by an above-knee amputee. [Figure 7] FIG. 7 is a side view illustrating an exemplary prosthetic leg used by a below-knee amputee. [Figure 8] FIG. 8 is an exemplary perspective view of a mounting bracket for a prosthetic limb according to an exemplary embodiment of the present technology. [Figure 9] FIG. 9 is an exemplary side view of a mounting bracket for a prosthetic limb according to an exemplary embodiment of the present technology. [Figure 10] FIG. 10 is an exemplary perspective view of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 11A] FIG. 11A is an exemplary perspective view of an upper member of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 11B]FIG. 11B is an exemplary side view of an upper member of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 11C] FIG. 11C is an exemplary bottom view of an upper member of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 12A] FIG. 12A is an exemplary side view of a lower member of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 12B] FIG. 12B is an exemplary perspective view of a lower member of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 13] FIG. 13 is an exemplary top view of a lower member of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 14A] FIG. 14A is an exemplary top view of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 14B] 14B is a partial cross-sectional side view taken along line AA of FIG. 14A illustrating an exemplary mounting bracket according to an exemplary embodiment of the present technology. [Figure 15] FIG. 15 is a partial cross-sectional side view taken along line BB of FIG. 14A illustrating an exemplary mounting bracket according to an exemplary embodiment of the present technology. [Figure 16] FIG. 16 is an exemplary partial exploded cross-sectional view of a mounting bracket taken along line AA of FIG. 14A in accordance with an exemplary embodiment of the present technology. [Figure 17] FIG. 17 is an exemplary perspective view of a lower member of a mounting bracket with a compression collar and compression / torsion bumper in accordance with an exemplary embodiment of the present technology. [Figure 18] FIG. 18 is an exemplary top view of a lower member of a mounting bracket with a compression collar and compression / torsion bumper in accordance with an exemplary embodiment of the present technology. [Figure 19] FIG. 19 is an exemplary exploded perspective view of the mounting bracket of FIG. 10 in accordance with an exemplary embodiment of the present technology. [Figure 20A]FIG. 20A is a partial assembly top view of a lower member showing an exemplary portion of a mounting bracket according to an exemplary embodiment of the present technology. [Figure 20B] 20B is a partial cross-sectional side view taken along line AA of FIG. 20A illustrating an exemplary portion of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 21] FIG. 21 is an exemplary partial exploded cross-sectional view taken along line AA of FIG. 20A showing a portion of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 22A] FIG. 22A is an exemplary perspective view of an elastomeric ring of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 22B] FIG. 22B is an exemplary top view of an elastomeric ring of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 23A] FIG. 23A is an exemplary perspective view of a bumper of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 23B] FIG. 23B is an exemplary top view of a bumper of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 23C] FIG. 23B is an exemplary top view of a bumper of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 24A] FIG. 24A is an exemplary perspective view of a compression collar of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 24B] FIG. 24B is an exemplary top view of a compression collar of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 25] FIG. 25 is a perspective view of a sleeve of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 26A] FIG. 26A is an exemplary perspective view of a cap of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 26B] FIG. 26B is an exemplary side view of a cap of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 26C] FIG. 26C is an exemplary bottom view of a cap of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 27A] FIG. 27A is an exemplary perspective view of a mating post of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 27B] FIG. 27B is an exemplary side view of a mating post of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 28A] FIG. 28A is an exemplary perspective view of a pin of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 28B] FIG. 28B is an exemplary side view of a pin of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 29] FIG. 29 is an exemplary perspective view of an additional embodiment of a lower member of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 30] FIG. 30 is an exemplary bottom view of an additional embodiment of a lower member of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 31] FIG. 31 is an exemplary side view of an additional embodiment of an upper member of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 32] FIG. 32 is an exemplary perspective view of an additional embodiment of an upper member of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 33] FIG. 33 is an exemplary exploded perspective view of an additional embodiment of a mounting bracket with an additional embodiment of a compression-torsion joint in accordance with an exemplary embodiment of the present technology. [Figure 34] FIG. 34 is a perspective view of the lower member of the mounting bracket with the new part of the compression-torsion joint of FIG. 33 in accordance with an exemplary embodiment of the present technology. [Figure 35] FIG. 35 is a side view of the mounting bracket of FIG. [Figure 36]36 is a top cross-sectional view taken along line AA of FIG. 35 showing an exemplary portion of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 37] 37 is a partial cross-sectional side view taken along line BB of FIG. 35 illustratively showing a portion of a mounting bracket according to an exemplary embodiment of the present technology. [Figure 38] FIG. 38 is a top view of the mounting bracket of FIG. 33 in accordance with an exemplary embodiment of the present technology. [Figure 39] 39 is a side cross-sectional view taken along line CC of FIG. 38 showing an exemplary portion of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 40A] FIG. 40A is a front view of a crescent shaped rotation restraint according to an exemplary embodiment of the present technology. [Figure 40B] FIG. 40B is a side view of a crescent shaped rotation restraint according to an exemplary embodiment of the present technology. [Figure 41] FIG. 41 is an exemplary perspective view of an additional embodiment of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 42] 42 is an exemplary top view of an additional embodiment of the mounting bracket of FIG. 41 in accordance with an exemplary embodiment of the present technology. [Figure 43] 43 is a side cross-sectional view taken along line AA of FIG. 42 showing an exemplary portion of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 44] FIG. 44 is an exploded side cross-sectional view taken along line AA of FIG. 42 showing an exemplary portion of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 45A] FIG. 45A is a perspective view illustrating an additional embodiment of an upper member of the mounting bracket of FIG. 41 in accordance with an exemplary embodiment of the present technology. [Figure 45B] FIG. 45B is a side view illustrating an additional embodiment of an upper member of the mounting bracket of FIG. 45A in accordance with an exemplary embodiment of the present technology. [Figure 45C]FIG. 45C is a bottom view illustrating an additional embodiment of the upper member of the mounting bracket of FIG. 45A in accordance with an exemplary embodiment of the present technology. [Figure 46A] FIG. 46A is a perspective view illustrating an additional embodiment of a lower member of the mounting bracket of FIG. 41 in accordance with an exemplary embodiment of the present technology. [Figure 46B] FIG. 46B is a top view of an additional embodiment of the upper member of the mounting bracket of FIG. 45A in accordance with an exemplary embodiment of the present technology. [Figure 47A] FIG. 47A is an exemplary perspective view of an additional embodiment of an elastomeric ring in accordance with an exemplary embodiment of the present technology. [Figure 47B] FIG. 47B is an exemplary top view of an additional embodiment of an elastomeric ring of the mounting bracket of FIG. 47A in accordance with an exemplary embodiment of the present technology. [Figure 47C] 47C is a side cross-sectional view taken along line CC of FIG. 47A illustratively illustrating an additional embodiment of an elastomeric ring of the mounting bracket of FIG. 47A in accordance with an exemplary embodiment of the present technology. [Figure 48A] FIG. 48A is an exemplary perspective view of an additional embodiment of an elastomeric ring in accordance with an exemplary embodiment of the present technology. [Figure 48B] FIG. 48B is an exemplary top view of an additional embodiment of an elastomeric ring of the mounting bracket of FIG. 48A in accordance with an exemplary embodiment of the present technology. [Figure 48C] 48C is a side cross-sectional view taken along line DD of FIG. 48A illustratively illustrating an additional embodiment of an elastomeric ring of the mounting bracket of FIG. 47A in accordance with an exemplary embodiment of the present technology. [Figure 49A] FIG. 49A is an exemplary perspective view of an additional embodiment of an elastomeric ring in accordance with an exemplary embodiment of the present technology. [Figure 49B] FIG. 49B is an exemplary top view of an additional embodiment of an elastomeric ring of the mounting bracket of FIG. 48A in accordance with an exemplary embodiment of the present technology. [Figure 49C]49C is a side cross-sectional view taken along line DD of FIG. 48A illustratively illustrating an additional embodiment of an elastomeric ring of the mounting bracket of FIG. 47A in accordance with an exemplary embodiment of the present technology. [Figure 50A] FIG. 50A is an exemplary perspective view of a compression cap of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 50B] FIG. 50B is an exemplary top view of the compression cap of FIG. 50A of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 50C] FIG. 50C is an exemplary side view of the compression cap of FIG. 50A of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 50D] FIG. 50D is an exemplary bottom view of the compression cap of FIG. 50A of the mounting bracket according to an exemplary embodiment of the present technology. [Figure 51A] FIG. 51A is a perspective view showing a torsion limiter of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 51B] FIG. 51B is a top or bottom view of the torsion limiter of FIG. 51A of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 52A] FIG. 52A is an exemplary side view of an additional embodiment of a mating post of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 52B] FIG. 52B is an exemplary perspective view of a mating post of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 53A] FIG. 53A is an exemplary perspective view of an additional embodiment of a mating post of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 53B] FIG. 53B is an exemplary side view of a mating post of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 54A] FIG. 54A is an exemplary top view of an additional embodiment of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 54B]54B is a side cross-sectional view taken along line GG of FIG. 54A showing an exemplary portion of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 55] FIG. 55 is an exploded side cross-sectional view taken along line GG of FIG. 54A showing an exemplary portion of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 56] FIG. 56 is an exemplary top view of an additional embodiment of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 57] FIG. 57 is a side cross-sectional view taken along line HH in FIG. 56 showing an exemplary portion of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 58] FIG. 58 is a side view of the mounting bracket with the upper and lower members visible and the elastomer ring omitted. [Figure 59] FIG. 59 is a front view of the mounting bracket with the upper and lower members visible and the elastomer ring omitted. [Figure 60] FIG. 60 is a top cross-sectional view taken along line KK of FIG. 59 showing an exemplary portion of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 61] FIG. 61 is a rear perspective view of a lower member of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 62] FIG. 62 is a top view of a lower member of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 63] FIG. 63 is a side view of a lower member of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 64] FIG. 64 is a front view of a lower member of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 65] FIG. 65 is a top view of an upper member of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 66] FIG. 66 is a side view of an upper member of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 67] FIG. 67 is a top perspective view of an upper member of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 68] FIG. 68 is a bottom perspective view of an upper member of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 69] FIG. 69 is a front view of an upper member of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 70] FIG. 70 is a front cross-sectional view of the upper member of the mounting bracket taken along line JJ in FIG. 59 in accordance with an exemplary embodiment of the present technology. [Figure 71] FIG. 71 is a perspective view of an internal bumper that facilitates coupling of upper and lower members of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 72] FIG. 72 is a bottom perspective view of an inner bumper of a mounting bracket according to an exemplary embodiment of the present technology. [Figure 73] FIG. 73 is a bottom view of an inner bumper of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 74] FIG. 74 is a side view of an inner bumper of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 75] FIG. 75 is an exemplary exploded perspective view of a mounting bracket in accordance with an exemplary embodiment of the present technology. [Figure 76] FIG. 76 is a side cross-sectional view of a retention system according to an exemplary embodiment of the present technology. [Figure 77] FIG. 77 is an exploded side view of a retention system and lower member according to an exemplary embodiment of the present technology. [Figure 78A] FIG. 78A is a perspective view of a retaining ring of a retention system according to an exemplary embodiment of the present technology. [Figure 78B] FIG. 78B is a top view of a retaining ring of a retention system according to an exemplary embodiment of the present technology. [Figure 78C] FIG. 78C is a side view of a retaining ring of a retention system according to an exemplary embodiment of the present technology. [Figure 79A]FIG. 79A is a perspective view of a plug of a retention system according to an exemplary embodiment of the present technology. [Figure 79B] FIG. 79B is a top view of a plug of a retention system according to an exemplary embodiment of the present technology. [Figure 79C] FIG. 79C is a side view of a plug of a retention system according to an exemplary embodiment of the present technology. [Figure 80A] FIG. 80A is a perspective view of a compression collar in accordance with an exemplary embodiment of the present technology. [Figure 80B] FIG. 80B is a top view of a compression collar in accordance with an exemplary embodiment of the present technology. [Figure 80C] FIG. 80C is a side view of a compression collar in accordance with an exemplary embodiment of the present technology. [Figure 81] FIG. 81 is an exemplary side view of the mounting bracket shown in FIGS. 56-57 of a prosthetic leg according to an exemplary embodiment of the present technology.

[0010] Elements and steps in the figures are illustrated for simplicity and clarity and are not necessarily described in any particular order, for example, steps that may be performed simultaneously or in a different order are shown in the figures to help improve understanding of embodiments of the present technology. DETAILED DESCRIPTION OF THE INVENTION

[0011] The present technology can be described in terms of functional block components and various processing steps. Such functional blocks may be realized by any number of components configured to perform the specified functions and achieve various results. For example, the present technology can be used in prosthetic limbs for various amputation types (e.g., above-knee, below-knee, etc.). Furthermore, the present technology can be implemented in combination with any number of materials and manufacturing methods, and the described system is merely one exemplary application of the present technology.

[0012] Although exemplary embodiments are described herein in sufficient detail to enable those skilled in the art to practice the invention, it is to be understood that other embodiments may be realized and that logical, structural, material, and mechanical changes may be made without departing from the spirit and scope of the invention. Accordingly, the following description is not intended as a limitation on the uses or applicability of the invention, but instead is merely provided to enable a full and complete description of exemplary embodiments.

[0013] Briefly, in accordance with exemplary embodiments, a prosthetic foot provides an improvement over prior art prosthetic feet in that it results in a more natural movement and response of the foot during movement. In particular, the movement of the exemplary prosthetic foot replicates the natural flexion of the foot and provides a person with continuous energy during heel-to-toe stepping.

[0014] Briefly, in accordance with an exemplary embodiment, a mounting bracket for a prosthetic foot is illustrated that includes a more natural movement and response during movement. In particular, the movement of the mounting bracket can replicate the natural movement of the foot, provide vertical shock absorption, and allow torsional rotation.

[0015] A typical prosthetic foot transfers return potential energy to store energy and "pump the stride" during the gait cycle. Prosthetic roll-through is defined as the process of moving from the heel-strike phase to the mid-stance phase and to the toe-off phase of the gait cycle. The heel-strike phase begins when the heel of the foot strikes the ground and includes the weight-bearing response of the foot. The mid-stance phase occurs when the foot is flat on the ground and the center of mass of the body is over the foot. The toe-off phase concludes the stance phase, ending with only the tip of the foot in contact with the ground and all weight bearing on the toes. This occurs immediately before the swing phase, which is the remaining half of the gait cycle.

[0016] As a user moves through the stance phase of the gait cycle, the tibial portion of the leg, i.e., the portion of the leg defined below the knee, rotates relative to the ground. If we define mid-stance as when the lower leg is at a 90-degree angle relative to the ground, then, when viewing an individual from the side, the lower leg angle during the heel-strike phase may be approximately 65 degrees, and during the toe-off phase, the lower leg angle may be approximately 110 degrees. The theoretical rotation of the lower leg around the ankle is referred to as tibial advancement or lower leg advancement during the stance phase. The mounting bracket provides vertical shock absorption during the gait cycle and standing, as well as torsional rotation.

[0017] 1A and 1B , according to various embodiments, a prosthetic foot 100 includes a resilient bottom member 110, a resilient top member 120, a connection point 130 attached to the top member 120 and configured for attachment to a user, and a bumper member 140. The resilient bottom member 110 may have a front bottom end 111 and a rear bottom end 112. The resilient top member 120 may have a front top end 121 and a rear top end 122. Furthermore, the front top end 121 of the resilient top member 120 can be connected to the front bottom end 111 of the resilient bottom member 110, while the resilient top member 120 can be positioned on top of the resilient bottom member 120 and directed toward the rear of the prosthetic foot 100.

[0018] Additionally, in various embodiments, the prosthetic foot 100 also includes an elastomeric bumper member 140 having a tapered surface configured to contact the resilient bottom member 110 and attached to the underside of the rear upper end 122 of the resilient top member 120. The bumper member 140 can be oriented perpendicular to the prosthetic foot 100. The bumper member 140 can function as a heel cushion to absorb the force of downward strikes while the user is walking.

[0019] In various embodiments, bumper member 140 may be made from an elastomeric material. In one embodiment, the elastomeric material has an energy return of about 80% or greater. In another embodiment, the elastomeric material has an energy return of about 90% or greater. Bumper member 140 can be designed to behave like a non-linear spring, thereby allowing for greater deflection of the posterior toe and 122 during heel strike. A gradual "spring rate" may result in a soft heel strike, but without excessive deflection as bumper member 140 is compressed. One advantage of bumper 140 is its relatively lightweight nature compared to prosthetic legs with coiled springs.

[0020] The bumper member 140 can be positioned aft of the vertical axis of the connection point 130. The bumper member 140 can be attached to the underside of the top member 120 in various manners. For example, and with reference to FIG. 2, the bumper member 140 can be fixedly attached using adhesive or fasteners such as screws. In another example, the bumper member 140 may be removable using fasteners for replacement purposes. Additionally, in other embodiments, the bumper member 140 can be attached to various locations on the underside of the top member 120 or the top surface of the bottom member 110. In various embodiments, the prosthetic foot 100 in the resting mode has a gap between the bumper member 140 and the bottom member 110. For example, there may be a gap of about one-tenth of an inch between the bumper member 140 and the bottom member 110. In various other ways, the bumper member 140 can contact both the top member 120 and the bottom member 110 when the prosthetic foot 100 is in the resting position. The lack of gaps allows the bumper member 140 to be continuously compressed during the gait cycle, but because the bumper member 140 is only attached to either the top member 120 or the bottom member 110, the bumper member 140 is a compression member, not a tension member. The lack of attachment of the bumper member 140 to either the top member 120 or the bottom member 110 allows the prosthetic foot 100 flexibility during the gait cycle, allowing it to more closely mimic the natural foot / ankle system. Connecting the bumper member 140 to both the resilient top member 120 and the bottom member 110 creates a generally triangular structure that is very stiff.

[0021] The bumper member 140 can have many shapes. In various embodiments, the separated portion of the bumper member 140 can have a conical, rectangular, or pyramidal shape. The tapered surface of the bumper member 140 can terminate in an apex or hemispherical shape, and the apex can be configured to contact the base member 110 in response to flexion of the prosthetic foot 100. Furthermore, in various embodiments, the bumper member 140 can terminate at multiple points. The tapered bumper member 140 facilitates damping of vibrations and sounds generated during heel strike or release. Furthermore, in various embodiments, the extruded portion of the bumper member 140 can be any shape with a non-flat surface. Furthermore, the non-flat surface increases lateral flexibility when the heel strike is not vertical.

[0022] The prosthetic foot 100 can be adjusted to accommodate a user in part by adjusting the properties of the bumper member 140. For example, in various embodiments, the durometer of the bumper member 140 can be increased for users with greater heel strike forces, which may be due to additional body weight or dynamic activity. A heavier user may be better suited to using a bumper member with a larger cross-sectional area compared to a lighter user using a bumper member with a smaller cross-sectional area.

[0023] Referring to FIG. 3 , according to various embodiments, prosthetic foot 300 includes a resilient base member 310, a resilient top member 320, a connection point 330 attached to the top member and configured for attachment to a user, and a toe pad 350 coupled to an upper surface of base member 310 at a first lower end and coupled to a lower surface of top member 320 at a first upper end. Also, in various embodiments, prosthetic foot 300 may further include a bumper member 340. In various embodiments, toe pad 350 includes at least one spacer and adhesive bonding the upper surface of base member 310 and the lower surface of top member 320. For example, the front quarter of bottom member 310 may be adhesively connected to top member 320. In various embodiments, 23-27% of the top surface area of ​​bottom member 310 may be connected to top member 320 using adhesive. Furthermore, in various embodiments, approximately one-third of the top surface area of ​​bottom member 310 may be connected to top member 320 using adhesive.

[0024] In various embodiments, the toe pad 350 has a substantially constant thickness. In other various embodiments, the toe pad 350 can have a thickness that tapers toward the leading edge of the prosthetic foot 300. In other words, the toe pad 350 closer to the heel can be thicker than the toe pad 350 closer to the toe. Additionally, the adhesive bond of the toe pad 350 can create stress distribution. According to various embodiments, the adhesive can have a higher modulus of elasticity as opposed to the elastomer of the toe pad. Other modulus values ​​are contemplated, and various moduli can also be used, although a stiffer adhesive is preferred as compared to a softer adhesive.

[0025] The spacers of the toe pad 350 form a space between the upper surface of the base member 310 and the lower surface of the top member 320. Adhesive can be intermixed with the spacers between the upper surface of the base member 310 and the toe pad 350, and also between the lower surface of the top member 320 and the toe pad 350. In various embodiments, the space formed by the spacers can provide a non-compressible space for placement of adhesive. In other words, the spacers can form a void between the top member 320 and the bottom member 310, which can be filled with adhesive for bonding. The inclusion of the toe pad 350 can reduce stress on the adhesive bond during the walking cycle. In various embodiments, the spacers can be elastomeric standoffs, such as dots, ribs, or other patterns to create the desired spacing. Furthermore, in various embodiments, the spacers are a single piece of connected standoffs. A single-piece spacer can facilitate alignment during the manufacturing process and provide a more uniform standoff pattern compared to multiple standoff spacers.

[0026] The toe pad 350 can also include an adhesive composite with a spacer. In various embodiments of the prosthetic foot 300, the spacer is a mass material that combines with an adhesive to form an adhesive composite. In various embodiments, the adhesive composite includes an adhesive and microspheres. The microspheres can create spacing between the top and bottom members 320, 310.

[0027] 4A and 4B, in various embodiments, the prosthetic foot 400 may include a bottom member 410, a top member 420, a toe pad 450, and a toe wrap 460 bonded around the top and bottom of the combined bottom and top members 410, 420. The toe wrap 460 may be made of a fabric material. The toe wrap material may also be a woven fabric with an elastomeric material. For example, the toe wrap may be a Kevlar or nylon belt approximately less than one-tenth of an inch thick. The toe wrap 460 may be configured to provide a secondary retention function in the event that the adhesive bond of the toe pad 450 between the top and bottom members fails. The toe wrap 460 may also strengthen the attachment between the bottom and top members 410, 420 under tension.

[0028] Additionally, in various embodiments, and with reference again to FIG. 3, the prosthetic foot 300 can further include a damper bar 351 attached to the underside of the resilient top member 320 and configured to contact the resilient bottom member 310. The damper bar 351 can be configured to block upward motion of the bottom member 310 after tiptoeing and also to block rotational energy during the gait cycle. The blocked motion creates a slower velocity and less motion at the contact point of the damper bar 351. Without the damper bar, the bottom member 310 would bump against the bumper member 340 during walking, which could result in vibrations traveling down the user's leg.

[0029] In various embodiments, the damper bar 351 can be located near the rear edge of the toe pad 350. As an example, the damper bar 351 can be spaced a half inch from the rear edge of the toe pad 350. In another example, the damper bar 351 can be located at the front portion of the bottom member 310. Furthermore, the damper bar 351 can be approximately a half inch long, the length being measured from the front to the rear of the bottom member 310. In various embodiments, the width of the damper bar 351 can be as wide as the attached top member 320. However, the damper bar 351 can also be less than the overall width of the attached top member 320. Furthermore, in various embodiments, the contact surface of the damper bar 351 can be flat. In an alternative embodiment, the contact surface of the damper bar 351 can be tapered toward the apex. The contact surface can be configured to reduce vibrations and sounds resulting from contact between the uncoupled bottom member 310 and the damper bar 351 during the walking cycle. Additionally, in various embodiments, the contact surface of the damper bar 351 can have various shapes other than flat, such as a preload taper.

[0030] In various embodiments, the damper bar 351 is connected to or formed as part of the toe pad 350. One advantage of having the toe pad 350 and damper bar 351 integrated is that it facilitates alignment during manufacture of the prosthetic foot 300.

[0031] The damper bar 351 can be a minimal load-bearing member, while the bumper member 340 can be the primary load-bearing member. In various embodiments, the bumper member 340 can be located approximately four to five times farther from the fulcrum of the toe pad 350 than the damper bar 351. Furthermore, in various embodiments, and with reference to FIGS. 5A-5C, the damper bar can be attached to the prosthetic foot in various configurations. For example, FIG. 5A illustrates the damper bar 551 attached to the top member 520, while FIG. 5B illustrates the damper bar 551 attached to the bottom member 510. In another example, FIG. 5C illustrates the damper bar 551 attached to both the bottom member 510 and the top member 520, with the damper bar 551 split so that the top and bottom members can separate and still prevent movement of the prosthetic foot.

[0032] 1A and 1B, the top member 120, the base member 110, and the bumper member 140 transfer energy therebetween in a natural, true-foot state. The load response during the heel strike phase compresses the bumper member 140 and the top member 120, thereby transferring energy to the rear of the base member 110 and causing it to deflect. Energy is transferred toward the front of the prosthetic foot 100 during the mid-stance phase. Furthermore, the upward deflection of at least one of the base member 110 and the top member 120 stores energy during the transition from the mid-stance phase to the toe-off phase of the gait cycle. In an exemplary embodiment, approximately 90% or more of the heel strike load energy is stored and transferred to the top member 120 to assist in the toe-off phase. In another exemplary embodiment, approximately 95% or more of the heel strike load energy is stored and transferred to the top member 120 to assist in the toe-off phase. In yet another exemplary embodiment, approximately 98% or more of the heel strike load energy is stored and transferred to the crown member 120 to assist in the toe-off phase. The prosthetic foot 100 may be designed to release stored energy during the toe-off phase to assist in propelling the user in a forward direction.

[0033] 3, in the exemplary embodiment, the resilient base member 310 includes a bottom surface 313 and a top surface 314. The resilient bumper member 340 includes a contact surface 341. When the prosthetic foot 300 is compressed, the resilient top member 320 and the bumper member 340 are compressed and displaced downward toward the resilient base member 310.

[0034] With respect to walking, the prosthetic foot is configured to provide increased surface contact to the foot throughout the gait cycle. The increased surface contact allows for a smoother gait cycle and provides improved stability compared to typical prior art prosthetic feet. In exemplary embodiments, the lower surface of the bottom member has different contours that provide increased surface contact for different types of applications.

[0035] The base member of the prosthetic leg can have a variety of shapes depending on the desired application. Desired applications may include an above-knee amputee prosthesis or a below-knee amputee prosthesis. In various embodiments, and referring to FIG. 6 , an above-knee amputee prosthesis 600 includes a base member 610 having a curved bottom without an inflection point. In various embodiments, the base member 610 has a constant arc with a single radius that forms a partial curve of the base member. In various other embodiments, the curve of the base member 610 can be designed as a variable-radius spline. The curve of the base member 610 in the above-knee prosthesis 600 facilitates stability of the prosthetic knee by substantially limiting forces that bend the knee. The curved base member 610 allows for rocking motion even when the prosthetic knee is hyperextended.

[0036] Similarly, in various embodiments, referring to FIG. 7 , a prosthetic foot 700 for a below-knee amputee includes a base member 710 having a partially curved portion at the front of the base member 710 and a substantially straight portion at the rear of the base member 710. Similar to the above-knee prosthetic foot 600, the anterior portion of the base member 710 can have a constant arc with a single radius forming a partial curve. In various embodiments, the anterior portion of the base member 710 can have a curve designed as a variable radius spline. According to various embodiments, the posterior portion of the base member 710 can meet the anterior portion in a substantially straight line such that the base member 710 has no inflection points. The straight posterior portion and curved anterior portion of the base member 710 in the below-knee prosthetic foot 700 can facilitate tibial rotation, promote natural knee rotation, and prevent knee hyperextension.

[0037] According to an exemplary embodiment, the resilient members 110, 120 are made of a glass fiber composite. The glass fiber composite may be a glass-reinforced unidirectional fiber composite. In one embodiment, the fiber composite is made of multiple layers of unidirectional fibers and resin to create a strong and flexible material. The fibers may be glass fiber or carbon fiber. Specifically, a layer of fiber may be impregnated with resin, and a glass-reinforced layer may be disposed between at least two layers of woven fiber. Typically, several layers of unidirectional fiber or tape are laminated together to achieve the desired strength and flexibility. Furthermore, in various embodiments, the layers of unidirectional fiber or tape may be oriented at various angles.

[0038] Mounting Bracket 800 8-10 , according to various embodiments, connection point 130 can include a mounting bracket 800. Mounting bracket 800 can be attached to top member 120 and configured for attachment to a user. In various embodiments, mounting bracket 800 can include an upper member 802, a lower member 1004, and a compression-torsion joint 806. Upper member 802 can be configured for attachment to a user's residual limb. Lower member 1004 can be configured for attachment to a prosthetic foot. In one embodiment, lower member 1004 is coupled to prosthetic foot 100.

[0039] 11A-C, in various embodiments, the upper member 802 may include an attachment portion 808 and an upper flange 810. The attachment portion 808 may be configured to attach to a user's residual limb. The attachment portion 808 may include a spherical dome 812 and an attachment portion 814 that is a standard male pyramid adapter used in the prosthetic and orthotic industry. The pyramid adapter may mate with a standard receiver used in prosthetic and orthotic practice, such as a Staats style attachment commonly known in the prosthetic and orthotic industry. The attachment portion 814 may use a standard receiver adapter, as will be understood by those skilled in the art. According to various embodiments, the attachment portion 814 can facilitate attachment to a user's residual limb. The attachment portion 814 may include a centerline that aligns with the user's weight line.

[0040] The spherical dome 812 may be located on an upper surface 816 of the upper flange 810. In various embodiments, the upper flange 810 may include a lip 818 extending down its periphery and a lower surface 820 having a channel 822 contained therein. In various embodiments, the lower surface 820 of the upper flange 810 may include a recess 824. In one embodiment, the recess 824 may include a crescent-shaped recess 824.

[0041] 14B, 16, 19, 27A, and 27B, the upper member 802 can also include a mating post 826. The mating post 826 can include a cylindrical collar 828 extending downwardly from the lower surface 820 of the upper flange 810. In various embodiments, the mating post 826 can be removable. An upper portion 830 of the mating post 826 can be coupled to the upper member 802 within a recess 832 by any known method, such as by threading, pressing, or the like. In one embodiment, the mating post 826 can be coupled to the upper member 802 by a threaded connection. The mating post 826 can include threads (not shown) on the upper portion 830 of the cylindrical collar 828 that are received by threads (not shown) in the recess 832 of the upper member 802. Mating post 826 may further include at least one recess 834 around the periphery of cylindrical collar 828 that can receive an O-ring (not shown). The O-ring serves to fill the clearance between the outer diameter of mating post 826 and the inner diameter of sleeve 902, providing smooth, quiet operation between the relatively moving components. In one embodiment, mating post 826 includes at least one recess 836 around the periphery of cylindrical collar 828 that can receive grease or other lubricant during assembly.

[0042] 12-13, in various embodiments, the lower member 804 may include a mounting portion 840, a lower flange 842, and a mating portion 844. The mounting portion 840 may be located at a trailing edge of the lower flange 842. The mounting portion 840 may include at least one threaded opening 846 used to couple the mounting bracket 800 to the prosthetic foot 100 (see FIGS. 8 and 9). In one embodiment, the mounting portion 840 includes three threaded openings 846 that receive bolts 864 to couple the mounting bracket 800 to the prosthetic foot 100.

[0043] In various embodiments, as shown in FIG. 9 , the upper end 862 of the prosthetic foot 100 can be connected to the mounting portion 840 of the lower member 804 via a mechanical connection that receives a fastener 864 into an opening (not shown) present in the upper end 862 of the prosthetic foot 100 and the mounting portion 840 of the lower member 804. While a bolted connection is shown, any mechanical connection is contemplated, such as a screw, rivet, etc. The material of the bolted connection can include titanium or other suitable material. Other types of materials may include mild steel, alloy steel, high-strength stainless steel such as 13-8, and alloy aluminum such as the 2000 series or 7000 series.

[0044] The mating portion 844 of the lower member 804 may include an upper collar 848 and a lower collar 850. The upper collar 848 extends upward from an upper surface 852 of the lower flange 842, while the lower collar 850 extends downward from a lower surface 854 of the lower flange 842. As shown in FIGS. 12A-B and 14B , the upper and lower collars 848, 850 of the mating portion 844 mate to receive the cylindrical collar 828 of the mating post 826 of the upper member 802 when the upper and lower members 802, 804 are coupled. As shown in FIGS. 12A, 12B, 13, and 15, the upper surface 852 of the lower flange 842 may include a recessed channel 856 and a lip 858 surrounding a portion of its periphery.

[0045] In various embodiments, the lower member 804 may include a pair of stops 860. The stops 860 serve to limit rotation of the upper member 802 relative to the lower member 804 during use, as described in more detail below.

[0046] 32, lower member 934 is provided without stops. In this embodiment, bumper 868 may function as a compression bumper rather than a torsion bumper. The remainder of lower member 934 is similar to lower member 804.

[0047] 9, 10, 16, and 19, in various embodiments, compression torsion joint 806 may include an elastomeric ring 866. In various embodiments, compression torsion joint 806 may include a bumper 868. In various embodiments, compression torsion joint 806 may include a compression collar 870. In one embodiment, compression torsion joint 806 may include a combination of elastomeric ring 866, bumper 868, and compression collar 870.

[0048] 19, 22A, and 22B, the elastomeric ring 866 may include a wall 872 having an inner 874, an outer 876, an upper 878, and a lower 880 surface. In one embodiment shown in FIGS. 22A and 22B, the inner surface 874 of the wall 872 includes a substantially smooth surface. In one embodiment, the inner surface 874 may include a raised surface, a surface with raised portions, and a wall of varying thickness. In one embodiment, the inner and outer surfaces 874, 876 may be curved from the upper surface 878 to the lower surface 880 and / or convex relative to the center of the elastomeric ring 866. In one embodiment, the outer surface 876 may be curved and / or convex relative to the center of the elastomeric ring 866. 11C , 13 , 15 , and 22A , an upper surface 878 of elastomeric ring 866 may be received in channel 822 of upper flange 810 of upper member 802. An outer surface 876 generally abuts lip 818 of upper flange 810 of upper member 802. A lower surface 880 of elastomeric ring 866 may be received in channel 856 of lower flange 842 of lower member 804. An outer surface 876 generally abuts lip 858 of lower flange 842 of lower member 804.

[0049] In one embodiment, shown in FIGS. 17, 19, and 23A-C, compression-torsion joint 806 may include bumper 868. In one embodiment, bumper 868 may include a compression / torsion bumper. In another embodiment, bumper 868 may include a compression bumper. Bumper 868 may be crescent-shaped and received within crescent-shaped recess 824 in upper flange 810 of lower member 804 (see FIG. 11C). An upper surface 881 of bumper 868 may be received within and adhered to crescent-shaped recess 824 in a manner described below with respect to elastomeric ring 866. In use, lower surface 882 of bumper 868 contacts upper surface 852 of lower flange 842, thereby allowing only a limited amount of vertical movement of upper member 802 relative to lower member 804 (see FIGS. 12A-B). Bumper 868 limits vertical movement while elastomeric ring 866 provides vertical shock absorption during the walking cycle and while standing. In one embodiment, 868 may include a pair of holes 883 that receive pin 884 (see FIGS. 28A-B). Pin 884 may include an at least partially threaded shaft that is received in a pair of threaded holes 886 in upper member 802. In one embodiment, stop 860 in combination with bumper 868 and pin 884 helps to limit torsional rotation of upper member 802 relative to lower member 804 during use. When used in combination with stop 860, bumper 868 is a compression / torsion bumper. In the embodiments described above in which a stop is absent from the lower member, bumper 868 may function as a compression bumper and not as a torsion bumper.

[0050] 17, 19, and 24, compression collar 870 may be received over cylindrical collar 826 and abuts underside 820 of upper flange 810. In one embodiment, when assembled, there may be a gap between the underside of compression collar 870 and the upper surface of upper collar 848. There may also be a gap between the underside of bumper 868 and the upper surface of lower flange 842. In another embodiment, when assembled, the underside of compression collar 870 may abut the upper surface of upper collar 848.

[0051] Referring to FIG. 29, in another embodiment, a lower member 924 is shown having a crescent-shaped recess 926. The lower surface 882 of a bumper 868 can be received within and coupled to the crescent-shaped recess 926 in the manner described below with respect to coupling of an elastomeric ring 866. Referring to FIGS. 30 and 31, in one embodiment, an upper member 930 is shown including a pair of stops 932 and a channel 822. In this embodiment, the bumper 868 is a compression / torsion bumper. The remainder of the upper member 930 is similar to the upper member 802, but without the crescent-shaped recess. This embodiment shown in FIGS. 29-31 operates similarly to the previously described embodiment of a lower member 804 having a stop 860 and an upper member 802 having a crescent-shaped recess 824.

[0052] 9 and 12A-B, in various embodiments, the mounting bracket 800 may include a washer plate 888. The washer plate 888 may be used to couple the mounting bracket 800 to the upper end 862 of the prosthetic foot 100. The washer plate 888 may include the same number of openings as there are mounting portions 840 on the upper end 862 and lower member 804 of the prosthetic foot 102. The washer plate 888 is designed to distribute the load across the surface of the upper end 862 of the prosthetic foot 100 and reduce stress concentrations. In another embodiment, the prosthetic foot 100 may also utilize a standard washer configuration.

[0053] 19-21 and 25, in various embodiments, the mounting bracket 800 may include a retention system 900. The retention system 900 is utilized as a fail-safe to ensure that the upper member 802 does not separate from the lower member 804 in the event that the bond on the elastomeric ring 866 connecting the upper and lower members 802, 804 is lost. In various embodiments, the retention system 900 may include a sleeve 902, a plug 904, and a connector 906.

[0054] In various embodiments, the sleeve 902 may include a cylindrical wall 908 and first and second ends 910, 912. The sleeve 902 fits within the mating portion 844 of the lower member 804. The sleeve 902 may be inserted into the lower end of the lower member 804 and extend along the length of the mating portion 844. The first end 910 of the sleeve 902 may abut a lip formed within the upper collar 848 of the lower member 804. The lip is configured to retain the first end 910 within the mating portion 844.

[0055] In various embodiments, the plug 904 includes threads that are received within internal threads located on an inner wall 914 within the cylindrical collar 828 of the mating post 826. The connector 906, in combination with the mating post 826 received within the sleeve 902, can be used to couple the upper member 802 to the lower member 804. The sleeve 902 may include a low-friction material that facilitates smooth movement between the upper and lower members 802, 804. The connector 906 may include a retention washer 916 and a retention connector 918. The retention connector 918 is used in combination with the retention washer 916 and is received within a threaded opening in the plug 904. When tightened, the retention connector 918 seats the retention washer 916 against an internal shelf 920 of the lower member 804 (see FIGS. 14B, 20B, and 21). In one embodiment, the retention connector 918 is a screw.

[0056] 19, 20B, and 21, in various embodiments, the retention system 900 may include a cap 922. The cap 922 retains the second end 912 of the sleeve 902 within the lower collar 850 of the mating portion 844. The cap 922 may be press fit or may include threads that mate with internal threads (not shown) of the lower collar 850 of the mating portion 844. In use, the cylindrical collar 828 of the mating post 826 is received within the sleeve 902, which is received within the upper and lower collars 848, 850 of the mating portion 844 when the upper and lower members 802, 804 are coupled.

[0057] The cap 922 can abut the retaining washer 916 against the second end 912 of the sleeve 902. The cap 922 also seats the spacer within the mating portion 844 to prevent dirt, sand, or small objects from entering the mating portion 844 of the lower member 804. Objects such as small stones or sand can wear down the movable internal members, eventually causing damage and failure.

[0058] The sleeve 902 can be made from any suitable low-friction material. In one embodiment, the low-friction sleeve is made from plastic to allow smooth movement between the components of the prosthetic foot. In one embodiment, a low-coefficient plastic bushing material may be used.

[0059] In various embodiments, the mounting bracket 800 may include a vent assembly 928. In one embodiment, the vent assembly 928 may include a screw, a washer, and an opening in the lower member 804. The screw is received within the opening in the lower member 804. Removing the screw from the opening in the vent assembly 928 may be used to equalize the pressure inside the mounting bracket 800 (during adhesive bond curing) with the ambient pressure. Without this vent assembly 928, pressure would build up within the cavity of the mounting bracket 800, forcing the metal component to partially separate from the elastomeric ring 866.

[0060] In use under load, the lower surface of bumper 868, in conjunction with compression collar 870, contacts the upper surface of lower flange 842, thereby allowing only a limited amount of vertical movement of upper member 802 relative to lower member 804. Compression collar 870 limits vertical movement. Bumper 868 limits vertical and torsional movement when used with upper or lower members having stops. Bumper 868 limits vertical movement when used with upper or lower members without stops. Elastomeric ring 866 provides vertical shock absorption and torsional stability during the gait cycle and while standing.

[0061] The mounting bracket 800 provides a multi-phase system. When an initial load is applied to the prosthetic foot 100, the elastomeric ring 866 provides soft resistance for both vertical compression and torsional rotation. With greater loads, the lower surface 882 of the bumper 868 contacts the upper surface 852 of the lower flange 842, and the lower surface of the compression collar 870 contacts the upper surface of the upper collar 848, thereby allowing only a limited amount of vertical movement of the upper member 802 relative to the lower member 804. While the bumper 868 and compression collar 870 limit vertical movement, the elastomeric ring 866 provides vertical shock absorption during the gait cycle and while standing.

[0062] As greater torsional loads are applied, elastomeric ring 866 provides increasingly stiff torsional stability until bumper 868 contacts stop 860, limiting the amount of torsional rotation. In one embodiment, bumper 868 and stop 860 serve to limit torsional rotation by approximately 5-10 degrees. In one embodiment, bumper 868 and stop 860 serve to limit torsional rotation by approximately plus or minus 8 degrees.

[0063] In various embodiments, the elastomeric ring 866 may comprise a lower hardness than the bumper 868 and the compression collar 870, thereby providing an initial soft resistance to vertical loads and torsional rotation. A higher hardness compression collar 870 provides greater resistance during high vertical loads. The compression collar 870 may comprise different heights that affect the feel of the mounting bracket 800 during vertical compression. If the compression collar 870 is taller, it may contact before the bumper 868. A higher hardness bumper 868 provides greater resistance during high loads, both vertical and torsional. Thus, the above-described system can provide multi-phase resistance to vertical loads and torsional rotation based on the user's needs.

[0064] According to various embodiments, the upper and lower members 802, 804 can be made from titanium (any type) or any other suitable material. In one embodiment, the upper member 802 may include titanium. In one embodiment, the lower member 804 may include alloy aluminum. Some other types of materials that may be used for the upper and lower members 802, 804 include mild steel, alloy steel, steel, high strength stainless steel such as 13-8, alloy aluminum such as 2000 and 7000 series, and any suitable composite material.

[0065] In various embodiments, the upper and lower members 802, 804 described above can be a unitary piece or multiple pieces joined together by any suitable method. In some embodiments, depending on the type of material, the upper and lower members 802, 804 can be made by milling, casting, forging, powder metal, etc. In one embodiment, the upper and lower members 802, 804 can be made with a titanium CNC milling machine. More specifically, in one embodiment, the upper and lower members 802, 804 can be made integrally from alloy aluminum fabricated using a CNC milling machine. In other embodiments, the aluminum, titanium, magnesium, or other suitable material for the upper and lower members 802, 804 can be fabricated using a CNC milling machine. In other embodiments, the aluminum, titanium, magnesium, or other suitable material for the upper and lower members 802, 804 can be fabricated by casting, forging, powder metal, etc. In other embodiments, the chrome molybdenum, steel, or other suitable material for the upper and lower members 802, 804 may be made from multiple pieces and joined together by welding or any other suitable method.

[0066] According to various embodiments, and with reference to FIGS. 10-12 and 22 , the upper and lower members 802, 804 may be joined by an elastomeric ring 866. The elastomeric ring 866 may comprise any rubber, polyurethane, and / or elastomeric material. The elastomeric ring 866 may be joined to the upper and lower members 802, 804 using an adhesive. An upper surface 878 of the elastomeric ring 866 may be received and bonded within the channel 822 of the upper flange 810 of the upper member 802. A lower surface 880 of the elastomeric ring 866 may be received and bonded within the channel 856 of the lower flange 842 of the lower member 804. The elastomeric ring 866 may act as a cushion to absorb the force of downward strikes while the user is walking.

[0067] In various embodiments, the elastomeric ring 866 can include an adhesive bond, thereby bonding the lower member to the upper member. Additionally, the adhesive bond of the elastomeric ring 866 can provide stress distribution. Other modulus values ​​are contemplated, and various moduli may be used as well, although a stiffer adhesive is preferred compared to a softer adhesive. The elastomeric ring 866 forms a space between the upper flange 810 of the upper member 802 and the lower flange 842 of the lower member 106. An adhesive can be intermixed with the elastomeric ring 866.

[0068] The prosthetic foot 100 can be adjusted to accommodate a user in part by adjusting the properties of the elastomeric ring 866 between the upper and lower members 802, 804. For example, in various embodiments, the hardness of the elastomeric ring 866 can be increased for users with greater heel strike forces, which may be due to additional body weight or dynamic activity.

[0069] In various embodiments, and as shown, the elastomeric ring 866 and the bumper 868 may comprise an elastomeric material. The elastomeric material may include common elastomeric materials, polyurethane, natural rubber, synthetic rubber, or various combinations of natural and synthetic rubber. The hardness of the elastomeric material of both the elastomeric ring 866 and the bumper 868 can be varied to provide additional adjustment to the prosthetic foot. The elastomeric material of the elastomeric ring 866 and the bumper 868 supports load. Additionally, because the elastomeric ring 866 connects the upper and lower members 802, 804, the members are able to torsionally rotate during use of the prosthetic foot 100. The adjustable hardness of the elastomeric material allows the spring rate of the elastomeric ring to be adjusted based on the user's needs, such as activity level, compliance level, and weight changes. For example, in various embodiments, the hardness of the elastomeric material can be increased for users with greater heel strike forces, which may be due to the user's additional weight or the user's dynamic activity. The increased heel strike force also results in greater compression of the heel member. As discussed above, the elastomeric ring 866 may comprise a lower hardness than the bumper 868, thereby providing an initial softer resistance to vertical loads and torsional rotation. The higher hardness of the bumper 868 provides greater resistance when high loads are applied in both the vertical and torsional directions.

[0070] In another embodiment, referring to FIG. 29, a lower member 924 is shown having a crescent-shaped recess 926. The lower surface 882 of a bumper 868 can be received within and coupled to the crescent-shaped recess 926 in the manner described below with respect to coupling of an elastomeric ring 866. Referring to FIGS. 30 and 31, in one embodiment, an upper member 930 is shown including a pair of stops 932 and a channel 822. In this embodiment, the bumper 868 is a compression / torsion bumper. The remainder of the upper member 930 is similar to the upper member 802, but without the crescent-shaped recess. This embodiment, shown in FIGS. 29-31, operates similarly to the previously described embodiment of a lower member 804 having a stop 860 and an upper member 802 having a crescent-shaped recess 824.

[0071] 8-10 , according to various embodiments, connection point 130 can include a mounting bracket 800. Mounting bracket 800 can be attached to top member 120 and can be configured for attachment to a user. In various embodiments, mounting bracket 800 can include an upper member 802, a lower member 804, and a compression-torsion joint 806. Upper member 802 can be configured for attachment to a user's residual limb. Lower member 804 can be configured for attachment to a prosthetic foot. In one embodiment, lower member 804 is coupled to prosthetic foot 100.

[0072] 33-35, an additional embodiment of a compression-torsion joint 936 for a mounting bracket 938 is shown. The mounting bracket can be attached to the prosthetic foot 100. Many of the components of the compression-torsion joint 936 and mounting bracket 938 are the same as those in the embodiment described above in FIGS. 10 and 19. The mounting bracket includes an upper member 940 and a lower member 942 similar to those described above. The bumper 868, pin 884, and threaded hole 886 in the upper member 802 shown in the embodiment described in FIGS. 10 and 19 have been eliminated from the upper member 940 and compression-torsion joint 936 described in FIGS. 33-35. The remainder of the construction of the upper member 940 is similar to that of the upper member 802 described above.

[0073] In various embodiments, the compression torsional joint 936 may include an elastomeric ring 866. In various embodiments, the compression torsional joint 936 may include a rotational restraint 944. In various embodiments, the compression torsional joint 936 may include a compression collar 870. In one embodiment, the compression torsional joint 936 may include a combination of the elastomeric ring 866, the rotational restraint 944, and the compression collar 870.

[0074] 33, 34, 40A, and 40B, the rotational restraint 994 may include a crescent-shaped member 946 having a pair of downwardly projecting stops 948, 950 and a central stop 952. The crescent-shaped member 946 is received within a crescent-shaped recess 954 in the upper member 940, similar to the crescent-shaped recess 824 described above with respect to the upper member 802.

[0075] 33, 37, and 39, the central stop 952 may include a fastener 956 that is received in a hole 958 in the lower member 942. The fastener 956 and hole 958 configuration may both be threaded, or the fastener may be threaded, received in the hole 958, and coupled to the lower member 942 via a nut (not shown). In one embodiment, a rubber bumper 960 may be coupled to the fastener 956. The hole 958 is centrally located in the lower member 942. The vent assembly 928 is displaced toward the centrally located hole 958. The remainder of the configuration of the lower member 942 is similar to the lower member 804 described above.

[0076] Stops 948, 950 and central stop 952 on crescent member 946 along with elastomeric ring 866 are configured to limit torsional rotation of upper member 940 relative to lower member 942 in a manner similar to that described above.

[0077] Mounting bracket 938 provides a multi-phase system. When an initial load is applied to prosthetic foot 100, elastomeric ring 866 provides soft resistance for both vertical compression and torsional rotation. As greater loads are applied, the lower surface of compression collar 870 contacts the upper surface of upper collar 848, thereby allowing only a limited amount of vertical movement of upper member 940 relative to lower member 942. Elastomer ring 866 and compression collar 870 limit vertical movement, while elastomeric ring 866 provides vertical shock absorption during the gait cycle and while standing.

[0078] As greater torsional loads are applied, the elastomeric ring 866 provides increasingly stiff torsional stability until the stops 948, 950 on the crescent-shaped members 946 contact the central stop 952, limiting the amount of torsional rotation. In one embodiment, the stops 948, 950 on the crescent-shaped members 946 contact the central stop 952 and serve to limit the torsional rotation to approximately 5-10 degrees. In one embodiment, the stops 948, 950 on the crescent-shaped members 946 contact the central stop 952 and serve to limit the torsional rotation to approximately plus or minus 8 degrees.

[0079] In various embodiments, the crescent-shaped members may comprise materials similar to those described above for the upper and lower members 802 , 804 on the mounting bracket 800 .

[0080] 41-44, in various embodiments, additional embodiments of a mounting bracket 1000 are shown. Similar to the previous mounting brackets described above, the mounting bracket 1000 may be attached to the top member 120 of the prosthetic foot 100 and configured for attachment to a user. In various embodiments, the mounting bracket 1000 may include an upper member 1002, a lower member 1004, and a compression-torsion joint 1006. The upper member 1002 may be configured for attachment to a user's residual limb. The lower member 1004 may be configured for attachment to the prosthetic foot 100. In one embodiment, the lower member 1004 is coupled to the prosthetic foot 100.

[0081] 45A-C, the upper member 1002 may include an attachment portion 1008 and an upper flange 1010. The attachment portion 1008 may be configured to attach to a user's residual limb. The attachment portion 1008 may include a spherical dome 1012 and an attachment portion 1014 that is a standard male pyramid adapter used in the prosthetic and orthotic industry. The pyramid adapter may mate with a standard receiver used in prosthetic and orthotic implementations, such as a Studz-style attachment commonly known in the prosthetic and orthotic industry. The attachment portion 1014 may use a standard receiver adapter, as will be understood by those skilled in the art. According to various embodiments, the attachment portion 1014 can facilitate attachment to a user's residual limb. The attachment portion 1014 may include a centerline that aligns with the user's weight line.

[0082] The spherical dome 1012 may be disposed on the upper flange 1010. In various embodiments, the upper flange 1010 may include a lip 1016 extending down its periphery and a lower surface 1018 having a channel 1020 contained therein.

[0083] In various embodiments, as shown in FIGS. 44, 52A, and 52B, the mounting bracket 1000 may also include a mating post 1022 similar to the mating post 826 shown in FIGS. 27A and 27B above. The mating post 1022 may include a cylindrical collar 1024 that extends downwardly from the lower surface 1018 of the upper flange 1010 when the mating post 1022 is coupled to the upper member 1002. In various embodiments, the mating post 1022 may be a separate, removable part or may be an integral part. An upper portion 1026 of the mating post 1022 may be coupled to the upper member 1002 within a recess 1028 by any known method, such as a threaded fit, a press, or the like. In one embodiment, the mating post 1022 may be coupled to the upper member 1002 by a threaded connection. The mating post 1022 may include threads (not shown) on an upper portion 1026 of the cylindrical collar 1024 that are received by threads (not shown) in a recess 1028 of the upper member 1002. The mating post 1022 may further include at least one recess 1030 on the outer periphery of the cylindrical collar 1024 that can receive an O-ring (not shown). The O-ring serves to fill the clearance between the outer diameter of the mating post 1022 and the inner diameter of the sleeve 1132, providing smooth and quiet operation between the relatively moving components. In one embodiment, the mating post 1022 includes at least one recess 1034 on the outer periphery of the cylindrical collar 1024 that can receive grease or another lubricant during assembly.

[0084] 53A and 53B show an alternative variation of a mating post 1022A. The mating post 1022A includes many of the same features as the mating post 1022. Specifically, the mating post 1022A can include an upper portion 1026A, a cylindrical collar 1024A, and at least one recess 1030A on the outer periphery of the cylindrical collar 1024A that can receive an O-ring.

[0085] 43, 44, 46A, and 46B, in various embodiments, the lower member 1004 may include a mounting portion 1036, a lower flange 1038, and a mating portion 1040. The mounting portion 1036 may be located at a trailing edge of the lower flange 1038. The mounting portion 1036 may include at least one threaded opening 1042 that is used to couple the mounting bracket 1000 to the prosthetic foot 100. In one embodiment, the mounting portion 1036 includes three threaded openings 1042 that receive fasteners to couple the mounting bracket 1000 to the prosthetic foot 100.

[0086] In various embodiments, as shown in FIG. 9 , the upper end 862 of the prosthetic foot 100 may be connected to the mounting portion 1036 of the lower member 1004 via a mechanical connection, whereby a fastener 864 is received within an aperture (not shown) present in the upper end 862 of the prosthetic foot 100 and the mounting portion 1036 of the lower member 1004. While the mounting bracket 1000 is not shown in FIG. 9 , the mounting bracket 1000 may be coupled in the same manner as the mounting bracket 800. While a bolted connection is shown, any mechanical connection is contemplated, such as screws, rivets, etc. Materials for the bolted connection may include titanium or other suitable materials. Other types of materials may include mild steel, alloy steel, high-strength stainless steel such as 13-8, and alloy aluminum such as the 2000 series or 7000 series.

[0087] The mating portion 1040 of the lower member 1004 may include an upper collar 1044 and a lower collar 1046. The upper collar 1044 extends upwardly from the lower flange 1038, while the lower collar 1046 extends downwardly from the lower flange 1038. As shown in FIGS. 43 and 44 , the upper and lower collars 1044, 1046 of the mating portion 1040 mate to receive the cylindrical collar 1024 of the mating post 1022 when the upper and lower members 1002, 1004 are coupled. As shown in FIGS. 46A and 46B , the lower flange 1038 may include a recessed channel 1048 and a lip 1050 surrounding at least a portion of its perimeter.

[0088] 45A-45C , in various embodiments, the upper member 1002 may include a pair of stops 1052. The stops 1052 serve to limit rotation of the upper member 1002 relative to the lower member 1004 during use, as described in more detail below. The stops 1052 reside on the upper member 1002 adjacent to the outer periphery of the upper flange 1010 and project outward therefrom. The stops 1052 are located on the outer surface of the upper flange 1010. The location of the stops 1052 determines how much twisting must occur before the compression-torsion coupling 1006 is engaged. In various embodiments, the stops 1052 may be activated when the upper member 1002 of the mounting bracket 1000 rotates enough to overcome the torsional stiffness of the elastomeric ring 1054 and allow the stops 1052 to contact the torsion limiter 1056. The system of detents 1052 and rotation limiters 1056 engage each other at the same rotation angle regardless of the amount of vertical compression to which the mounting bracket 1000 is subjected.

[0089] 43 and 44, in various embodiments, the compression torsion coupling 1006 may include an elastomeric ring 1054. In various embodiments, the compression torsion coupling 1006 may include a torsion limiter 1056. In various embodiments, the compression torsion coupling 1006 may include a compression collar 1058. In one embodiment, the compression torsion coupling 1006 may include a vertical spring 1060. In one embodiment, the compression torsion coupling 1006 may include a combination of the elastomeric ring 1054, the torsion limiter 1056, the compression collar 1058, and the vertical spring 1060.

[0090] In various embodiments, the elastomeric ring shown in FIGS. 47-49 is similar to the elastomeric rings described above in FIGS. 19, 22A, and 22B. The elastomeric ring 1054 may generally include a wall 1062 having inner 1064, outer 1066, upper 1068, and lower 1070 surfaces. In various embodiments, the inner surface 1064 of the wall 1062 may include a substantially smooth surface. In various embodiments, the inner surface 1064 may include a raised surface, a surface with ridges, and / or a wall of varying thickness. In one embodiment shown in FIGS. 47A-47C, the inner and outer surfaces 1064, 1066 may be curved from the upper surface 1068 to the lower surface 1070 and / or may be concave relative to the center of the elastomeric ring 1054. In one embodiment, the outer surface 1066 may be curved and / or convex relative to the center of the elastomeric ring 1054. 48A-48C, the inner surface 1064 may be generally straight, and the outer surface 1066 may be curved from the upper side 1068 to the lower side 1070 and / or may be concave relative to the center of the elastomeric ring 1054. In one embodiment shown in FIGS. 49A-49C, the inner and outer surfaces 1064, 1066 may be generally straight from the upper side 1068 to the lower side 1070.

[0091] 43, 44, and 47-50, an upper surface 1068 of the elastomeric ring 1054 may be received within the channel 1020 of the upper flange 1010 of the upper member 1002. The outer surface 1066 generally abuts the lip 1016 of the upper flange 1010 of the upper member 1002. A lower surface 1070 of the elastomeric ring 1054 may be received within the channel 1048 of the lower flange 1038 of the lower member 1004. The outer surface 1066 generally abuts the lip 1050 of the lower flange 1038 of the lower member 1004.

[0092] 41-43, the torsional limiter 1056 may be received within an opening 1072 located within an upper portion of the mounting portion 1036 of the lower member 1004. In use, the torsional limiter 1056 is configured to contact a stop 1052 on the upper member 1002 to limit torsional rotation of the upper member 1002 relative to the lower member 1004 during use. The torsional limiter 1056 may comprise an elastomeric material, including, but not limited to, natural rubber, synthetic rubber, a combination of natural and synthetic rubber, polyurethane, etc.

[0093] 43 and 44 , the compression collar 1058 can be received over the mating post 1022 and abut the underside 1018 of the upper flange 1010. In one embodiment, when assembled, there can be a gap between the underside of the compression collar 1058 and the upper side of the upper collar 1044. There can also be a gap between the underside of the torsion limiter 1056 and the upper side of the lower flange 1038. In another embodiment, when assembled, the underside of the compression collar 1058 can abut the upper side of the upper collar 1044.

[0094] In various embodiments, a vertical spring 1060 can be received within a cylindrical collar 1024 of the mating post 1022. The vertical spring 1060 can comprise an elastomeric material, including, but not limited to, natural rubber, synthetic rubber, a combination of natural and synthetic rubber, polyurethane, etc. The vertical spring 1060 limits the amount of vertical movement of the upper member 1002 relative to the lower member 1004.

[0095] In various embodiments, the vertical spring 1060 can be between the underside of the cylindrical collar 1024 and the compression cap 1074. In one embodiment, the vertical spring 1060 can be between the compression cap 1074 and a plug 1076 located within the cylindrical collar 1024 adjacent the underside. The vertical spring 1060 limits the amount of vertical movement of the upper member 1002 relative to the lower member 1004 by contacting the underside of the cylindrical collar 1024 within the mating post 1022 and the compression cap 1074.

[0096] 45 and 50A-B, in various embodiments, the compression cap 1074 may include threads that are received within internal threads (check diagram) located on the inner wall of the cylindrical collar 1024 of the mating post 1022. The compression cap 1074, in combination with the mating post 1022 that is received within the sleeve 1132, may be used to couple the upper member 1002 to the lower member 1004. The sleeve 1132 may include a low-friction material to facilitate smooth movement between the upper and lower members 1002, 1004. In various embodiments, the compression cap 1074 may include a tall post 1078 that contacts the underside of the vertical spring 1060.

[0097] In use, the cylindrical collar 1024 of the mating post 1022 is received within a sleeve 1132 that is received within the upper and lower collars 1044, 1046 of the mating portion 1040 when the upper and lower members 1002, 1004 are joined.

[0098] The sleeve 1132 is similar to the sleeve 910 described above in FIG. 25 . The sleeve 1132 may include a cylindrical wall and first and second ends. The sleeve 1132 fits within a mating portion 1040 of the lower member 1004. The sleeve 1132 may be inserted into the lower end of the lower member 1004 and extend along the length of the mating portion 1040. The first end of the sleeve 1132 may abut a lip formed inside an upper collar 1044 of the lower member 1004. The lip is configured to retain the first end within the mating portion 1040.

[0099] The sleeve 1132 can be made from any suitable low-friction material. In one embodiment, the low-friction sleeve is made from plastic to allow smooth movement between the components of the prosthetic foot. In one embodiment, a low-coefficient plastic bushing material may be used.

[0100] In use under load, the vertical spring 1060 and elastomeric ring 1054 in conjunction with the compression collar 1058 provide a limited amount of vertical movement of the upper member 1002 relative to the lower member 1004. The compression collar 1058, elastomeric ring 1054, and vertical spring 1060 limit vertical movement, while the torsional limiter 1056 limits torsional movement. The elastomeric ring 1054 provides vertical shock absorption and torsional stability during the gait cycle and while standing. The vertical spring 1060 provides vertical shock absorption and compression during use.

[0101] The mounting bracket 1000 provides a multi-phase system. When an initial load is applied to the prosthetic foot 100, the elastomeric ring 1054 provides soft resistance for both vertical compression and torsional rotation. During compression, the elastomeric ring 1054 and vertical spring 1060 simultaneously provide resistance. The elastomeric ring 1054 carries a smaller portion of the compressive load compared to the vertical spring 1060, which carries the majority of the compressive load. When a larger load is applied, the vertical spring 1060 is compressed between the plug 1076 located within the cylindrical collar 1024 and the compression cap 1074, and the lower surface of the compression collar 1058 contacts the upper surface of the upper collar 1044, thereby allowing only a limited amount of vertical movement of the upper member 1002 relative to the lower member 1004. While the compression collar 1058 limits vertical movement, the elastomeric ring 1054 and vertical spring 1060 provide vertical shock absorption during the gait cycle and while standing.

[0102] As greater torsional loads are applied, the elastomeric ring 1054 provides increasingly stiff torsional stability until the torsional limiter 1056 contacts the stop 1052, limiting the amount of torsional rotation. In one embodiment, the torsional limiter 1056 and stop 1052 serve to limit the torsional rotation to approximately 5-10 degrees. In one embodiment, the torsional limiter 1056 and stop 1052 serve to limit the torsional rotation to approximately plus or minus 8 degrees.

[0103] In various embodiments, the elastomeric ring 1054 may comprise a lower hardness than the torsional limiter 1056 and the compression collar 1058, thereby providing an initial soft resistance to vertical load and torsional rotation. A higher hardness compression collar 1058 provides greater resistance during high vertical loads. The compression collar 1058 may comprise different heights that affect the feel of the mounting bracket 1000 during vertical compression. If the compression collar 1058 is taller, it may contact before the torsional limiter 1056. A higher hardness torsional limiter 1056 provides greater resistance during high load twisting. Thus, the above-described system can provide multi-phase resistance to vertical load and torsional rotation based on the user's needs.

[0104] According to various embodiments, the upper and lower members 1002, 1004 can be made from titanium (any type) or any other suitable material. In one embodiment, the upper member 1002 may include titanium. In one embodiment, the lower member 1004 may include alloy aluminum. Some other types of materials that may be used for the upper and lower members 1002, 1004 include mild steel, alloy steel, steel, high strength stainless steel such as 13-8, alloy aluminum such as 2000 and 7000 series, and any suitable composite material.

[0105] In various embodiments, the upper and lower members 1002, 1004 described above may be a unitary piece or multiple pieces joined together by any suitable method. In some embodiments, depending on the type of material, the upper and lower members 1002, 1004 may be fabricated by milling, casting, forging, powder metal, etc. In one embodiment, the upper and lower members 1002, 1004 may be fabricated with a titanium CNC milling machine. More specifically, in one embodiment, the upper and lower members 1002, 1004 may be fabricated integrally from alloy aluminum fabricated using a CNC milling machine. In other embodiments, aluminum, titanium, magnesium, or other suitable materials for the upper and lower members 1002, 1004 may be fabricated using a CNC milling machine. In other embodiments, aluminum, titanium, magnesium, or other suitable materials for the upper and lower members 1002, 1004 may be fabricated by casting, forging, powder metal, etc. In other embodiments, the chrome molybdenum, steel, or other suitable material for the upper and lower members 1002, 1004 may be made from multiple pieces and joined together by welding or any other suitable method.

[0106] According to various embodiments, and with reference to FIGS. 41-44 , the upper and lower members 1002, 1004 may be joined by an elastomeric ring 1054. The elastomeric ring 1054 may comprise any rubber, polyurethane, and / or elastomeric material. The elastomeric ring 1054 may be joined to the upper and lower members 1002, 1004 using an adhesive. An upper surface 1068 of the elastomeric ring 1054 may be received within and bonded to a channel 1020 in the upper flange 1010 of the upper member 1002. A lower surface 1070 of the elastomeric ring 1054 may be received within and bonded to a channel 1048 in the lower flange 1038 of the lower member 1004. The elastomeric ring 1054 may act as a cushion to absorb the force of downward strikes while the user is walking.

[0107] In various embodiments, the elastomeric ring 1054 can include an adhesive bond, thereby bonding the lower member to the upper member. Additionally, the adhesive bond of the elastomeric ring 1054 can provide stress distribution. While other modulus values ​​are contemplated and various moduli may be used as well, a stiffer adhesive is preferred compared to a softer adhesive. The elastomeric ring 1054 forms a space between the upper flange 1010 of the upper member 1002 and the lower flange 1038 of the lower member 106. An adhesive can be intermixed with the elastomeric ring 1054.

[0108] The prosthetic foot 100 can be adjusted to accommodate a user in part by adjusting the properties of the elastomeric ring 1054 between the upper and lower members 1002, 1004. For example, in various embodiments, the hardness of the elastomeric ring 1054 can be increased for users with greater heel strike forces, which may be due to additional body weight or dynamic activity.

[0109] In various embodiments, and as shown, the elastomeric ring 1054, torsional limiter 1056, and vertical spring 1060 may comprise an elastomeric material. The elastomeric material may include common elastomeric materials, polyurethane, natural rubber, synthetic rubber, or various combinations of natural and synthetic rubber, plastic, metal, and the like. The hardness of the elastomeric material of both the elastomeric ring 1054, torsional limiter 1056, and vertical spring 1060 can be varied to provide additional adjustment of the prosthetic foot. The elastomeric material of the elastomeric ring 1054, torsional limiter 1056, and vertical spring 1060 supports load. Furthermore, because the elastomeric ring 1054 connects the upper and lower members 1002, 1004, the members can torsionally rotate during use of the prosthetic foot 100. The adjustable hardness of the elastomeric material allows the spring rate of the elastomeric ring to be adjusted based on the user's needs, such as activity level, compliance level, and weight changes. For example, in various embodiments, the hardness of the elastomeric material can be increased for users with greater heel strike forces, which may be due to the user's additional weight or the user's dynamic activity. Increased heel strike forces also result in greater compression of the heel member. As described above, the elastomeric ring 1054 and vertical spring 1060 can include a lower hardness than the torsional limiter 1056, thereby providing an initial softer resistance to vertical loads and torsional rotation. The higher hardness of the torsional limiter 1056 provides greater resistance when high torsional loads are applied.

[0110] 56, 57, and 75, in various embodiments, additional embodiments of a mounting bracket 1100 are shown. Similar to the previous mounting brackets described above, the mounting bracket 1100 may be attached to the top member 120 of the prosthetic foot 100 and configured for attachment to a user. In various embodiments, the mounting bracket 1100 may include an upper member 1102, a lower member 1104, and a compression-torsion joint 1106. The upper member 1102 may be configured for attachment to a user's residual limb. The lower member 1104 may be configured for attachment to the prosthetic foot 100. In one embodiment, the lower member 1104 is coupled to the prosthetic foot 100.

[0111] 57, 67, and 70, the upper member 1102 may include an attachment portion 1108 and an upper flange 1110. The attachment portion 1108 may be configured to attach to a user's residual limb. The attachment portion 1108 may include a spherical dome 1112 and an attachment portion 1114 that is a standard male pyramid adapter used in the prosthetic and orthotic industry. The pyramid adapter may mate with a standard receiver used in prosthetic and orthotic implementations, such as a Studz-style attachment commonly known in the prosthetic and orthotic industry. The attachment portion 1114 may use a standard receiver adapter, as will be understood by those skilled in the art. According to various embodiments, the attachment portion 1114 can facilitate attachment to a user's residual limb. The attachment portion 1114 may include a centerline that aligns with the user's weight line.

[0112] A spherical dome 1112 can be located on the upper flange 1110. In various embodiments shown in Figures 57, 66, and 70, the upper flange 1110 can include a downwardly extending lip 1116 around its periphery and a lower surface 1118 having a channel 1120 contained therein.

[0113] In various embodiments, as shown in FIGS. 57 and 75 , the mounting bracket 1100 can also include a mating post 1122 similar to the mating post 826 shown in FIGS. 27A and 27B above and the mating post 1022 shown in FIGS. 44 , 52A, and 52B . The mating post 1122 can include a cylindrical collar 1124 that extends downwardly from the lower surface 1118 of the upper flange 1110 when the mating post 1122 is coupled to the upper member 1102. In various embodiments, the mating post 1122 can be a separate, removable part or a unitary part. An upper portion 1126 (see also FIG. 75 ) of the mating post 1122 can be coupled to the upper member 1102 within a recess 1128 (see also FIG. 70 ) by any known method, such as threaded fitting, pressing, or the like. In one embodiment, the mating post 1122 can be coupled to the upper member 1102 by a threaded connection. The mating post 1122 may include threads (not shown) on an upper portion 1126 of the cylindrical collar 1124 that are received by threads (not shown) in a recess 1128 of the upper member 1102. The mating post 1122 may further include at least one recess 1130 (see also FIG. 75 ) on the outer periphery of the cylindrical collar 1124 that may receive an O-ring (not shown). The O-ring serves to fill the clearance between the outer diameter of the mating post 1122 and the inner diameter of the sleeve 1132, providing smooth and quiet operation between the relatively moving components. In one embodiment, the mating post 1122 includes at least one recess 1034 (see FIGS. 52A and 52B ) on the outer periphery of the cylindrical collar 1124 that may receive grease or other lubricant during assembly.

[0114] 57 and 60-64, in various embodiments, the lower member 1104 may include a mounting portion 1108, a lower flange 1138, and a mating portion 1140. The mounting portion 1108 may be located at a trailing edge of the lower flange 1138. The mounting portion 1108 may include at least one threaded opening 1142 that is used to couple the mounting bracket 1100 to the prosthetic foot 100. In one embodiment, the mounting portion 1108 includes three threaded openings 1142 that receive fasteners to couple the mounting bracket 1100 to the prosthetic foot 100.

[0115] In various embodiments, as shown in FIG. 9 , the upper end 862 of the prosthetic foot 100 may be connected to the mounting portion 1108 of the lower member 1104 via a mechanical connection, whereby a fastener 864 is received within an aperture (not shown) present in the upper end 862 of the prosthetic foot 100 and the mounting portion 1108 of the lower member 1104. While the mounting brackets 1000, 1100 are not shown in FIG. 9 , the mounting brackets 1000, 1100 may be coupled in the same manner as the mounting bracket 800. While a bolted connection is shown, any mechanical connection is contemplated, such as screws, rivets, etc. Materials for the bolted connection may include titanium or other suitable materials. Other types of materials may include mild steel, alloy steel, high-strength stainless steel such as 13-8, and alloy aluminum such as the 2000 series or 7000 series.

[0116] The mating portion 1140 of the lower member 1104 may include an upper collar 1144 and a lower collar 1146. The upper collar 1144 extends upwardly from the lower flange 1138, while the lower collar 1146 extends downwardly from the lower flange 1138. As shown in FIG. 57 , the upper and lower collars 1144, 1146 of the mating portion 1140 mate to receive the cylindrical collar 1124 of the mating post 1122 when the upper and lower members 1102, 1104 are coupled. As shown in FIGS. 61 and 62 , the lower flange 1138 may include a recessed channel 1148 and a lip 1150 surrounding at least a portion of its perimeter.

[0117] 66 and 68, in various embodiments, the upper member 1102 may include at least one ear extending from the lower surface 1118 of the upper flange 1110. In one embodiment, the upper member 1102 may include a pair of extending ears 1152 and 1154. The ears 1152 and / or 1154 may extend downwardly from the lower surface 1118 of the upper flange 1110. As shown in FIG. 68, the ears 1152 and / or 1154 may be located inside a channel 1120 on the lower surface 1118 of the upper flange 1110 so as to be contained within the periphery of the upper and lower members 1102, 1104 and the elastomeric ring 1158 (see also FIG. 57). The ears 1152 and / or 1154 may be positioned as follows:

[0118] The ears 1152 and / or 1154 serve to limit rotation of the upper member 1102 relative to the lower member 1104 during use, as described in detail below. The ears 1152 and / or 1154 may reside on the upper member 1102 adjacent to and projecting inwardly from an inner periphery 1156 of the channel 1120 located on the upper flange 1110. As shown in FIG. 68 , the ears 1152 and / or 1154 may reside on opposing undersides 1118 of the upper member 1102 and project inwardly from and downwardly from the inner periphery 1156 of the channel 1120 located on the upper flange 1110.

[0119] 58, 59, and 61-64, in various embodiments, the lower member 1104 may include at least one ear extending upward from the upper collar 1144 of the lower flange 1138. In one embodiment, the lower member 1104 may include a pair of extending ears 1160 and 1162. The ears 1160 and / or 1162 extend upward from the upper collar 1144 of the lower flange 1138. The ears 1160 and / or 1162 are positioned inside a channel 1148 on the upper collar 1144 of the lower flange 1138 so as to be fully received within the outer periphery of the upper and lower members 1102, 1104 and the interior of the elastomeric ring 1158. As shown in FIG. 61, the ears 1160 and / or 1162 may be positioned opposite each other on the upper collar 1144 inside the inner periphery 1169 of the channel 1148.

[0120] While the upper member 1102 and the lower member 1104 are shown as having a pair of extending ears, one of the upper and lower members may comprise a single extending ear, while the other may include a pair of extending ears. Thus, in one embodiment, one of the upper and lower members may include a single extending ear, while the other may include a pair of extending ears. For example, in one embodiment, the upper member 1102 may include a pair of ears 1152 and / or 1154 extending downwardly from the upper collar 1044 of the lower flange 1138, and the lower member 1104 may include at least one ear extending upwardly from the upper collar 1044 of the lower flange 1138.

[0121] 71-74, the internal bumper 1164 will be described. The internal bumper 1164 may include a ring 1166, a pair of recesses 1168, and a pair of extending arms 1170. The ring 1166 resides inside the channels 1120, 1148 of the upper and lower members 1102, 1104, respectively. The internal bumper 1164 may include a torsion-resilient material. The internal bumper 1164 may include an elastomeric material similar to the materials described above with respect to the elastomeric ring 1158, torsion limiter 1056, and vertical spring 1176. The internal bumper 1164 may be formed as a single piece, as shown, or may be formed as multiple pieces. The main function of the recess 1168 in the internal bumper 1164 is to surround the pair of extending ears 1152 and / or 1154 of the upper member 1102 (see FIG. 70) to eliminate metal-to-metal contact at the end of the rotational movement when the extending ears 1152 and 1154 of the upper member 1102 rotate and contact the extending ears 1160 and 1162 of the lower member 1104.

[0122] The pair of extending arms 1170 may include bumpers for the end of vertical travel. The pair of extending arms 1170 protrude upward and are inserted into a pair of recessed slots 1172 in the upper dome body of the upper member 1102 (see FIG. 68). In use, the extending ears 1160 and 1162 of the lower member 1104 will contact the pair of extending arms 1170 when they reach the end of their vertical travel, preventing metal-to-metal contact at the end of vertical travel, similar to what is done for the enclosed pair of extending ears 1152 and 1154 of the upper member 1102 during rotational travel.

[0123] The internal bumper 1164 can vary depending on the orientation of the ears provided on the upper and lower members 1102, 1104. For example, as shown in FIGS. 71-74, if the upper member 1102 includes a pair of extending ears 1152, 1154, the internal bumper will include a pair of recesses for accommodating the pair of extending ears 1152, 1154. If the upper member 1102 includes a single extending ear, the internal bumper will include a single recess for accommodating the single extending ear.

[0124] 57 and 75, in various embodiments, the compression torsion joint 1106 may include an elastomeric ring 1158. In various embodiments, the compression torsion joint 1106 may include an internal bumper 1164. In various embodiments, the compression torsion joint 1106 may include a vertical spring 1176. In one embodiment, the compression torsion joint 1106 may include a combination of the elastomeric ring 1158, the internal bumper 1164, and the vertical spring 1176. In one embodiment, shown in FIG. 81, the compression torsion joint 1106 may be located above the midpoint of the height of the mounting bracket 1100. In one embodiment, shown in FIG. 81, the compression torsion joint 1106 may be located above the midpoint of the height of the prosthetic foot 100. The compression torsion joint 1106 is positioned proximate to a mounting portion 1108 of the mounting bracket 1100, which attaches to the prosthetic foot 100 and the user. This reduces the moments / loads placed on the compression-torsion joint 1106, the foot 100, and the user. This arrangement, in conjunction with the foot design, allows for the most compact and lightest bracket solution to carry the required load while allowing for compression and torsion movement. Furthermore, in one embodiment, the mounting bracket 1100 is attached to the prosthetic foot 100 approximately parallel to the vertical axis of the foot, which requires that the compression-torsion joint 1106 be above the midpoint of the mounting bracket 1100 to the prosthetic foot 100 by the lower member 1104 to accommodate the attachment of the bracket to the prosthetic foot 100.

[0125] In various embodiments, the elastomeric ring 1158 shown in FIG. 57 is similar to the elastomeric ring 1054 described above in FIGS. 19, 22A, 22B, and 47-49. The elastomeric ring 1054 / 1158 may generally include a wall 1062 having inner 1064, outer 1066, upper 1068, and lower 1070 surfaces. In various embodiments, the inner surface 1064 of the wall 1062 may include a substantially smooth surface. In various embodiments, the inner surface 1064 may include a raised surface, a surface with raised portions, and / or a wall of varying thickness. In one embodiment shown in FIGS. 47A-47C, the inner and outer surfaces 1064, 1066 may be curved from the upper 1068 to the lower surface 1070 and / or concave relative to the center of the elastomeric ring 1158. In one embodiment, the outer surface 1066 may be curved and / or convex relative to the center of the elastomeric ring 1054 / 1158. In one embodiment shown in Figures 48A-48C, the inner surface 1064 may be generally straight, and the outer surface 1066 may be curved from the upper side 1068 to the lower side 1070 and / or may be concave relative to the center of the elastomeric ring 1054 / 1158. In one embodiment shown in Figures 49A-49C, the inner and outer surfaces 1064, 1066 may be generally straight from the upper side 1068 to the lower side 1070.

[0126] 43, 44, 47-50, and 57, an upper surface 1068 of the elastomeric ring 1054 / 1158 can be received in the channel 1120 of the upper flange 1110 of the upper member 1102. The outer surface 1066 generally abuts the lip 1016 of the upper flange 1110 of the upper member 1102. A lower surface 1070 of the elastomeric ring 1054 / 1158 can be received in the channel 1048 of the lower flange 1138 of the lower member 1104. The outer surface 1066 generally abuts the lip 1050 of the lower flange 1138 of the lower member 1104.

[0127] 57 and 75, in various embodiments, a vertical spring 1176 can be received within the cylindrical collar 1124 of the mating post 1122. The vertical spring 1176 can comprise an elastomeric material, including, but not limited to, natural rubber, synthetic rubber, a combination of natural and synthetic rubber, polyurethane, etc. The vertical spring 1176 resists and limits the amount of vertical movement of the upper member 1102 relative to the lower member 1104.

[0128] In various embodiments, the vertical spring 1176 may reside between the underside of the cylindrical collar 1124 and the compression cap 1178. In one embodiment, the vertical spring 1176 may reside between a spacer (not shown) located within the cylindrical collar 1124 and the compression cap 1178. The vertical spring 1176 limits the amount of vertical movement of the upper member 1102 relative to the lower member 1104 by contacting the underside of the cylindrical collar 1124 within the mating post 1122 and the compression cap 1178.

[0129] 57 and 75-77, in various embodiments, the mounting bracket 1100 can include a retention system 1180. The retention system 1180 is utilized as a fail-safe to ensure that the upper member 1102 does not separate from the lower member 1104 in the event that the bond on the elastomeric ring 1158 connecting the upper and lower members 1102, 1104 is lost. In various embodiments, the retention system 1180 can include a retaining ring 1182, a plug 1184, and a retaining connector 1186.

[0130] 78A-C, the retaining ring 1182 may include threads 1188 that are received within internal threads 1190 located within an inner wall 1192 within the cylindrical collar 1124 of the mating post 1122. The plug 1184 shown in FIGS. 79A-C may be received within the inner wall 1192 of the cylindrical collar 1124 and includes internal threads 1194 that receive the retaining connector 1186 and a mating collar 1196.

[0131] The retaining connector 1186 is used in combination with the compression cap 1178 and is received within the internal threads 1194 of the plug 1184. When tightened, the retaining connector 1186 seats the mating collar 1196 within a mating recess 1198 of the compression cap 1178. In one embodiment, the retaining connector 1186 is a screw.

[0132] 76 and 80A-C, in various embodiments, the retention system 1180 may include a compression cap 1178. The compression cap 1178 carries a portion of the vertical load applied to the upper member 1102 through the vertical spring 1176 and the retention system 1180 and transfers it to the lower member 1104. The compression cap 1178 may be press-fit or may include threads 1200 that mate with internal threads 1202 of the lower collar 1146 of the mating portion 1140. The compression cap 1178 may be used in combination with a mating post 1122 received within a sleeve 1132 to couple the upper member 1102 to the lower member 1104. The sleeve 1132 may include a low-friction material to facilitate smooth movement between the upper and lower members 1102, 1104.

[0133] In use, the cylindrical collar 1124 of the mating post 1122 is received within a sleeve 1132 that is received in the upper and lower collars 1144, 1146 of the mating portion 1140 when the upper and lower members 1102, 1104 are connected.

[0134] The compression cap 1178 also prevents dirt, sand, or small objects from entering the mating portion 1140 of the lower member 1104. Objects such as small stones or sand can wear down the moving internal members, eventually causing damage and failure.

[0135] The sleeve 1132 is similar to the sleeve 910 described above in FIG. 25 . The sleeve 1132 may include a cylindrical wall and first and second ends. The sleeve 1132 fits within a mating portion 1140 of the lower member 1104. The sleeve 1132 may be inserted into the lower end of the lower member 1104 and extend along the length of the mating portion 1140. The first end of the sleeve 1132 may abut a lip formed inside the upper collar 1044 of the lower member 1104. The lip is configured to retain the first end within the mating portion 1140.

[0136] The sleeve 1132 can be made from any suitable low-friction material. In one embodiment, the low-friction sleeve is made from plastic to allow smooth movement between the components of the prosthetic foot. In one embodiment, a low-coefficient plastic bushing material may be used.

[0137] In use under load, the vertical spring 1176 and elastomeric ring 1158 in conjunction with the internal bumper 1164 provide a limited amount of vertical movement of the upper member 1102 relative to the lower member 1104. The internal bumper 1164, elastomeric ring 1158, and vertical spring 1176 limit vertical movement, while the torsional limiter 1156 limits torsional movement. The elastomeric ring 1158 provides vertical shock absorption and torsional stability during the gait cycle and while standing. The vertical spring 1176 provides vertical shock absorption and compression during use.

[0138] The mounting bracket 1100 provides a multi-phase system. When an initial load is applied to the prosthesis 100, the elastomeric ring 1158 provides soft resistance for both vertical compression and torsional rotation. During compression, the elastomeric ring 1158 and vertical spring 1176 simultaneously provide resistance. The elastomeric ring 1158 carries the majority of the compressive load compared to the vertical spring 1176. As greater loads are applied, the vertical spring 1176 compresses between the plug 1084 located within the cylindrical collar 1124 and the compression cap 1178, thereby allowing only a limited amount of vertical movement of the upper member 1102 relative to the lower member 1104. This cooperates with the internal bumpers 1164 surrounding the ears 1152 and 1154 of the upper member 1102, which contact the upper collar 1144 of the lower member 1104.

[0139] According to various embodiments, and referring to FIG. 57 , the upper and lower members 1102, 1104 may be joined by an elastomeric ring 1158. The elastomeric ring 1158 may comprise any rubber, polyurethane, and / or elastomeric material. The elastomeric ring 1158 may be joined to the upper and lower members 1102, 1104 using an adhesive. An upper surface of the elastomeric ring 1158 may be received within and glued to the channel 1120 of the upper flange 1110 of the upper member 1102. A lower surface of the elastomeric ring 1158 may be received within and glued to the channel 1148 of the lower flange 1138 of the lower member 1104. The elastomeric ring 1158 may act as a cushion to absorb the force of a downward strike during a user's stride.

[0140] In various embodiments, the elastomeric ring 1158 can include an adhesive bond, thereby bonding the lower member to the upper member. Additionally, the adhesive bond of the elastomeric ring 1158 can provide stress distribution. Other modulus values ​​are contemplated, and various moduli may be used as well, although a stiffer adhesive is preferred compared to a softer adhesive. The elastomeric ring 1158 forms a space between the upper flange 1110 of the upper member 1102 and the lower flange 1138 of the lower member 1104. An adhesive can be intermixed with the elastomeric ring 1158.

[0141] The prosthetic foot 100 can be adjusted to accommodate a user in part by adjusting the properties of the elastomeric ring 1158 between the upper and lower members 1102, 1104. For example, in various embodiments, the hardness of the elastomeric ring 1158 can be increased for users with greater heel strike forces, which may be due to additional body weight or dynamic activity.

[0142] In various embodiments, and as shown, the elastomeric ring 1158, the internal bumper 1164, and the vertical spring 1176 may comprise an elastomeric material. The elastomeric material may include common elastomeric materials, polyurethane, natural rubber, synthetic rubber, or various combinations of natural and synthetic rubber, plastic, metal, and the like. The hardness of the elastomeric material of both the elastomeric ring 1158, the internal bumper 1164, and the vertical spring 1176 can be varied to provide additional adjustment of the prosthetic foot. The elastomeric material of the elastomeric ring 1158, the internal bumper 1164, and the vertical spring 1176 supports load. Additionally, because the elastomeric ring 1158 connects the upper and lower members 1102, 1104, the members can torsionally rotate during use of the prosthetic foot 100. The adjustable hardness of the elastomeric material allows the spring rate of the elastomeric ring to be adjusted based on the user's needs, such as activity level, compliance level, and weight changes. For example, in various embodiments, the hardness of the elastomeric material can be increased for users with greater heel strike forces, which may be due to the user's additional weight or the user's dynamic activity. Increased heel strike forces also result in greater compression of the heel member. As described above, the elastomeric ring 1158 and vertical spring 1176 can comprise a lower hardness than the internal bumper 1164, thereby providing an initial softer resistance to vertical loads and torsional rotation. A harder internal bumper 1164 provides greater resistance to high torsional loads.

[0143] The extending ears 1152 and 1154 of the upper member 1102 and the extending ears 1160 and 1162 of the lower member 1104, when assembled with the internal bumper 1164, serve to limit rotation of the upper member 1102 relative to the lower member 1104 during use, as described in detail below.

[0144] In various embodiments, the extending ears 1152 and 1154 of the upper member 1102 and the extending ears 1160 and 1162 of the lower member 1104 may actuate when the upper member 1102 of the mounting bracket 1100 rotates enough to overcome the torsional stiffness of the elastomeric ring 1158 and allow the extending ears 1152 and 1154 of the upper member 1102 and the extending ears 1160 and 1162 of the lower member 1104 to contact one another. The extending ears 1152 and 1154 of the upper member 1102 and the extending ears 1160 and 1162 of the lower member 1104 engage one another at the same rotational angle regardless of the amount of vertical compression to which the mounting bracket 1100 is subjected.

[0145] FIG. 59 shows the gap between the extending ears 1152 and 1154 of the upper member 1102 and the extending ears 1160 and 1162 of the lower member 1104, which acts as a stop when the ears are rotated until they contact one another. The extending ears 1152 and 1154 of the upper member 1102 are surrounded by an internal bumper 1164 to cushion the end of the rotational movement. See FIG. 75. The extending ears 1160 and 1162 of the lower member 1104 contact the lower surface 1118 of the upper member 1102 at the end of their vertical movement, regardless of the amount of twisting movement. The extending ears 1152 and 1154 of the upper member 1102 contact the upper collar 1044 at the end of their vertical movement, regardless of the amount of twisting movement. In one embodiment, the extending ears 1160 and 1162 of the lower member 1104 can limit the amount of vertical movement simultaneously with the extending ears 1152 and 1154 of the upper member 1102. In another embodiment, the extending ears 1160 and 1162 of the lower member 1104 can limit the amount of vertical movement individually. In another embodiment, the extending ears 1152 and 1154 of the upper member 1102 can limit the amount of vertical movement individually.

[0146] According to various embodiments, the upper and lower members 1102, 1104 can be made from titanium (any type) or any other suitable material. In one embodiment, the upper member 1102 may include titanium. In one embodiment, the lower member 1104 may include alloy aluminum. Some other types of materials that may be used for the upper and lower members 1102, 1104 include mild steel, alloy steel, steel, high-strength stainless steel such as 13-8, alloy aluminum such as 2000 and 7000 series, and any suitable composite material.

[0147] In various embodiments, the upper and lower members 1102, 1104 described above can be a single piece or multiple pieces joined together by any suitable method. In some embodiments, depending on the type of material, the upper and lower members 1102, 1104 can be made by milling, casting, forging, powder metal, etc. In one embodiment, the upper and lower members 1002, 1004 can be made with a titanium CNC milling machine. More specifically, in one embodiment, the upper and lower members 1102, 1104 can be made integrally from alloy aluminum fabricated using a CNC milling machine. In other embodiments, aluminum, titanium, magnesium, or other suitable materials for the upper and lower members 1102, 1104 can be fabricated using a CNC milling machine. In other embodiments, aluminum, titanium, magnesium, or other suitable materials for the upper and lower members 1102, 1104 can be fabricated by casting, forging, powder metal, etc. In other embodiments, the chrome molybdenum, steel, or other suitable material for the upper and lower members 1102, 1104 may be made from multiple pieces and joined together by welding or any other suitable method.

[0148] The present technology has been described with reference to specific exemplary embodiments. However, various modifications and changes can be made without departing from the scope of the present technology. The description and figures should be considered illustrative, not limiting, and all such modifications are intended to be included within the scope of the present technology. Thus, the scope of the present technology should be determined by the general embodiments described and their legal equivalents, not merely by the specific examples described above. For example, the steps recited in any method or process embodiment may be performed in any order unless expressly specified otherwise, and are not limited to the explicit order presented in the specific examples. Furthermore, the components and / or elements recited in any apparatus embodiment may be assembled or otherwise operatively configured in various permutations to produce substantially the same results as the present technology, and accordingly are not limited to the specific configurations recited in the specific examples.

[0149] Although advantages, other benefits, and solutions to problems have been described above with respect to particular embodiments, any advantage, benefit, solution to a problem, or any element that may cause or make more pronounced any particular advantage, benefit, or solution, is not to be construed as a critical, essential, or required feature or component.

[0150] As used herein, the terms "comprises," "including," or variations thereof are intended to refer to a non-exclusive inclusion, such that a process, method, article, composition, or apparatus comprised of a list of elements does not include only those elements mentioned, but may also include other elements not expressly listed or inherent in such process, method, article, composition, or apparatus. Other combinations and / or modifications of the above-described structure, arrangement, application, proportions, elements, materials, or components used in the practice of the present technology, in addition to those not specifically mentioned, can be varied or otherwise specifically adapted to particular environments, manufacturing specifications, design parameters, or other operating requirements without departing from its general principles.

[0151] The present technology has been described above with reference to preferred embodiments. However, changes and modifications can be made to the preferred embodiments without departing from the scope of the technology. These and other changes or modifications are intended to be included within the scope of the technology, as expressed in the following claims.

Claims

1. 1. A mounting bracket for a prosthetic limb configured to be attached to a residual limb, comprising: an upper member including an upper flange with a channel, a mating post, a pair of ears extending downward from a lower surface of the upper flange and positioned inside an inner periphery of the channel, and an attachment portion configured to be attached to the residual limb; a lower member including a fitting portion with a channel, a lower flange, a pair of ears extending up from an upper collar of the lower flange and positioned inside the channel, and an attachment portion configured to attach to the prosthetic limb; a compression-torsional joint connecting the upper member to the lower member and configured to limit vertical and torsional movement of the upper member relative to the lower member.

2. A mating post of the upper member is received within a mating portion of the lower member; The mounting bracket of claim 1 .

3. the channels in the upper and lower flanges are adjacent to the outer peripheries of the upper and lower flanges; The mounting bracket of claim 1 .

4. the compression-torsion joint includes an elastomeric ring configured to limit vertical and torsional movement of the upper member relative to the lower member; The mounting bracket of claim 3 .

5. an upper surface of the elastomeric ring received within a channel in the upper flange and a lower surface of the elastomeric ring received within a channel in the lower flange; 5. The mounting bracket of claim 4.

6. an upper surface of the elastomeric ring interlocking with a channel in the upper flange and a lower surface of the elastomeric ring interlocking with a channel in the lower flange; 6. The mounting bracket of claim 5.

7. A pair of ears extending from the upper flange are positioned opposite each other on the inside of the inner circumference of the channel, 7. The mounting bracket of claim 6.

8. A pair of ears extending from the upper collar of the lower flange are positioned opposite each other inside the inner circumference of the channel, 8. The mounting bracket of claim 7.

9. The upper flange and a pair of ears on the upper collar of the lower flange are configured to limit rotational movement of the upper member relative to the lower member.

9. The mounting bracket of claim 8.

10. The compression-torsion joint includes an internal bumper connected to a pair of ears on the upper flange.

8. The mounting bracket of claim 7.

11. The inner bumper includes a pair of recesses that receive a pair of ears on the upper collar of the lower flange. The mounting bracket of claim 10.

12. The compression-torsion joint includes a vertical spring configured to limit vertical movement.

5. The mounting bracket of claim 4.

13. The mounting bracket further comprises a retention system; The retention system is a compression cap coupled to a mating portion of the lower member; a plug coupled within the lower end of the mating post of the upper member; a connector received within the lower end of the compression cap and coupled to the plug; The mounting bracket of claim 1 .

14. The compression twist joint is not located outside the outer periphery of the upper flange and the lower flange; The mounting bracket of claim 1 .

15. A pair of ears of the upper and lower members are disposed between and surrounded by the upper member, the lower member, and the elastomer ring.

8. The mounting bracket of claim 7.

16. A mounting bracket for a prosthetic limb configured to be attached to a residual limb, comprising: The mounting bracket includes an upper member; The upper member is an upper flange with a channel; a mating post; a pair of ears extending downward from the lower surface of the upper flange and positioned inside the inner periphery of the channel; an attachment portion configured to be attached to the residual limb; The mounting bracket also includes a lower member; The lower member is a lower flange with a channel; a mating portion configured to receive a mating post; a pair of ears extending upward from the upper collar of the lower flange and positioned inside the channel; an attachment portion configured to be attached to the prosthetic limb; The mounting bracket also includes a compression torsion joint; The compression-torsion joint includes an elastomeric ring configured to couple the upper member to the lower member and limit vertical and torsional movement of the upper member relative to the lower member, the elastomeric ring having an upper surface coupled with the channel in the upper flange and a lower surface coupled with the channel in the lower flange; The mounting bracket also includes a retention system; The retention system is a compression cap coupled to a mating portion of the lower member; a plug coupled within the lower end of the mating post of the upper member; a connector received within the lower end of the compression cap and coupled to the plug; Includes mounting bracket.

17. The compression twist joint is not located outside the outer periphery of the upper flange and the lower flange; 17. The mounting bracket of claim 16.

18. A pair of ears of the upper and lower members are disposed between and surrounded by the upper member, the lower member, and the elastomer ring.

18. The mounting bracket of claim 17.

19. A prosthetic foot for use within a foot shell and configured for attachment to a residual limb, comprising: The prosthetic foot includes a resilient sole member; The elastic base member is It includes a front end, a rear end, and has no inflection points; The center of curvature of the front end of the resilient bottom member is located on the bottom member, and the rear end of the resilient bottom member is substantially linear; The prosthetic foot also includes a resilient apex member; The resilient top member comprises: a front end, a rear end, The front end of the elastic top member is connected to the front end of the elastic bottom member, and the connection point is connected to the upper side of the rear end of the elastic top member, and the elastic top member is disposed on the elastic bottom member; The prosthetic foot also includes a bumper member directly attached to the underside of the rear end of the resilient top member and spaced apart from the upper side of the rear end of the resilient bottom member in the unloaded state; The prosthetic leg also includes a mounting bracket; The mounting bracket includes an upper member; The upper member is an upper flange with a channel; a mating post; a pair of ears extending downward from the lower surface of the upper flange and positioned inside the inner periphery of the channel; an attachment portion configured to be attached to the residual limb; The mounting bracket also includes a lower member; The lower member is a lower flange with a channel; a mating portion configured to receive a mating post; a pair of ears extending upward from the upper collar of the lower flange and positioned inside the channel; an attachment portion configured to be attached to the prosthetic limb; The mounting bracket also includes a compression torsion joint; a compression-torsion joint connecting the upper member to the lower member and configured to limit vertical and torsional movement of the upper member relative to the lower member; Prosthetic leg.

20. The compression-torsion joint includes an elastomeric ring having an upper surface coupled to the channel in the upper flange and a lower surface coupled to the channel in the lower flange.

20. The prosthetic foot of claim 19.

21. The mounting bracket further comprises a retention system; The retention system is a compression cap coupled to a mating portion of the lower member; a plug coupled within the lower end of the mating post of the upper member; a connector received within the lower end of the compression cap and coupled to the plug; Including, 20. The prosthetic foot of claim 19.

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