Double-wall prosthetic limb assembly

1. A double-wall prosthetic limb socket assembly comprising:

a first substantially rigid inner-wall socket adapted to receive a patient's residual limb; and

a second substantially rigid outer-wall socket slidingly and removably seating the first inner-wall socket therein with a resilient liner fitted over the first substantially rigid inner wall socket and interposing the first substantially rigid inner-wall socket and the second substantially rigid outer-wall socket, the second outer-wall socket including,

a distal, circular base-plate; and

a molded circumferential wall bonded to and extending proximally from the distal, circular base-plate;

the circular base-plate including a vacuum port extending radially from a circumferential outer side of the base-plate in fluid communication with a vacuum channel extending through the circular base-plate and out through an outlet hole in a proximal side of the circular base-plate;

whereby, when the vacuum port is coupled to a vacuum pump, the vacuum will help to draw the first inner-wall socket into the second outer-wall socket;

wherein the first substantially rigid inner-wall socket and the second substantially rigid outer-wall socket comprise at least one of (a) substantially hard thermoset plastic and (b) layers of fabric-type material impregnated with cured resin; wherein the resilient liner comprises a substantially closed distal end and an open proximal end; and wherein the resilient liner is adapted to be rolled proximally over the first substantially rigid inner wall socket.

2. The double-wall prosthetic limb socket assembly of claim 1 , wherein the circular base-plate includes one or more indentations extending into a circumferential outer side of the circular base-plate into which material of the molded circumferential wall is received, thus facilitating a mechanical bond between the circular base-plate and the molded circumferential wall.

3. The double-wall prosthetic limb socket assembly of claim 1 , wherein the circular base-plate is less than 0.75 inches thick.

4. The double-wall prosthetic limb socket assembly of claim 1 , further comprising:

a first one of a female and a male component of a mechanical lock seated between the first inner-wall socket and the second outer-wall socket over a proximal end of the circular base-plate; and

a complimentary component of the first component of the mechanical lock extending distally from the first inner-wall socket and mating with the first component of the mechanical lock thus providing a mechanical lock between the first inner-wall socket and second outer-wall socket.

5. The double-wall prosthetic limb socket assembly of claim 4 , wherein:

the first component of the mechanical lock is a male, ratchet-type interlock pin; and

the complimentary component of the mechanical lock is a female, biased-pawl type lock base.

6. The double-wall prosthetic limb socket assembly of claim 5 , wherein the interlock pin extends from the resilient liner fitted over the first inner-wall socket and includes a vacuum channel extending completely therethrough in fluid communication with the outlet hole of the circular base-plate when locked into the lock base and providing a vacuum between the resilient sleeve and the inner-wall socket.

7. The double-wall prosthetic limb socket assembly of claim 1 , wherein the distal end of the circular base-plate includes a fastener for coupling to a prosthetic limb upright assembly.

8. The double-wall prosthetic limb socket assembly of claim 1 , wherein the distal end of the circular base-plate is coupled to a prosthetic limb pyramid coupling component.

9. The double-wall prosthetic limb socket assembly of claim 1 , wherein the substantially hard thermoset plastic comprises substantially hard polyester resin, acrylic resin, polypropylene, and polyethylene.

10. A double-wall prosthetic limb socket assembly comprising:

a first substantially rigid inner-wall socket adapted to receive a patient's residual limb;

a second substantially rigid outer-wall socket slidingly and removably seating the first inner-wall socket therein with a resilient liner fitted over the first substantially rigid inner wall socket and interposing the first substantially rigid inner-wall socket and the second substantially rigid outer-wall socket, the second outer-wall socket including,

a distal, circular base-plate; and

a molded circumferential wall bonded to and extending proximally from the distal, circular base-plate;

a first one of a female and a male component of a mechanical lock seated between the first inner-wall socket and the second outer-wall socket over a proximal end of the circular base-plate; and

a complimentary component of the first component of the mechanical lock extending distally from the first inner-wall socket and mating with the first component of the mechanical lock thus providing a mechanical lock between the first inner-wall socket and second outer-wall socket;

the circular base-plate including a vacuum port extending through an outer surface of the base-plate in fluid communication with a vacuum channel extending through the circular base-plate and an outlet hole in a proximal side of the circular base-plate;

whereby, when the vacuum port is coupled to a vacuum pump, the vacuum will help to draw the first inner-wall socket into the second outer-wall socket;

wherein the first substantially rigid inner-wall socket and the second substantially rigid outer-wall socket comprise at least one of (a) substantially hard thermoset plastic and (b) layers of fabric-type material impregnated with cured resin; wherein the resilient liner comprises a substantially closed distal end and an open proximal end; and wherein the resilient liner is adapted to be rolled proximally over the first substantially rigid inner wall socket.

11. The double-wall prosthetic limb socket assembly of claim 10 , wherein:

the first component of the mechanical lock is a male, ratchet-type interlock pin; and

the complimentary component of the mechanical lock is a female, biased-pawl type lock base.

12. The double-wall prosthetic limb socket assembly of claim 11 , wherein the interlock pin extends from the resilient liner fitted over the first inner-wall socket and includes a vacuum channel extending completely therethrough in fluid communication with the outlet hole of the circular base-plate when locked into the lock base and providing a vacuum between the resilient sleeve and the inner-wall socket.

13. The double-wall prosthetic limb socket assembly of claim 10 , wherein the distal end of the circular base-plate includes a fastener for coupling to a prosthetic limb upright assembly.

14. The double-wall prosthetic limb socket assembly of claim 10 , wherein the distal end of the circular base is coupled to a prosthetic limb pyramid coupling component.

15. The double-wall prosthetic limb socket assembly of claim 10 , wherein the substantially hard thermoset plastic comprises substantially hard polyester resin, acrylic resin, polypropylene, and polyethylene.

16. A double-wall prosthetic limb socket assembly comprising:

a first substantially rigid inner-wall socket adapted to receive a patient's residual limb; and

a second substantially rigid outer-wall socket slidingly and removably seating the first inner-wall socket therein with a resilient liner fitted over the first inner wall socket and interposing the first inner-wall socket and the second outer-wall socket, the second outer-wall socket including,

a distal, circular base-plate; and

a molded circumferential wall bonded to and extending proximally from the distal, circular base-plate;

the circular base-plate including one or more indentations extending into a circumferential outer side of the circular base-plate into which material of the molded circumferential wall is received, thus facilitating a mechanical bond between the circular base-plate and the molded circumferential wall;

the circular base-plate also including a vacuum port extending through an outer surface of the base-plate in fluid communication with a vacuum channel extending through the circular base-plate and an outlet hole in a proximal side of the circular base-plate;

whereby, when the vacuum port is coupled to a vacuum pump, the vacuum will help to draw the first inner-wall socket into the second outer-wall socket;

wherein the first substantially rigid inner-wall socket and the second substantially rigid outer-wall socket comprise at least one of (a) substantially hard thermoset plastic and (b) layers of fabric-type material impregnated with cured resin; wherein the resilient liner comprises a substantially closed distal end and an open proximal end; and wherein the resilient liner is adapted to be rolled proximally over the first substantially rigid inner wall socket.

17. The double-wall prosthetic limb socket assembly of claim 15 , wherein the circular base-plate is less than 0.75 inches thick.

18. A double-wall prosthetic limb socket assembly comprising:

a first substantially rigid inner-wall socket adapted to receive a patient's residual limb; and

a second substantially rigid outer-wall socket slidingly and removably seating the first inner-wall socket therein with a resilient liner fitted over the first substantially rigid inner wall socket and interposing the first substantially rigid inner-wall socket and the second substantially rigid outer-wall socket, the second outer-wall socket including,

a distal, circular base-plate; and

a molded circumferential wall bonded to and extending proximally from the distal, circular base-plate;

the circular base-plate including one or more projections extending from a circumferential outer side of the circular base-plate around which material of the molded circumferential wall is received, thus facilitating a mechanical bond between the circular base-plate and the molded circumferential wall;

the circular base-plate also including a vacuum port extending through an outer surface of the base-plate in fluid communication with a vacuum channel extending through the circular base-plate and an outlet hole in a proximal side of the circular base-plate;

whereby, when the vacuum port is coupled to a vacuum pump, the vacuum will help to draw the first inner-wall socket into the second outer-wall socket;

wherein the first substantially rigid inner-wall socket and the second substantially rigid outer-wall socket comprise at least one of (a) substantially hard thermoset plastic and (b) layers of fabric-type material impregnated with cured with resin; wherein the resilient liner comprises a substantially closed distal end and an open proximal end; and wherein the resilient liner is adapted to be rolled proximally over the first substantially rigid inner wall socket.