Segmented Prosthetic Pylon Frame for Shock Absorption
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Solution Overview
Problem
Conventional below-the-knee prosthetics are uncomfortable due to the rigidity of titanium pylons, which fail to absorb shock effectively, leading to discomfort and potential injuries in amputees, and are costly and time-consuming to manufacture, with limited customization options.
Innovation Solution
A prosthetic device featuring an internal frame assembled from multiple planar longitudinal and transverse members with peripheral slots, allowing for lightweight, crush-resistant structures that can withstand axial and torsional loads, and providing increased internal space for components, which can be customized to fit individual users and include shock-absorbing features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a simple titanium pylon is used for the load-bearing portion, then the structure is lightweight and easy to manufacture, but it is too rigid and fails to absorb shock effectively, causing discomfort and potential injuries
Solution Approach 1:
The pylon is divided into multiple segments or zones with varying properties. The patent describes a pylon with a proximal portion, intermediate portion, and distal portion, where each section can have different structural characteristics to optimize both strength and shock absorption. This segmentation allows the structure to be manufactured from a single material while achieving gradient properties through geometric variation.
Solution Approach 2:
The patent implements local quality by varying the cross-sectional geometry, wall thickness, or internal structure at different locations along the pylon. The proximal portion may have different structural characteristics than the distal portion to match the varying mechanical requirements and shock absorption needs at different heights, while maintaining ease of manufacture through techniques like variable thickness extrusion or selective reinforcement.
2Strength
If conventional titanium pylons are used, then the structure provides sufficient strength, but production time and costs are high, and customization options are limited
Solution Approach 1:
The patent employs parameter changes by varying geometric parameters such as cross-sectional area, wall thickness, curvature, or internal rib structures along the length of the pylon. These parameter variations can be achieved through modern manufacturing techniques like CNC machining, extrusion with variable profiles, or additive manufacturing, allowing customization without significantly increasing production time or cost.
Solution Approach 2:
The patent describes a universal pylon design that can serve multiple functions: load bearing, shock absorption, and potential integration with electronic components or sensors. The standardized yet adaptable geometry allows the same basic pylon structure to be used across different prosthetic leg models while permitting customization through parameter adjustment, thereby improving productivity through economies of scale.
3Device complexity
If conventional prosthetic structures are used, then the design is simple, but internal space for electronic components and customization is limited
Solution Approach 1:
The patent describes a pylon structure with internal cavities, channels, or hollow sections that can accommodate electronic components, batteries, or sensors. The nested design allows components to be integrated within the pylon itself rather than requiring external mounting, thereby increasing internal space without significantly increasing external dimensions or structural complexity.
Solution Approach 2:
The patent utilizes dimensional optimization by transitioning from solid to hollow or partially hollow structures, creating internal volume while maintaining external dimensions. The pylon may feature varying wall thicknesses, internal ribs, or modular sections that provide space for components in the radial or longitudinal dimensions without compromising structural integrity or increasing overall complexity.
Data Source
AI summary
A prosthetic device includes an internal frame assembled from multiple longitudinal members and multiple transverse members that are substantially planar in character and are arranged to be joined together. A medially arranged opening is defined in each transverse member, and is substantially registered with openings of adjacent transverse members to form a longitudinal passage, such as may be useful to receive an actuator and/or other items. At least some transverse members differ from one another in one or more of shape, length, or width. A covering member may be provided over the internal frame. Rear-facing gaps in transverse members may receive one or more elements such as dampers, batteries, or the like.