Customizable lightweight prosthetic leg frame, prosthetic leg comprising same, and method for manufacturing same

Abstract

According to the present embodiments, a customizable lightweight prosthetic leg frame, a prosthetic leg comprising same, and a method for manufacturing same can be provided, the customizable lightweight prosthetic leg frame having improved fidelity of healthy-side lower limb simulation and enabling a reduction in the number and weight of components due to the integrally designed components.

Description

Customized lightweight prosthetic frame, a prosthetic leg including the same, and a method for manufacturing the same

[0001] The present embodiments relate to a custom lightweight prosthetic frame, a prosthetic leg including the same, and a method for manufacturing the same.

[0002] Various types of prosthetic devices, such as artificial arms and legs, are designed to effectively replace necessary movements in place of a severed body part, depending on the amputation site.

[0003] Early assistive devices were primarily developed to replace amputated body parts for aesthetic purposes, but they are gradually being developed to enable natural physical performance and prevent excessive metabolic expenditure on the user. For example, in the case of a prosthetic leg, it must be able to provide appropriate braking force according to each stage of the gait cycle to ensure the wearer's safety and enable natural walking.

[0004] Conventional prosthetic frames are mostly manufactured using metal processing to ensure durability and mechanical properties, and additional design covers are combined to complete the product. Conventional prosthetic products cannot faithfully reproduce the shape of the lower leg area below the knee, and are finished with a mechanical appearance in which the mechanical frame is partially exposed while having a minimal volume shape within the range that satisfies the functional characteristics of the prosthetic.

[0005] Referring to FIGS. 1 to 3, an example of a conventional prosthetic leg structure can be described as follows: the conventional prosthetic leg (10) may include a drive module (11) comprising a drive unit, a control unit, a battery, etc., for performing the function of the prosthetic leg; a frame module (14) supporting the drive module (11); an artificial foot (13); a connecting pipe (12) connecting the artificial foot (13) and the drive module (11); and an outer cover (15) forming the exterior. The frame module (14) includes a main frame (21) that provides a basic skeletal structure, and the main frame (21) is also coupled with a finishing cover (22, 23) for wiring finishing, product exterior, protection of parts, prevention of foreign matter intrusion, and prevention of pinching. The outer cover (15) includes a side finishing part (32), a front finishing part (33), a rear finishing part (34), etc., centered around the main cover (31).

[0006] As such, existing prosthetic legs are constructed with a structure in which components for functional implementation are combined with components for product shape and finishing. That is, the main body of the prosthetic leg consists of a combination of a main frame module and separate accessory parts for finishing quality, and the final finishing is achieved by overlaying a leg-shaped outer shell onto the prosthetic leg. However, this does not perfectly reproduce the normal leg, resulting in low fidelity in the simulation of the unaffected lower limb, and acts as a limiting factor that increases the weight of the prosthetic leg, while also raising manufacturing costs due to the large number of parts.

[0007] The present embodiments are conceived from the background described above and relate to a customized lightweight prosthetic frame that improves the fidelity of the unaffected lower limb and reduces the number and weight of parts by designing the parts in an integrated manner, a prosthetic leg including the same, and a method for manufacturing the same.

[0008] According to the embodiments, a custom lightweight prosthetic frame may be provided, comprising a connecting part that is connected to the prosthetic mechanism to form a lower limb appearance, a mimic part that forms a prosthetic volume to form the lower limb appearance, and a skeletal part that connects the connecting part and the mimic part.

[0009] In addition, according to the embodiments thereof, a prosthetic leg may be provided comprising the custom lightweight prosthetic leg frame and the prosthetic leg mechanism, wherein the artificial foot, the prosthetic leg mechanism comprises an upper module connected to the user's thigh and a lower module connected to the artificial foot, and the custom lightweight prosthetic leg frame is divided into an upper frame connected to the upper module and a lower frame connected to the lower module.

[0010] In addition, according to the embodiments thereof, a method for manufacturing a customized lightweight prosthetic frame may be provided, comprising the steps of: obtaining three-dimensional surface information to form the external appearance of the prosthetic and defining the volume of the prosthetic; defining design parameter conditions to implement the function of the prosthetic; defining a prosthetic frame that satisfies the defined design parameter conditions; and manufacturing the defined prosthetic frame.

[0011] According to the embodiments, a customized lightweight prosthetic frame that improves the fidelity of the unaffected lower limb and reduces the number and weight of parts by designing the parts in an integrated manner, a prosthetic leg including the same, and a method for manufacturing the same may be provided.

[0012] Figure 1 is an exploded perspective view illustrating the structure of a conventional prosthetic leg.

[0013] Figure 2 is an exploded perspective view of the frame module of Figure 1.

[0014] Figure 3 is an exploded perspective view of the outer shell cover of Figure 1.

[0015] FIG. 4 is a perspective view of a custom lightweight prosthetic frame according to the embodiments and a prosthetic leg including the same.

[0016] FIG. 5 is a perspective view of a customized lightweight prosthetic frame according to the embodiments.

[0017] FIG. 6 is a cross-sectional view of a custom lightweight prosthetic frame according to the embodiments.

[0018] FIG. 7 is an exploded view of a prosthetic leg according to the embodiments.

[0019] FIG. 8 is a perspective view of a custom lightweight prosthetic frame according to the embodiments and a prosthetic including the same.

[0020] FIG. 9 is a perspective view of a custom lightweight prosthetic frame according to the embodiments.

[0021] FIG. 10 is a cross-sectional view of a custom lightweight prosthetic frame according to the embodiments.

[0022] FIG. 11 is an exploded perspective view of a prosthetic leg according to the embodiments of the present invention.

[0023] FIG. 12 is a flowchart of a method for manufacturing a customized lightweight prosthetic frame according to the embodiments.

[0024] FIG. 13 is a drawing illustrating the starting shape definition step among the design parameter condition definition steps of the manufacturing method of a customized lightweight prosthetic leg frame according to the embodiments.

[0025] FIG. 14 is a diagram illustrating the step of defining the retained shape during the step of defining design parameter conditions of the method for manufacturing a customized lightweight prosthetic frame according to the embodiments.

[0026] FIG. 15 is a diagram illustrating the step of defining obstacle shapes during the step of defining design parameter conditions of the method for manufacturing a customized lightweight prosthetic frame according to the embodiments.

[0027] FIG. 16 is a diagram illustrating the step of defining constraint and load conditions among the step of defining design parameter conditions of the method for manufacturing a customized lightweight prosthetic frame according to the embodiments.

[0028] FIG. 17 is a diagram illustrating the step of defining constraint and load conditions among the step of defining design parameter conditions of the method for manufacturing a customized lightweight prosthetic frame according to the embodiments.

[0029] FIG. 18 is a diagram illustrating the step of defining constraint and load conditions among the step of defining design parameter conditions of the method for manufacturing a customized lightweight prosthetic frame according to the embodiments.

[0030] FIG. 19 is a diagram illustrating the step of defining constraint and load conditions among the step of defining design parameter conditions of the method for manufacturing a customized lightweight prosthetic frame according to the embodiments.

[0031] FIG. 20 is a drawing illustrating the step of defining constraint and load conditions among the step of defining design parameter conditions of the method for manufacturing a customized lightweight prosthetic frame according to the embodiments.

[0032] Hereinafter, the present disclosure will be described in detail with reference to the attached drawings. However, this is merely illustrative and the present disclosure is not limited to the specific embodiments described illustratively.

[0033] The following embodiments are provided to more faithfully and completely explain the technical concept of the present disclosure to those skilled in the art to which the present disclosure pertains. Accordingly, the technical concept of the present disclosure is not necessarily limited to the following embodiments. The present disclosure should be understood to broadly include various equivalents, substitutions, modifications, etc., that embody the technical concept to be described below.

[0034] The terms used in the following description are intended to describe specific embodiments more faithfully and completely in the same light as above. Accordingly, the terms used in the following description should not be interpreted to reduce, limit, or restrict the technical scope of the present disclosure.

[0035] In the following description, terms such as "first," "second," etc., may be used to refer to specific components to distinguish them from other components. However, such terms are used for clarity of explanation, and the technical concept of the present disclosure should not be interpreted as being limited by such terms.

[0036] In the following description, singular expressions may be interpreted to include the plural unless explicitly excluded by the context. Furthermore, in the following description, the expression "includes" means that the components, parts, actions, features, steps, numbers, etc. described in the description exist, and does not exclude the addition of one or more other components, parts, actions, features, steps, numbers, etc.

[0037] In the following description, terms related to direction, such as "beneath," "above," "lower," and "upper," may be used to facilitate understanding of the components. However, such terms are provided to facilitate understanding of the present disclosure based on various operations and usage conditions, and should not be interpreted to reduce, limit, or restrict the technical scope of the present disclosure. For example, terms related to direction may be determined from a relative perspective.

[0038] Meanwhile, in the drawings below, the depiction of each component may be exaggerated or omitted for the convenience and clarity of explanation.

[0039] FIG. 1 is an exploded perspective view illustrating a conventional prosthetic structure; FIG. 2 is an exploded perspective view of the frame module of FIG. 1; FIG. 3 is an exploded perspective view of the outer shell cover of FIG. 1; FIG. 4 is a perspective view of a custom lightweight prosthetic frame according to the present embodiments and a prosthetic including the same; FIG. 5 is a perspective view of a custom lightweight prosthetic frame according to the present embodiments; FIG. 6 is a cross-sectional view of a custom lightweight prosthetic frame according to the present embodiments; FIG. 7 is an exploded perspective view of a prosthetic according to the present embodiments; FIG. 8 is a perspective view of a custom lightweight prosthetic frame according to the present embodiments and a prosthetic including the same; FIG. 9 is a perspective view of a custom lightweight prosthetic frame according to the present embodiments; FIG. 10 is a cross-sectional view of a custom lightweight prosthetic frame according to the present embodiments; FIG. 11 is an exploded perspective view of a prosthetic according to the present embodiments; FIG. 12 is a flowchart of a manufacturing method of a custom lightweight prosthetic frame according to the present embodiments; FIG. 13 is a custom lightweight A drawing for explaining the starting shape definition step among the design parameter condition definition steps of the manufacturing method of a prosthetic leg frame; FIG. 14 is a drawing for explaining the maintenance shape definition step among the design parameter condition definition steps of the manufacturing method of a customized lightweight prosthetic leg frame according to the present embodiments; FIG. 15 is a drawing for explaining the obstacle shape definition step among the design parameter condition definition steps of the manufacturing method of a customized lightweight prosthetic leg frame according to the present embodiments; FIG. 16 is a drawing for explaining the restraint and load condition definition step among the design parameter condition definition steps of the manufacturing method of a customized lightweight prosthetic leg frame according to the present embodiments; FIG. 17 is a drawing for explaining the restraint and load condition definition step among the design parameter condition definition steps of the manufacturing method of a customized lightweight prosthetic leg frame according to the present embodiments; FIG. 18 is a drawing for explaining the restraint and load condition definition step among the design parameter condition definition steps of the manufacturing method of a customized lightweight prosthetic leg frame according to the present embodiments; FIG. 19 is a drawing for explaining the restraint, among the design parameter condition definition steps of the manufacturing method of a customized lightweight prosthetic leg frame according to the present embodiments.FIG. 20 is a drawing for explaining the step of defining load conditions, and is a drawing for explaining the step of defining constraint and load conditions among the step of defining design parameter conditions of the method for manufacturing a customized lightweight prosthetic frame according to the present embodiments.

[0040] According to the embodiments, a custom lightweight prosthetic frame (100) may be provided, comprising a connecting part (110) that is connected to the prosthetic mechanism (210) to form a lower limb appearance, a mimicry part (120) that forms a prosthetic volume to form a lower limb appearance, and a skeletal part (130) that connects the connecting part (110) and the mimicry part (120).

[0041] Additionally, according to the embodiments, a prosthetic leg (200) may be provided, comprising a custom lightweight prosthetic leg frame (100) and a prosthetic leg mechanism (210) according to the embodiments, wherein the prosthetic leg mechanism (210) includes an upper module (220) connected to the user's thigh and a lower module (230) connected to the prosthetic foot (202), and the custom lightweight prosthetic leg frame (100) according to the embodiments is divided into an upper frame (101) connected to the upper module (220) and a lower frame (102) connected to the lower module (230).

[0042] In addition, according to the embodiments thereof, a method for manufacturing a customized lightweight prosthetic frame may be provided, comprising the steps of: obtaining three-dimensional surface information to form the external appearance of the prosthetic and defining the volume of the prosthetic (S100); defining design parameter conditions to implement the function of the prosthetic (S200); defining a prosthetic frame that satisfies the design parameter conditions (S300); and manufacturing the defined prosthetic frame (S400).

[0043] Hereinafter, we will first look at a custom lightweight prosthetic leg frame (100) according to the first embodiment and a prosthetic leg (200) including the same with reference to FIGS. 4 to 7. Meanwhile, each component of the embodiments can be joined through various means such as bolting and riveting, and for convenience of illustration and understanding, such means or methods of joining are not limited.

[0044] The custom lightweight prosthetic frame (100) according to the embodiments may include a connecting part (110), a mimicry part (120), and a skeletal part (130). And, the prosthetic leg (200) according to the embodiments may include the custom lightweight prosthetic frame (100) according to the embodiments, a prosthetic leg mechanism part (210), and an artificial foot (202).

[0045] The prosthetic leg (200) according to the embodiments thereof may be a device for constructing a femoral prosthesis. Generally, the femoral prosthesis may include a prosthetic leg comprising a femoral socket connected to the femur and an artificial knee joint connected to the femoral socket. The prosthetic leg (200) according to the embodiments thereof may be a prosthetic leg in which a prosthetic leg mechanism (210) is connected to the femoral socket.

[0046] The customized lightweight prosthetic leg frame (100) according to the embodiments may be a frame in which the remaining parts, excluding the prosthetic leg mechanism and artificial foot which are functional components for implementing the function of the prosthetic leg, are integrated. Accordingly, the number of parts of the prosthetic leg (200) according to the embodiments may be reduced, and the manufacturing cost and weight may be reduced.

[0047] The customized lightweight prosthetic frame (100) according to the embodiments can be manufactured based on three-dimensional surface information obtained to form the external appearance of the prosthetic leg as described below. The three-dimensional surface information can be obtained, for example, by 3D scanning the user's opposite lower limb. The obtained three-dimensional surface information is used to define the volume of the prosthetic leg formed by the customized lightweight prosthetic frame (100) according to the embodiments, and the structure of the imitation part (120) can be determined from the defined volume of the prosthetic leg. That is, the outer structure of the customized lightweight prosthetic frame (100) according to the embodiments can be designed by directly reflecting the characteristic shape of the unaffected lower limb, and thus the fidelity of the imitation of the unaffected lower limb can be maximized.

[0048] According to one embodiment, the prosthetic leg (200) according to the embodiments may further include a skin cover (201) that is supported by a replica part (120) and covers a custom lightweight prosthetic leg frame (100) according to the embodiments to form the lower limb appearance. FIG. 4(a) illustrates a state in which the custom lightweight prosthetic leg frame (100) and the prosthetic leg mechanism part (210) according to the embodiments are combined, and FIG. 4(b) illustrates a state in which the skin cover (201) is further combined.

[0049] The skin cover (201) has its inner surface supported by the imitation part (120) and forms the lower limb appearance. As described above, since the structure of the imitation part (120) is determined from three-dimensional surface information obtained to form the prosthetic leg appearance, the fidelity of the imitation of the unaffected lower limb can be maximized. The skin cover (201) can be manufactured by 3D printing using a flexible material such as polypropylene or TPU (Thermoplastic Polyurethane). The skin cover (201) is supported by the imitation part (120) and can be attached to the customized lightweight prosthetic leg frame (100) according to the embodiments. The method of attaching the skin cover (201) to the customized lightweight prosthetic leg frame (100) according to the embodiments is not particularly limited, but, for example, it can be attached by a detachable method using magnets.

[0050] In addition, the customized lightweight prosthetic frame (100) according to the embodiments can be manufactured by considering the structure, range of motion, and assembly tool usage space of the prosthetic mechanism for implementing the function of the prosthetic leg, as described below. That is, the inner structure of the customized lightweight prosthetic frame (100) according to the embodiments can be designed to reflect the shape and operation of the prosthetic mechanism and the assembly method. Therefore, the structure of the prosthetic mechanism to which the customized lightweight prosthetic frame (100) according to the embodiments can be applied is not limited. In the embodiments, the structure of the prosthetic mechanism (210) is not limited to that shown in the drawings, and various structures of the prosthetic mechanism (210) can be applied. For example, the prosthetic mechanism (210) shown in the drawings includes an upper module (220) and a lower module (230), as described in detail below, and a change in load can be sensed through a load cell (231) provided in the lower module (230). At this time, so that the load to be transmitted to the load cell (231) is not dispersed, the customized lightweight prosthetic frame (100) according to the embodiments may be divided into an upper frame (101) connected to the upper module (220) and a lower frame (102) connected to the lower module (230). However, if a prosthetic mechanism of a different structure is applied, the customized lightweight prosthetic frame (100) according to the embodiments may be provided as an integrated type that is not divided, or it may be provided to be divided into two or more parts.

[0051] According to one embodiment, the imitation part (120) includes a plurality of plates, and a prosthetic volume can be formed by the outer surface of such a plurality of plates. The plurality of plates of the imitation part (120) form a prosthetic volume defined using the aforementioned three-dimensional surface information and can form the outer structure of a customized lightweight prosthetic frame (100) according to the embodiments.

[0052] According to one embodiment, the imitation portion (120) may include a plurality of first plates (121) spaced apart along the circumferential direction of the lower limb, formed from the top to the bottom of the prosthetic leg volume. In the first embodiment illustrated in FIGS. 4 to 7, the imitation portion (120) may be provided in the form of a first plate (121) which is a thin plate formed approximately vertically. A plurality of such first plates (121) are arranged along the circumferential direction of the lower limb, and the drawings illustrate an embodiment in which a total of four first plates (121) are arranged in the front, rear, and both sides. The first plates (121) of the imitation portion (120) may be formed in a shape to realize the prosthetic leg volume defined using three-dimensional surface information. Furthermore, by the skin cover (201) covering the first plates (121) and forming the exterior of the lower limb, the fidelity of the imitation of the unaffected lower limb can be maximized. Meanwhile, in the second embodiment, the imitation part (120) is provided in a form including a plurality of second plates (122), and details will be described later.

[0053] As described above, the structure of the prosthetic mechanism to which the customized lightweight prosthetic frame (100) according to the embodiments can be applied is not limited, and the coupling part (110) may be formed in a structure for coupling with the prosthetic mechanism corresponding to the shape of the prosthetic mechanism. Below, we will examine the structure of the prosthetic mechanism (210) according to one embodiment and the structure of the coupling part (110) for coupling thereto.

[0054] According to one embodiment, the prosthetic leg mechanism (210) may include an upper module (220) connected to the user's thigh and a lower module (230) connected to the artificial foot (202). Additionally, the custom lightweight prosthetic leg frame (100) according to the embodiments may be divided into an upper frame (101) connected to the upper module (220) and a lower frame (102) connected to the lower module (230).

[0055] The upper module (220) may include a socket coupling part (110) for performing the role of an artificial knee joint that is coupled to a femoral socket, a driving part (223) connected to the socket coupling part (110) for providing appropriate braking force and damping to the user during walking, and a control part (225) for controlling the driving part (223) and supplying power.

[0056] The socket coupling part (110) may be provided with a portion at the top that is coupled to the thigh socket. Additionally, the socket coupling part (110) is provided with a rotation axis (222) to which the upper frame (101) is rotatably coupled, so that the rotation angle of the prosthetic leg according to the user's walking state can be sensed. For example, the socket coupling part (110) may be equipped with a Hall sensor to sense the rotation angle of the prosthetic leg through changes in magnetic force.

[0057] The drive unit (223) has its upper end rotatably connected to the socket coupling part (110), and its lower end can be rotatably connected to the coupling part (110-3) of the upper frame (101) via a rotation axis (224). The drive unit (223) is provided in an extendable form and may be, for example, a hydraulic cylinder. As the drive unit (223) extends, appropriate braking force and damping can be provided to the user during walking.

[0058] The control unit (225) receives rotation angle information of the prosthetic leg sensed by the socket coupling unit (110), load state information sensed by the load cell (231) of the lower module (230) to be described later, and can control the drive unit (223) based on this. Additionally, the control unit (225) may be equipped with a battery to supply power to the drive unit (223).

[0059] According to one embodiment, the lower module (230) may include a load cell (231) that is coupled to the upper module (220) and senses a change in load. Additionally, according to one embodiment, the lower module (230) includes an upper adapter (232) coupled to the load cell (231) and a lower adapter (233) connected to the artificial foot (202), and the coupling portion (110) of the lower frame (102) may connect the upper adapter (232) and the lower adapter (233). That is, the upper adapter (232) and the lower adapter (233) may be coupled through the coupling portion (110-5) of the lower frame (102). In the existing prosthetic leg structure, the structure of the connecting pipe (12, see FIG. 1) may be replaced by the coupling portion (110-5) of the lower frame (102). The load cell (231) senses changes in load during the user's walking, and this load state information can be transmitted to the control unit (225).

[0060] For the accuracy and precision of sensing the load state information of the load cell (231), the customized lightweight prosthetic frame (100) according to the present embodiments may be divided into an upper frame (101) and a lower frame (102). That is, the upper module (220) of the prosthetic mechanism (210) is coupled to the lower module (230) through the load cell (231), so that all loads during walking are transmitted through the load cell (231) and load changes can be sensed. To prevent such loads from being dispersed, the customized lightweight prosthetic frame (100) according to the present embodiments may be divided into an upper frame (101) coupled to the upper module (220) and a lower frame (102) coupled to the lower module (230). The upper frame (101) and the lower frame (102) may each include a coupling part (110), a mimicry part (120), and a skeletal part (130). For example, the imitation part (120), which is provided from the top to the bottom in the form of a first plate (121), may be divided in the middle so that the upper part belongs to the upper frame (101) and the lower part belongs to the lower frame (102).

[0061] The upper frame (101) may include a coupling part (110) coupled to an upper module (220). More specifically, the upper frame (101) may include a coupling part (110-1) coupled to a rotation axis (222) of a socket coupling part (110), a coupling part (110-2) coupled to a control part (225), a coupling part (110-3) coupled to a rotation axis (224) of a driving part (223), and a coupling part (110-4) coupled to a load cell (231).

[0062] Additionally, the lower frame (102) may include a coupling portion (110) that is coupled with the lower module (230). More specifically, the coupling portion (110-5) of the lower frame (102) may be provided in the form of a hollow shaft that penetrates vertically, and an upper adapter (232) and a lower adapter (233) may be inserted and coupled to the upper and lower ends, respectively.

[0063] As previously described, the imitation part (120) can be determined from the volume of the prosthetic leg defined using three-dimensional surface information, and the coupling part (110) can be formed in a shape to be coupled thereto according to the structure of the prosthetic leg mechanism part (210).

[0064] The skeletal part (130) is configured to connect the imitation part (120) and the coupling part (110), and can be formed to stably maintain the structure of the prosthetic leg (200) and the custom lightweight prosthetic leg frame (100) according to the embodiments, and to properly support the load without interfering with the operation of the prosthetic leg mechanism part (210) during walking, etc. The specific shape of the skeletal part (130) is not particularly limited and can be designed according to the definitions after the maintenance shape, obstacle shape, and constraint and load conditions are defined, as will be described in detail later.

[0065] Next, with reference to FIGS. 8 to 11, we will examine a custom lightweight prosthetic leg frame (100) according to a second embodiment and a prosthetic leg (200) including the same. For components identical to those in the previously described embodiment, the same reference numerals will be used and the descriptions will be brief, with the focus on the differences.

[0066] According to one embodiment, the imitation part (120) includes a plurality of plates, and the volume of the prosthetic leg can be formed by the outer surface of the plurality of plates.

[0067] According to one embodiment, the imitation part (120) may include a plurality of second plates (122) spaced apart along the periphery and up-down directions of the lower limb. In the second embodiment illustrated in FIGS. 8 to 11, the imitation part (120) may be provided in the form of a second plate (122) which is a plate with a roughly rectangular structure. These second plates (122) may be spaced apart along the periphery and up-down directions of the lower limb and may be arranged in a plurality to realize a prosthetic leg volume defined using three-dimensional surface information. Furthermore, by having a skin cover (201) cover the second plate (122) and form the appearance of the lower limb, the fidelity of the imitation of the unaffected lower limb can be maximized.

[0068] In the second embodiment, in which the imitation part (120) is provided in the form of a second plate (122), for the accuracy and precision of the load state information sensing of the load cell (231), the custom lightweight prosthetic frame (100) according to the embodiments may be divided into an upper frame (101) coupled to an upper module (220) and a lower frame (102) coupled to a lower module (230). Likewise, the upper frame (101) and the lower frame (102) of the second embodiment may each include a coupling part (110), an imitation part (120), and a skeletal part (130).

[0069] The upper module (220) may include a socket coupling part (110), a driving part (223), and a control part (225). The socket coupling part (110) can sense the rotation angle of the prosthetic leg according to the user's walking state, and the driving part (223) may be provided in the form of, for example, a hydraulic cylinder to provide appropriate braking force and damping to the user during walking. The control part (225) receives information on the rotation angle of the prosthetic leg sensed by the socket coupling part (110), load state information sensed by the load cell (231) of the lower module (230) to be described later, and can control the driving part (223) based on this.

[0070] The upper frame (101) may include a coupling part (110) coupled to an upper module (220). More specifically, the upper frame (101) may include a coupling part (110-1) coupled to a rotation axis (222) of a socket coupling part (110), a coupling part (110-2) coupled to a control part (225), a coupling part (110-3) coupled to a rotation axis (224) of a driving part (223), and a coupling part (110-4) coupled to a load cell (231).

[0071] Additionally, the lower frame (102) may include a coupling portion (110) that is coupled with the lower module (230). More specifically, the coupling portion (110-5) of the lower frame (102) may be provided in the form of a hollow shaft that penetrates vertically, and an upper adapter (232) and a lower adapter (233) may be inserted and coupled to the upper and lower ends, respectively.

[0072] Next, with reference to FIGS. 12 to 20, we will examine the method for manufacturing a customized lightweight prosthetic frame according to the embodiments.

[0073] By the manufacturing method according to the embodiments, a customized lightweight prosthetic frame according to the first embodiment, a customized lightweight prosthetic frame according to the second embodiment, or another type of customized lightweight prosthetic frame satisfying the technical concept according to the embodiments can be manufactured.

[0074] Referring to FIG. 12, according to the embodiments thereof, a method for manufacturing a customized lightweight prosthetic frame may be provided, comprising the steps of: obtaining three-dimensional surface information to form the external appearance of the prosthetic leg and defining the volume of the prosthetic leg (S100); defining design parameter conditions to implement the function of the prosthetic leg (S200); defining a prosthetic frame that satisfies the defined design parameter conditions (S300); and manufacturing the defined prosthetic frame (S400).

[0075] In the step of defining the volume of the prosthetic leg (S100), three-dimensional surface information for configuring the external appearance of the prosthetic leg is first obtained, and the volume of the prosthetic leg can be defined therefrom. The three-dimensional surface information is information for faithfully reproducing the shape of the user's unaffected lower limb, and according to one embodiment, it can be obtained by 3D scanning and mirroring the user's opposite lower limb. Meanwhile, if it is difficult to 3D scan the user's opposite lower limb, three-dimensional surface information may be obtained from a statistical body shape database, etc., by referring to the dimensions of other body parts such as the user's height, waist circumference, and thigh circumference.

[0076] In the step of defining design parameter conditions (S200), design parameter conditions are defined to satisfy the functional characteristics of the prosthetic leg. According to one embodiment, the step of defining design parameter conditions (S200) may include: a step of defining a starting shape from a defined prosthetic leg volume (S210); a step of defining a retaining shape that mimics the defined prosthetic leg volume (S220); a step of defining an obstacle shape that considers the operating space of the prosthetic leg mechanism (210) (S230); a step of defining restraint and load conditions that consider the operation and durability of the prosthetic leg mechanism (210) (S240); a step of determining a manufacturing method of the prosthetic leg frame (100) (S250); and a step of determining the material of the prosthetic leg frame (100) (S260).

[0077] Referring to FIG. 13, in the starting shape definition step (S210), a starting shape to which a prosthetic leg volume defined from three-dimensional surface information is applied may be defined. This starting shape may be defined by being divided into an upper frame (101) and a lower frame (102). That is, the starting shape may be a step in which the approximate shape of the customized lightweight prosthetic leg frame (100) according to the embodiments is determined.

[0078] Referring to FIG. 14, in the maintenance shape definition step (S220), the shape of the imitation part (120) to which major feature lines or feature points capable of simulating the volume of the prosthetic leg are applied is defined, and the shape of the coupling part (110) to be coupled with the prosthetic leg mechanism part (210) can be defined. That is, the imitation part (120) can be designed in a shape capable of simulating the defined volume of the prosthetic leg, such as the structure of the first plate (121) in the first embodiment, the structure of the second plate (122) in the second embodiment, or a different structure. The coupling part (110) can be designed in a shape to be coupled thereto according to the structure of the prosthetic leg mechanism part (210). In the drawing, an example is shown in which a shaft axis and Hall sensor coupling part (110-1), a controller case coupling part (110-2), a shaft axis and load sensor (load cell) coupling part (110-3, 4), etc. are designed, and a simulation part (120) having the structure of a first plate (121) is designed and the retaining shape of an upper frame (101) is defined, and an example is shown in which a load sensor (load cell) adapter coupling part (232) and an artificial foot adapter coupling part (233) are designed, and a simulation part (120) having the structure of a first plate (121) is designed and the retaining shape of a lower frame (102) is defined.

[0079] Referring to FIG. 15, in the obstacle shape definition step (S230), obstacle shapes such as the structure, range of motion, and assembly tool usage space of the prosthetic leg mechanism (210) may be defined. That is, the obstacle shape definition step (S230) may be a step for considering the structure, operation, and assembly method of the prosthetic leg mechanism used. Looking at the prosthetic leg mechanism (210) described above, the obstacle shape of the upper frame (101) may include the structure and arrangement of the socket coupling part (110), the driving part (223), and the control part (225), the rotational movement around the rotation axis (222, 224), the extension and retraction movement of the driving part (223), and the load cell (231) coupling space. Also, the obstacle shape of the lower frame (102) may include the structure and arrangement of the upper adapter (232) and the lower adapter (233). In addition, the space for using an assembly tool to combine the prosthetic leg mechanism (210) and the coupling part (110) may be considered, and as an example, the drawing shows an example in which the shape of an obstacle is defined for fastening both rotation axes (222, 224) and fastening bolts to the coupling part (110-2, 110-5).

[0080] Referring to FIGS. 16 to 20, in the step of defining restraint and load conditions (S240), a design is performed to satisfy the operation and durability of the prosthetic leg mechanism (210). For example, a design to satisfy ISO 10328 durability test load conditions may be applied to the custom lightweight prosthetic leg frame (100) according to the embodiments. FIGS. 16 to 18 illustrate examples of considering restraint and load conditions applied to the imitation part (120) and the coupling part (110) of the upper frame (101), and FIGS. 19 and 20 illustrate examples of considering restraint and load conditions applied to the imitation part (120) and the coupling part (110) of the lower frame (102).

[0081] In the manufacturing method definition step (S250) and the material definition step (S260), the manufacturing method and material of the customized lightweight prosthetic leg frame (100) according to the embodiments are determined. According to one embodiment, by applying additive manufacturing using 3D printing as the manufacturing method, the manufacturing process can be integrated into a single process. In addition, as the material, for example, aluminum AlSi10Mg, titanium, etc. may be used. However, it is obvious that the manufacturing method and material are not limited to those described above.

[0082] In the prosthetic frame definition step (S300), a prosthetic frame satisfying the previously defined design parameter conditions can be defined. The shape of the retaining part (120) and the connecting part (110) are determined by defining the retaining shape, and the shape of the skeletal part (130) can be designed by applying the obstacle shape, constraint, and load conditions defined therein. Meanwhile, the shapes of the imitation part (120), the connecting part (110), and the skeletal part (130) can be automatically designed through the steps described above, for example, using Autodesk's Fusion 360 design software.

[0083] In the prosthetic frame manufacturing step (S400), the previously defined prosthetic frame can be manufactured according to the previously defined manufacturing method and material.

[0084] According to a custom lightweight prosthetic frame having such a structure, a prosthetic leg including the same, and a method for manufacturing the same, the fidelity of the simulation of the unaffected lower limb is improved, and the number of parts and weight can be reduced by designing the parts in an integrated manner.

[0085] The above description is merely an example of applying the principles of the present disclosure, and other configurations may be included without departing from the scope of the present invention.

[0086] Although embodiments of the present disclosure have been described above, those skilled in the art may modify or change the present disclosure in various ways by adding, changing, deleting, or adding components without departing from the technical spirit of the present disclosure as described in the claims, and such modifications or changes shall also be deemed to be included within the scope of the rights of the present disclosure.

Claims

1. As a prosthetic frame for forming the lower limb appearance by being coupled to a prosthetic mechanism, A connecting part coupled to the above-mentioned prosthetic leg mechanism; A mimic portion forming a prosthetic leg volume for constituting the above-mentioned lower limb appearance; A skeletal part connecting the above-mentioned connecting part and the imitation part; A custom lightweight prosthetic frame including 2. In Paragraph 1, A custom lightweight prosthetic frame in which the above-mentioned imitation part includes a plurality of plates, and the prosthetic volume is formed by the outer surfaces of the plurality of plates.

3. In Paragraph 2, A custom lightweight prosthetic frame comprising a plurality of first plates spaced apart along the circumferential direction of the lower limb, wherein the above-mentioned imitation portion is formed from the top to the bottom of the above-mentioned prosthetic volume.

4. In Paragraph 3, The above-described imitation part comprises a plurality of second plates spaced apart along the circumferential and vertical directions of the lower limb, forming a customized lightweight prosthetic frame.

5. A prosthetic leg comprising a customized lightweight prosthetic leg frame according to claim 1 and the prosthetic leg mechanism said above, Artificial foot; The above-mentioned prosthetic device includes an upper module connected to the user's thigh and a lower module connected to the artificial foot, and The above-described custom lightweight prosthetic frame is divided into an upper frame coupled to the upper module and a lower frame coupled to the lower module, forming a prosthetic leg.

6. In Paragraph 5, A prosthetic leg further comprising a skin cover that is supported by the above-mentioned imitation part and covers the above-mentioned custom lightweight prosthetic leg frame to form the above-mentioned lower limb appearance.

7. In Paragraph 5, The above lower module is combined with the above upper module and includes a load cell that senses changes in load, a prosthetic leg.

8. In Paragraph 7, The lower module includes an upper adapter coupled to the load cell and a lower adapter connected to the artificial foot, and The joint of the lower frame above connects the upper adapter and the lower adapter, prosthetic leg.

9. A method for manufacturing a customized lightweight prosthetic frame according to claim 1, A step of defining the volume of the prosthetic leg by acquiring three-dimensional surface information for configuring the external appearance of the prosthetic leg; A step of defining design parameter conditions to implement the function of the prosthetic leg; A step of defining a prosthetic frame that satisfies the design parameter conditions defined above; A step of manufacturing the prosthetic frame defined above; A method for manufacturing a customized lightweight prosthetic frame, comprising 10. In Paragraph 9, A method for manufacturing a customized lightweight prosthetic frame, wherein the above 3D surface information is obtained by 3D scanning and mirroring the user's opposite lower limb.

11. In Paragraph 9, The step of defining the above design parameter conditions is, A step of defining a starting shape from the above-defined prosthetic leg volume; A step of defining a retaining shape that mimics the volume of the prosthetic leg defined above; A step of defining an obstacle shape that considers the operating space of the above-mentioned prosthetic leg mechanism; A step of defining restraint and load conditions that consider the operation and durability of the above-mentioned prosthetic device; A step of determining the manufacturing method of the above-mentioned prosthetic frame; A step of determining the material of the above-mentioned prosthetic leg frame; A method for manufacturing a customized lightweight prosthetic frame, comprising

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