One-Piece Carbon Fiber Foot Prosthesis Spring Design
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Solution Overview
Problem
Modern foot prostheses with carbon laminate construction face limitations in mobility and spring characteristics due to the integration of heel damping elements, which shortens effective spring lengths and reduces deformation possibilities, leading to reduced adaptability on different ground surfaces and unevenness.
Innovation Solution
A one-piece, closed carbon fiber composite component forms the spring structure of the foot prosthesis, eliminating the need for special connection elements and allowing maximum spring length and excursion, enabling homogeneous deformation and torsional flexibility, with optional elastomer elements for additional damping and adjustability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heel damping elements are integrated into the prosthesis structure, then damping performance is improved, but spring length and deformation capability are reduced
Solution Approach 1:
The prosthesis is divided into distinct functional zones: a heel damping zone with integrated elastomer elements for impact absorption, and a forefoot spring zone with maximum length for energy storage and return. This segmentation allows each region to optimize its specific function without compromising the other.
Solution Approach 2:
Different material properties and structural characteristics are applied to different regions of the prosthesis. The heel area uses damping-optimized elastomer materials with specific Shore hardness values, while the forefoot spring area uses carbon fiber composite laminates with optimized fiber orientations and thicknesses to maximize elastic deformation capability.
2Strength
If connection elements are used to couple upper and lower parts, then structural integrity is improved, but spring excursion and mobility are reduced
Solution Approach 1:
The upper and lower parts of the prosthesis are merged into a single integrated carbon fiber composite shell structure. This unified construction eliminates the need for separate connection elements between parts, allowing continuous spring deformation throughout the entire prosthesis length while maintaining structural integrity through the composite material design.
Solution Approach 2:
A carbon fiber composite laminate structure is used to create a unified prosthesis body that provides both the necessary structural strength and the required spring characteristics. The composite material allows for anisotropic mechanical properties, with high strength in load-bearing directions and controlled flexibility in deformation directions.
3Stability of the object's composition
If the prosthesis structure is rigidly braced for secure connection, then stability is improved, but adaptability to ground surfaces is reduced
Solution Approach 1:
The prosthesis incorporates dynamic deformation capabilities through its spring structure, allowing it to adapt to varying ground conditions. The forefoot spring zone can deflect and twist in response to uneven surfaces, while the heel damping zone provides stable impact absorption, creating a dynamically adaptive connection to the ground.
Solution Approach 2:
The prosthesis design allows for adjustment of key parameters including elastomer Shore hardness, carbon fiber laminate thickness and orientation, and spring pre-tension. These parameter variations enable customization of the prosthesis characteristics to match different user requirements and ground conditions while maintaining stable connection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design provides uninterrupted spring action, enhanced mobility, and balanced pronation and supination, allowing better adaptation to various ground surfaces and unevenness, while allowing for adjustable hardness and energy return.
Implementation Method 1
the actual prosthesis body, namely the spring composed of upper part and lower part, is formed using only a one-piece, closed component, which is made from a carbon fiber composite
Implementation Method 2
an elastomer element (16), which damps the inward spring movement
Data Source
AI summary
Foot prosthesis, comprising an upper part, and a lower part that is placed on the ground when walking, which parts extend one above the other and at a distance from each other, are connected to each other at the forefoot and the heel and, forming a spring, move relative to each other during walking, wherein the upper part (3) and the lower part (4) are formed by means of a one-piece, closed component (2) made from a carbon fiber composite.