Prosthetic valve system and process for sealing a socket

Abstract

A valve housing for a prosthetic socket has a secure leak-free mechanical interlock formed between the valve housing and the socket. A valve housing has an opening for receiving a removable relief valve. A plug separate from the relief valve is first removably secured in the opening in the valve housing, followed by fastening the valve housing and the plug to a model defining the shape of the finished socket. The fastened plug closes off the opening through the valve housing. The exterior wall of the valve housing has a mechanical interlock, preferably a pair of O-rings extending circumferentially around the body of the valve housing. A thermoplastic material is drawn down over the plugged valve housing and around the interlock device to cover the valve housing and the model. In one embodiment, a releasable pressure clamp is applied to the softened plastic that extends circumferentially around the exterior of the valve housing. The clamp applies circumferential pressure inwardly to the plastic as it cools to form a secure bond and interlock between the plastic and the O-ring-sealed valve housing. Any plastic covering the plug can be removed and the plug is removed from the valve housing, leaving an annular lip or locking flange of the plastic material on an annular end face of the valve housing, which retains the valve against movement from downward pressure and avoids leakage of air between the valve housing and the plastic socket.