Modular Prosthetic Socket Using Adjustable Struts
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Solution Overview
Problem
Conventional prosthetic socket manufacturing is labor-intensive, time-consuming, and inflexible, requiring skilled craftsmen and resulting in sockets that are difficult to modify as the residual limb changes shape or size over time, leading to discomfort and the need for frequent re-fabrication.
Innovation Solution
A modular prosthetic socket assembly using assembleable components such as thermoplastic-fiber composite struts and distal bases, allowing for adjustable fit and easy modification through mechanical adjustments and tensioning mechanisms, enabling quick assembly and reconfiguration to accommodate changes in the residual limb.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional prosthetic socket manufacturing methods are used, then the socket can be fabricated with initial fit, but it cannot be easily modified when the residual limb changes shape or size over time
Solution Approach 1:
The prosthetic socket is divided into multiple modular components including a socket base, at least one strut with adjustable positioning, and a distal end assembly. These segmented components can be independently adjusted and reconfigured to accommodate changes in the residual limb's shape and size over time, eliminating the need for complete re-fabrication.
Solution Approach 2:
The socket incorporates dynamic adjustment mechanisms such as adjustable struts that can be repositioned relative to the socket base, and a distal end assembly that can be reconfigured. These dynamic elements allow the socket to adapt to changing residual limb conditions without requiring manual re-fabrication, providing ongoing adaptability throughout the prosthetic's service life.
2Manufacturing precision
If conventional custom-fabrication methods are used, then the socket can be patient-specific, but the process is labor intensive and time consuming
Solution Approach 1:
The modular component structure allows for standardized manufacturing of individual parts (socket base, struts, distal end assembly) that can be produced more efficiently through modern manufacturing techniques. These pre-fabricated components are then assembled and adjusted to achieve patient-specific fit, significantly reducing the overall production time while maintaining customization and precision.
Solution Approach 2:
The modular components are designed with universal interfaces and standardized features that can be used across different patient applications. This universality enables efficient production through standardized manufacturing processes while still allowing for patient-specific adjustments during assembly, thereby improving productivity without sacrificing manufacturing precision.
3Reliability
If conventional fixed-form sockets are used, then the initial fabrication can be completed, but frequent re-fabrication is needed when the residual limb changes
Solution Approach 1:
The socket incorporates dynamic adjustment mechanisms including adjustable struts and reconfigurable distal end assemblies that can be modified in the field without requiring complete re-fabrication. This dynamic capability maintains reliable fit over time as the residual limb changes, eliminating the need for frequent re-fabrication and reducing the time loss associated with replacement.
Solution Approach 2:
Instead of discarding the entire socket when adjustments are needed, the modular design allows for selective replacement or reconfiguration of individual components such as the distal end assembly or struts. This approach recovers the usable portions of the original socket, maintaining fit reliability while minimizing the time and resources required for modifications compared to complete re-fabrication.
Data Source
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AI summary
Embodiments of a modular prosthetic socket for a residual limb of a lower extremity of a patient are provided. Modular components include a base, multiple strut connectors, and multiple longitudinal struts. The base is selected from a collection of bases. The multiple strut connectors are selected from a collection of strut connectors, each strut connector being adjustably connectable to the base along the periphery of the base. The multiple longitudinal struts are selected from a collection of struts, each strut including a thermoplastic-fiber composite material, each strut being connectable to the base along the base periphery via one of the strut connectors. At least one of the component collections includes at least one of multiple sizes or multiple shapes of bases, struts or strut connectors, respectively. The prosthetic socket circumscribes a proximally-open internal space configured to conform to the residual limb of the patient.