Orthotic or prosthetic cushioned device and method of making the same

Abstract

Orthotic and prosthetic devices having integrated features such as cushioning features are described, as well as methods for computer aided designing and making of these devices. The orthotic or prosthetic devices comprise a cushioning layer superimposed onto an orthotic or prosthetic shell, the cushioning layer comprising an array ( 35 ) of discrete solid and resilient cushioning elements ( 31 ). In one preferred embodiment, said cushioning structure is a beam, defined around a centerline of any arbitrary shape. In another preferred embodiment, said cushioning structure has the shape of a spiral.

1 - 20 . (canceled) 
     
     
         21 . An orthotic or prosthetic device comprising:
 a plurality of orthotic or prosthetic shells and a plurality of cushioning layers forming a sandwich structure,   the plurality of cushioning layers comprising one or more cushioning elements that are homogenously formed with the plurality of orthotic or prosthetic shells, wherein at least one of the cushioning elements comprises a first side and a second side opposite the first side, wherein the first side is superimposed onto a first shell of the plurality of orthotic or prosthetic shells and wherein the second side is superimposed onto a second shell of the plurality of orthotic or prosthetic shells that is different from the first shell.   
     
     
         22 . The orthotic or prosthetic device of  claim 21 , wherein the at least one of the cushioning elements comprises a beam. 
     
     
         23 . The orthotic or prosthetic device of  claim 22 , wherein the beam is wider in a first direction than in a second direction. 
     
     
         24 . The orthotic or prosthetic device of  claim 21 , wherein the one or more cushioning elements and said plurality of orthotic or prosthetic shells are formed from the same material. 
     
     
         25 . The orthotic or prosthetic device of  claim 21 , wherein the at least one of the cushioning elements comprises a spiral. 
     
     
         26 . The orthotic or prosthetic device of  claim 21 , wherein the at least one of the cushioning elements comprises a rectangular shape. 
     
     
         27 . The orthotic or prosthetic device of  claim 21 , wherein said plurality of cushioning layers comprise a plurality of different types of cushioning elements. 
     
     
         28 . The orthotic or prosthetic device of  claim 21 , wherein at least one of the plurality of cushioning layers comprises a first cushioning area having first cushioning properties and a second cushioning area having second cushioning properties different from the first cushioning properties for adapting the orthotic or prosthetic device to a patient. 
     
     
         29 . The orthotic or prosthetic device of  claim 21 , wherein the at least one of the cushioning elements protrudes from at least one of the first shell or the second shell at an angle. 
     
     
         30 . The orthotic or prosthetic device of  claim 29 , wherein the angle is less than 90°. 
     
     
         31 . The orthotic or prosthetic device of  claim 21 , wherein the at least one of the cushioning elements comprises folds configured to deform when absorbing forces. 
     
     
         32 . The orthotic or prosthetic device of  claim 21 , wherein the sandwich structure forms a hollow volume with the one or more cushioning elements inside. 
     
     
         33 . The orthotic or prosthetic device of  claim 21 , further comprising at least one second cushioning element having a first side that is superimposed onto at least one of the first shell, the second shell, or a third shell of the plurality of orthotic or prosthetic shells and a second side for contacting a part of at least one of a user or an item directly contacting the user. 
     
     
         34 . A device configured to be worn by a user, comprising:
 a body arranged to spread pressure between a body part of the user and the device; and   a plurality of orthotic or prosthetic shells and a plurality of cushioning layers forming a sandwich structure, the plurality of cushioning layers comprising one or more cushioning elements that are homogenously formed with the plurality of orthotic or prosthetic shells, wherein at least one of the cushioning elements comprises a first side and a second side opposite the first side, wherein the first side is superimposed onto a first shell of the plurality of orthotic or prosthetic shells and wherein the second side is superimposed onto a second shell of the plurality of orthotic or prosthetic shells that is different from the first shell.   
     
     
         35 . The device of  claim 34 , wherein the at least one of the cushioning elements comprises a beam. 
     
     
         36 . The device of  claim 35 , wherein the beam is wider in a first direction than in a second direction. 
     
     
         37 . The device of  claim 34 , wherein the one or more cushioning elements and said plurality of orthotic or prosthetic shells are formed from the same material. 
     
     
         38 . The device of  claim 34 , wherein the at least one of the cushioning elements comprises a spiral. 
     
     
         39 . The device of  claim 34 , wherein the at least one of the cushioning elements comprises a rectangular shape. 
     
     
         40 . The device of  claim 34 , wherein said plurality of cushioning layers comprise a plurality of different types of cushioning elements.