Prosthetic limb kit and method of manufacture

A kit for preparing a prosthetic leg for a person having a missing portion of a leg and a remaining stump, the kit consisting of:

• a sock adapted to fit over the person's stump;
• a separator bag adapted to cover the sock and the person's stump, the separator bag having an open end and a closed end, the closed end having dimensions sufficient for covering the sock without exposing the sock;
• a distal pad having smooth surfaces configured and dimensioned for placement below the person's stump to provide cushioning;
• an inner coupling member having a concave lower surface and an upper inner surface forming an opening configured and dimensioned to receive at least part of the distal pad therein and to hold the distal pad in position below the person's stump;
• a flexible sheath having a closed end adapted to receive the inner coupling member and distal pad therein and an open end which allows the sheath to be extended over the separator bag and sock to hold the inner coupling member and the distal pad against the person's stump;
• a casting sock comprising a fabric containing a water activated settable material that, after activation, is adapted to fit over the flexible sheath, the inner coupling member, the distal pad, and at least part of the separator bag and the sock when those components are in position on the person's stump;
• an outer coupling member having a lower surface that includes a socket having an opening and an upper surface configured to receive the concave lower surface of the inner coupling member and being at least partially conformable about the inner coupling member;
• a casting tape comprising a fabric containing a water activated settable material and provided in a length or lengths that, after activation, are sufficient for attaching the outer coupling member to the person's stump while also covering the flexible sheath, the inner coupling member;
• the distal pad, and at least part of the separator bag and sock when those components are in position on the person's stump;
• a wooden dowel and a pylon comprising a plastic hollow tube configured to receive the wooden dowel each of the wooden dowel and the pylon having a length that is adjustable to provide an overall length for the prosthetic leg to conform to the length needed for the person;
• an artificial knee joint that is operatively associated with the pylon to provide knee movement to the prosthesis when constructed;
• components for forming an artificial foot that can support a wearer's weight during use, with the artificial foot comprising a plurality of shapeable members, one of which includes a hole for accommodating the pylon;
• and
• an adhesive for attaching the foot components together, for attaching the pylon or the wooden dowel to the hole of the foot component and to the socket opening of the outer coupling member, and for attaching the outer coupling member to the casting sock.

A method for preparing a prosthetic leg for a person having a missing portion of a leg and a remaining stump, which comprises:

• Providing a kit consisting of:
• a sock adapted to fit over the person's stump;
• a separator bag adapted to cover the sock and the person's stump, the separator bag having an open end and a closed end, the closed end having dimensions sufficient for covering the sock without exposing the sock;
• a distal pad having smooth surfaces configured and dimensioned for placement below the person's stump to provide cushioning;
• an inner coupling member having a concave lower surface and an upper inner surface forming an opening configured and dimensioned to receive at least part of the distal pad therein and to hold the distal pad in position below the person's stump;
• a flexible sheath having a closed end adapted to receive the inner coupling member and distal pad therein and an open end which allows the sheath to be extended over the separator bag and sock to hold the inner coupling member and the distal pad against the person's stump;
• a casting sock comprising a fabric containing a water activated settable material that, after activation, is adapted to fit over the flexible sheath, the inner coupling member, the distal pad, and at least part of the separator bag and the sock when those components are in position on the person's stump;
• an outer coupling member having a lower surface that includes a socket having an opening, and an upper surface configured to receive the concave lower surface of the inner coupling member and being at least partially conformable about the inner coupling member;
• a casting tape comprising a fabric containing a water activated settable material and provided in a length or lengths that, after activation, are sufficient for attaching the outer coupling member to the person's stump while also covering the flexible sheath, the inner coupling member, the distal pad, and at least part of the separator bag and sock when those components are in position on the person's stump;
• a wooden dowel and a pylon comprising a plastic hollow tube configured to receive the wooden dowel, each of the wooden dowel and the pylon having a length that is adjustable to provide an overall length for the prosthetic leg to conform to the length needed for the person;
• components for forming an artificial foot that can support a wearer's weight during use, with the artificial foot comprising a plurality of shapeable members, one of which includes a hole for accommodating the pylon;
• and
• an adhesive for attaching the foot components together, for attaching the pylon or the wooden dowel to the hole of the foot component and to the socket opening of the outer coupling member, and for attaching the outer coupling member to the casting sock
• and including strap members for assisting in retaining the prosthetic leg upon the person's stump during use;
• applying the sock over the person's stump;
• applying the separator bag over the sock and the person's stump;
• placing the distal pad below the person's stump;
• placing the inner coupling member below the distal pad to receive at least part of the distal pad therein and to hold the distal pad in position below the person's stump;
• applying the flexible sheath with the closed end placed around the inner coupling member and distal pad and with the open end extending the sheath over the separator bag and sock to hold those components against the person's stump;
• activating the casting sock by immersion in water and applying the activated casting sock to the flexible sheath;
• providing the upper surface of the outer coupling member beneath the closed end of the flexible sheath with the upper surface receiving the concave lower surface of the inner coupling member;
• conforming the upper surface of the outer coupling member at least partially about the distal pad;
• activating the casting tape by immersion in water;
• attaching the outer coupling member to the person's stump by wrapping the activated casting tape around the outer coupling member while also covering the flexible sheath, the inner coupling member, the distal pad, and at least part of the separator bag and sock when those components are in position on the person's stump;
• cutting the pylon to an appropriate length so that the prosthetic leg provides the correct height for the person;
• shaping the artificial foot components;
• adhesively attaching the shaped components of the artificial foot together to form the artificial foot;
• and
• adhesively attaching one end of the pylon to the socket opening of the outer coupling member and the other end of the pylon to the hole in the foot component of the artificial foot.