Apparatus and Method of Fitting a Prosthetic Using Structural Fabrics

A prosthetic socket system for securing a residual limb, comprising:

• (a) a flexible inner socket structure configured to conform to the shape of the residual limb, the flexible inner socket structure comprising:
• (i) a plurality of modular conforming panels selectively adhered together in anatomically specific regions to form a composite flexible inner socket;
• (ii) wherein at least a portion of the conforming panels are non-stretch;
• and
• (iii) wherein the composite flexible inner socket comprises:
• (A) portions that contact and cover a portion of the residual limb,
• (B) portions that do not contact and cover portions of the residual limb,
• (C) portions that are not circumferentially connected around the residual limb,
• (D) portions that do not extend continuously in a longitudinal direction from the proximal end to the distal end of the residual limb;
• (iv) wherein at least a portion of the composite flexible inner socket remains conforming after formation of the composite flexible inner socket;
• (b) an external frame structure configured to provide structural support to the composite flexible inner socket and the residual limb during weight bearing, the external frame structure comprising:
• (i) a distal end configured for modular connection to prosthetic foot or knee components;
• (ii) a proximal end configured to attach and secure the composite flexible inner socket such that the composite flexible inner socket is at least partially suspended therefrom;
• and
• (iii) wherein the external frame structure overlaps only a portion of the composite flexible inner socket;
• (c) a circumferential containment system configured to conform to and control the shape of at least a portion of the composite flexible inner socket, the circumferential containment system comprising:
• (i) at least one set of conforming straps positioned circumferentially around the composite flexible inner socket and the external frame structure;
• (ii) an adjustor means operable to vary the tension of the conforming straps to effect selective circumferential tightening for secure containment of the residual limb within the composite flexible inner socket and external frame structure combination;
• and
• (iii) wherein at least a portion of the conforming straps forms at least a portion of a prosthetic socket system's brim;
• wherein the interplay between the outward forces exerted by the residual limb from within the prosthetic socket system and the inward forces resulting from the tension exerted by the circumferential containment system defines the anatomically specific socket shape and contouring of at least a portion of the composite flexible inner socket materials, and wherein the prosthetic socket system provides structural integrity to support weight bearing, biomechanical control of the residual limb during weight bearing, and anatomically appropriate contouring for comfortable ambulation.

A prosthetic socket brim assembly, comprising:

• (a) a frame structure;
• (b) a plurality of conforming panels configured to form at least a portion of a brim;
• (c) at least a portion of the panels being connected to or suspended from the frame structure;
• (d) a fabric webbing component forming at least a portion of a brim of the prosthetic socket assembly, which is connected to at least a portion of the conforming panels;
• and
• (e) an adjustment means operably coupled with the fabric webbing component, the adjustment means configured to selectively vary the tension of the fabric webbing component;
• wherein selective tensioning of the fabric webbing component applies an inward force on the conforming panels such that the interplay between outward forces exerted by a residual limb and the inward forces resulting from the tension of the fabric webbing component defines an anatomically specific custom-fit brim shape and contouring of at least a portion of the conforming panels.

A method of fitting a prosthetic socket to a residual limb, comprising:

• (a) modularly attaching a plurality of conforming panels—each panel having predetermined non-stretch and conformable regions and configured for hook-and-loop-compatible interconnection—in a selectively arranged manner based on the residual limb's anatomy to form a composite flexible inner socket having regions of tailored support, cushioning, and stretch properties, including contiguous areas designed to contact the limb and non-contiguous areas to permit ventilation and tissue movement;
• (b) assembling an external frame structure about the residual limb, the external frame structure including a proximal attachment interface for suspending the composite flexible inner socket and a distal modular connection configured for attachment to prosthetic foot or knee components, wherein the frame structure aids in aligning the limb and supporting weight bearing;
• (c) coupling the composite flexible inner socket to the external frame structure at a plurality of predetermined attachment points that secure the inner socket to the frame while maintaining its anatomical contour;
• and
• (d) adjusting a tensioning mechanism associated with an integrated circumferential containment system—comprising one or more adjustable straps that form at least a portion of the socket's brim—to selectively tighten the composite flexible inner socket about the residual limb, thereby effecting a secure, custom-fit interface that dynamically conforms in real time to the unique contours and force distribution of the limb.

An external frame structure for a prosthetic socket system for securing a residual limb and supporting an anatomical knee joint, comprising:

• (a) knee stabilizer components positioned medially and laterally around an anatomical knee to support the anatomical knee joint;
• (b) at least one knee stabilizer component with an adjustment mechanism operably connected to the knee stabilizer, the adjustment mechanism configured to vary the angular orientation and/or positional placement of the knee stabilizer relative to the residual limb;
• (c) an adjustment interface coupled to the knee stabilizer adjustment mechanism and operable by a user to set the knee stabilizer to an optimal alignment relative to the residual limb;
• and
• (d) an integrated locking feature associated with the knee stabilizer adjustment mechanism, the locking feature configured to securely maintain the adjusted position of the knee stabilizer during weight-bearing activities without unintended movement.