Automatic anchor insertion system

Abstract

An automatic anchor inserter system for drilling a guide hole and inserting an anchor. The system includes a body having a first end and a second end. An input shaft extends from the first end of the body, and a guide tube extends from the second end of the body. The system also includes a first drive shaft recess and a second drive shaft recess within the body. The drill drive shaft is capable of moving within the input shaft, and the inserter drive shaft is capable of moving within the second drive shaft recess. In a first configuration, the input shaft and the drill drive shaft move distally together through the first drive shaft recess, and in a second configuration, the drill drive shaft moves proximally relative to the input shaft. In a third configuration, movement of the drill drive shaft causes the inserter drive shaft to move.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 62 / 869,718, filed on July 2, 2019, and entitled “Automated Anchor Insertion System,” the entire contents of which are incorporated herein by reference. Background Art 1. Technical Field

[0004] The present invention relates to a drill guide and anchor driver, and more particularly to an automated anchor insertion system.

[0005] 2. Related technologies

[0006] Many plastic surgery procedures and medical procedures require fixing one subject to another subject. Such subjects may include bone, soft tissue, and prosthesis. One subject may be fixed in place relative to another subject using connector devices such as screws and suture anchors (e.g., hollow non-knotted suture anchors and soft full suture anchors). For example, various plastic surgery procedures require insertion and fixation of suture anchors within bones.

[0007] An example of a suture anchor is a soft suture anchor such as Devices. See, e.g., U.S. 9826971. Because soft anchors are often made entirely of suture material, they are sometimes referred to as "all-suture" anchors, and typically include a fiber-constructed anchor body portion (or a fiber, braided or woven fabric-type structure, such as a flexible mesh, as described in U.S. Pat. No. 9173652) and a suture or filament portion.

[0008] In orthopedic surgery, a guide hole is drilled in the bone before inserting the suture anchor. Traditionally, a standard single-barrel drill guide is placed at the desired guide hole location (i.e., desired anchor location) on the bone. A drill bit attached to an electric instrument is then placed through the drill guide to create a guide hole. During this process, constant attention to the guide is required to ensure that the guide does not move from the previously selected position. The electric instrument is then activated, and the drill bit is used to create the guide hole. The drill bit is then removed and replaced with a driver (or "inserter") preloaded with a suture anchor.

[0009] While maintaining the guide placement, the anchor is then inserted into the guide and, along with the driver, into the guide hole. Thus, throughout the process, the user needs to alternate between the drill and the driver while maintaining the position of the guide. If the position of the guide is lost, it is difficult to find the guide hole position. If the position cannot be found, a new guide hole must be created. If the user does not notice that the guide has moved from the original guide hole position and inserts the anchor into the guide, the anchor will be damaged. In such a case, the user will need to load a new anchor on the driver.

[0010] Therefore, there is a need for an automated anchor insertion system that increases user efficiency by ensuring that the anchor is inserted into the guide hole.

[0011] Related Art Section Disclaimer Description: With respect to specific patents / publications / products discussed above in the Related Art Section Description or elsewhere in this disclosure, such discussion should not be considered an admission that the discussed patents / publications / products are prior art for patent law purposes. For example, some or all of the discussed patents / publications / products may not be sufficiently early in time, may not reflect subject matter that was developed early enough in time, and / or may not be sufficient to achieve prior art equivalents for patent law purposes. With respect to specific patents / publications / products discussed above in the Related Art Section Description and / or throughout the application, their descriptions / disclosures are incorporated herein by reference in their respective entireties. Summary of the invention

[0012] Embodiments of the present invention relate to an automatic anchor insertion system. According to one aspect, the system includes a body having a first end and a second end. An input shaft extends from the first end of the body, and a guide tube extends from the second end of the body. The system also includes a first drive shaft recess in the body. A drill drive shaft is movable within the input shaft. In a first configuration, the input shaft and the drill drive shaft move distally together through the first drive shaft recess, and in a second configuration, the drill drive shaft moves proximally relative to the input shaft.

[0013] According to another aspect, the system includes a body having a first end and a second end. An input shaft extends from the first end of the body, and a guide tube extends from the second end of the body. The system also includes a first drive shaft recess and a second drive shaft recess within the body. The drill drive shaft is capable of moving within the input shaft, and the inserter drive shaft is capable of moving within the second drive shaft recess. In a first configuration, the input shaft and the drill drive shaft move distally together through the first drive shaft recess, and in a second configuration, the drill drive shaft moves proximally relative to the input shaft. In a third configuration, movement of the drill drive shaft causes the inserter drive shaft to move.

[0014] According to yet another aspect, the present invention is a method for creating a guide hole and inserting an anchor. The method comprises the following steps: (i) providing a body having a first end and a second end, an input shaft extending from the first end of the body and a guide tube extending from the second end of the body, a first drive shaft recess and a second drive shaft recess in the body, a drill drive shaft movable in the input shaft and connected to a drill bit, and an inserter drive shaft movable in the second drive shaft recess and connected to an anchor driver; (ii) driving the input shaft, which drives the input shaft and the drill drive shaft together in a distal direction and extends the drill bit through the guide tube, thereby drilling the guide hole; (iii) connecting the input shaft to the first drive shaft recess; and (iv) retracting the drill bit by driving the input shaft and independently moving the drill drive shaft in a proximal direction.

[0015] These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The present invention will be more fully understood and appreciated by reading the following detailed description in conjunction with the accompanying drawings. The accompanying drawings illustrate only typical embodiments of the disclosed subject matter and are therefore not to be considered limiting of its scope, as the disclosed subject matter may admit of other equally effective embodiments. Reference is now made briefly to the accompanying drawings, in which:

[0017] Figure 1 is a perspective schematic diagram of an automated anchor insertion system according to an embodiment;

[0018] Figure 2 is an exploded schematic diagram of an automated anchor insertion system according to an embodiment;

[0019] Figure 3 is a schematic partial cross-sectional view of an automated anchor insertion system according to an embodiment;

[0020] Figure 4 is a schematic diagram of a partially cut-away front view of an anchor system in a starting configuration according to an embodiment;

[0021] Figure 5 is a schematic diagram of a front view, partially in section, of an anchor system in a first drilling configuration according to an embodiment;

[0022] Figure 6 is a schematic diagram of a partial cross-sectional front view of an anchor system in a second drilling configuration according to an embodiment;

[0023] Figure 7 is a schematic, partially cut-away front view of an anchor system in a first retracted configuration according to an embodiment;

[0024] Figure 8 is a schematic, partially cut-away front view of an anchor system in a second retracted configuration according to an embodiment;

[0025] Fig. 9 is a schematic, partially cut-away front view of an anchor system in a first insertion configuration according to an embodiment; and

[0026] Fig.10 is a schematic, partially cut-away front view of an anchor system in a second, inserted configuration according to an embodiment. DETAILED DESCRIPTION

[0027] Aspects of the present invention and certain features, advantages and details thereof are explained more fully below with reference to the non-limiting examples shown in the accompanying drawings. Descriptions of known structures are omitted so as not to unnecessarily obscure the present invention in detail. However, it should be understood that the detailed description and specific non-limiting examples, although indicating aspects of the present invention, are given only in an illustrative manner, rather than in a limiting manner. Various substitutions, modifications, additions and / or arrangements within the spirit and / or scope of the basic concepts of the present invention will be apparent to those skilled in the art in light of this disclosure.

[0028] Referring now to the drawings, wherein like reference numerals refer to like parts throughout, Figure 1 A perspective schematic diagram of an automatic anchor insertion system 10 (also referred to as an "anchor system" or "drilling system") according to an embodiment is shown. The anchor system 10 includes a body 12 having a first end 14 and a second end 16. Figure 1 As shown, an input shaft 18 extends proximally from the first end 14 , and a guide tube 20 extends distally from the second end 16 .

[0029] Reference now Figure 2 , shows an exploded schematic diagram of an automatic anchor insertion system 10 according to an embodiment. Figure 2 In the illustrated embodiment, the body 12 of the anchor system 10 comprises two pieces, a first outer body portion 22A and a second outer body portion 22B. It is contemplated that in alternative embodiments, the body 12 may be machined as a single component. Figure 2 , the first outer body portion 22A and the second outer body portion 22B each include a first drive shaft recess 24 and a second drive shaft recess 26. When the first outer body portion 22A and the second outer body portion 22B are connected or otherwise joined, the first drive shaft recess 24 forms a first drive shaft passage, and the second drive shaft recess 26 forms a second drive shaft passage.

[0030] like Figure 2As shown, the first drive shaft recess 24 (and the first drive shaft passage) extends through the first end 14 of the body 12 (including the first outer body portion 22A and the second outer portion 22B). In the depicted embodiment, the first drive shaft recess 24 includes a threaded portion, i.e., threads 25 machined into the first drive shaft recess 24. The size and configuration of the first drive shaft recess 24 are designed to receive the input shaft 18 and the drill drive shaft 28. Figure 2 As shown, the input shaft 18 is positioned proximally relative to the drill drive shaft 28. The drill drive shaft 28 includes a threaded portion having threads 27 between a proximal end 29 and a distal end 31 thereof.

[0031] Central to the functionality of the anchor system 10 is a drill pin 30 that is secured to and extends from a drill drive shaft 28. The distal end 32 of the input shaft 18 is attached to a drill retraction gear 36 (also referred to as a "collar"). The drill retraction gear 36 has an external thread 33 that is sized and configured to engage and couple to the threads 25 of the first drive shaft recess 24. The drill retraction gear 36 also has an internal thread (not shown) that is configured to engage and couple to the threads 27 of the drill drive shaft 28. The drill drive shaft 28 extends through one or more gears 34, including the drill retraction gear 36. The distal end 31 of the drill drive shaft 28 extends through the drill retraction gear 36 and the spur gear 38, and is attached to a dog gear 40. Thus, the dog gear 40 moves with the drill drive shaft 28.

[0032] Still refer to Figure 2 , the size and configuration of the second drive shaft recess 26 are designed to receive the inserter drive shaft 42. The inserter drive shaft 42 has a distal square portion 35 (i.e., a portion having a square cross-section) and a proximal threaded portion (having threads 37). A square nut (or nut) 44 is fixed within the second drive shaft recess 26, and the proximal end 46 of the inserter drive shaft 42 is rotated through the square nut 44, thereby allowing the square nut 44 to engage and grasp the threads 37 of the proximal threaded portion. The distal end 48 of the inserter drive shaft 42 can extend or otherwise move through the spur gear 50. In particular, as Figure 2 As shown, spur gear 50 has a square drive 52 to receive distal square portion 35 of inserter drive shaft 42. Square nut 44, inserter drive shaft 42, and spur gear 50 are located within second drive shaft recess 26 (and second drive shaft passage).

[0033] As mentioned above and Figure 2As shown, the anchor system 10 has a guide tube 20 extending from the second end 16 of the body 12. In particular, the guide tube 20 is bifurcated such that the guide tube 20 is divided into a first guide tube 54 and a second guide tube 56. In the depicted embodiment, the first guide tube 54 extends into the first drive shaft recess 24, and the second guide tube 56 extends into the second drive shaft recess 26. In particular, the first guide tube 54 is fixed to the first drive shaft recess 24, and the second guide tube 56 is fixed to the second drive shaft recess 26.

[0034] Reference now Figure 3 , shows a schematic partial cross-sectional view of an automatic anchor insertion system 10 according to an embodiment. In the partial cross-sectional view, the first outer body portion 22A is shown; however, the second outer body portion 22B appears to be Figure 3 In the depicted embodiment, the input shaft 18 is located in the first drive shaft recess 24. Figure 3 As shown, the input shaft 18 is hollow so that the input shaft 18 extends over the drill drive shaft 28. In other words, the drill drive shaft 28 is sized and configured to fit within the input shaft 18. Figure 3 As shown, the input shaft 18 extends over the drill drive shaft 28 to the drill retract gear 36 , while the drill drive shaft 28 extends through the drill retract gear 36 and the spur gear 38 and connects to the toothed gear 40 .

[0035] Still refer to Figure 3 , the inserter drive shaft 42 is located within the second drive shaft recess 26. The square nut 44 is shown engaging the threads 37 of the inserter drive shaft 42. The inserter drive shaft 42 extends through the square drive 52 of the spur gear 50. As described in detail below, the spur gear 50 of the inserter drive shaft 42 is adjacent to the spur gear 38 of the drill drive shaft 28 and may sometimes engage with it. Figure 3 As shown, the drill pin 30 attached to the drill drive shaft 28 is shown as a pin guide 58 extending through the input shaft 18 for providing guidance during surgery, as described in detail below. The pin guide 58 has additional functions, such as transmitting torque between the input shaft 18 and the drill drive shaft 28.

[0036] Reference now Figures 4 to 10 , shows a partially cut-away front view schematic diagram of an automatic anchor insertion system 10 in different stages of use according to an embodiment. In the depicted embodiment, a drill bit 100 is shown attached to and extending from the drill drive shaft 28. The drill bit 100 extends from the drill drive shaft 28 and passes through the first guide tube 54. Also as shown in FIG. Figures 4 to 10As shown, the anchor driver (or inserter) 200 is shown attached to and extending from the inserter drive shaft 42. The anchor driver 200 extends from the inserter drive shaft 42 and passes through the second guide tube 56. In the depicted embodiment, the second outer body portion 22B is shown; however, the first outer body portion 22A looks like a mirror image of those shown.

[0037] Figure 4 The anchor system 10 is shown in a starting configuration according to an embodiment. In the starting configuration, the anchor system 10 is placed at a desired location at the surgical site, and the user has full control over the translation and rotation of the drilling system 10. As shown, the input shaft 18 and the drill drive shaft 28 are in an extended state, which is maintained by the threaded collar 36 (via engagement and coupling with the threads 27 of the drill drive shaft 28) so that the drill pin 30 is located distally of the pin guide 58 (or at the distal end 39). In the starting configuration, the toothed gear 40 is spaced apart from or otherwise not engaged with the spur gear 38.

[0038] Figure 5 The anchor system 10 is shown in a first drilling configuration according to an embodiment. From the starting configuration, the input shaft 18 begins to drive the drill drive shaft 28, causing the drill bit 100 to advance through the first guide tube 54. The user pushes the input shaft 18 downward, thereby driving the drill drive shaft 28. The user can apply pressure to the input shaft 18 in a distal direction through a handpiece or other power device (not shown) connected to the input shaft 18. As the input shaft 18 drives the drill drive shaft 28, they both move distally while rotating within the first drive shaft recess 24. The drill retract gear 36 rotates with both the input shaft 18 and the drill drive shaft 28. As shown in FIG. Figure 5 As shown, the drill pin 30 remains distal to the pin guide 58 (or at the distal end 39). In the first drilling configuration, due to the distal translation of the drill drive shaft 28, the toothed gear 40 moves distally farther from the spur gear 38. Figure 5 ), the drill bit 100 is approximately halfway through the action of drilling into the medium (ie, halfway through the creation of the pilot hole).

[0039] From the first drilling configuration, the user continues to push (ie, applies force in the distal direction) the input shaft 18, which continues to drive the drill drive shaft 28 and advances the drill bit 100 through the first guide tube 54 to the desired depth for creating the pilot hole. Figure 6As shown, the input shaft 18 and the drill drive shaft 28 are advanced until they bottom out at the second drilling configuration. At the second drilling configuration, the threaded drill retract gear 36 is rotated into the internal threads 25 of the first drive shaft recess 24. Once the threads 33 of the drill retract gear 36 engage the internal threads 25 of the first drive shaft recess 24, the drill retract gear 36 is fixed relative to the body 12. As shown, in the second drilling configuration, the toothed gear 40 is farther from the spur gear 38 than in the first drilling configuration, and the drill pin 30 remains distally (or at the distal end 39) in the pin guide 58. Once the desired depth for creating the guide hole is reached (in the second drilling configuration), the user can no longer control the translation due to the fixation of the drill retract gear 36 to the body 12.

[0040] Then, from the second drilling configuration, the user must continue to apply rotational input (to the input shaft 18) to complete the insertion process. The anchor system 10 will begin to retract the drill bit 100 via the same rotational input used to drive the drill bit distally, which simplifies the anchor system 10 and eliminates the reliance on the user having to correctly perform the sequence of tasks. Specifically, the threads 27 of the drill drive shaft 28 are rotated relative to the internal threads (not shown) of the now-fixed drill retraction gear 36, which pulls the drill drive shaft 28 proximally into the input shaft 18, thereby pulling the drill bit 100 out of the guide hole. Figure 7 , according to an embodiment, the anchor system 10 is in a first retracted configuration. In the first retracted configuration, the drill drive shaft 28 has been moved proximally while the input shaft 18 remains in place and the threaded drill retraction gear 36 remains in the internal threads 25 of the first drive shaft recess 24. The proximal retraction of the drill drive shaft 28 is shown via the position of the drill pin 30 in the pin guide 58 of the input shaft 18. The drill pin 30 has been moved proximally within the pin guide 58 compared to its positioning in the starting configuration and the first and second drilling configurations. In the first retracted configuration, the toothed gear 40 has been moved proximally, closer to the spur gear 38, compared to its position in the second drilling configuration.

[0041] Figure 8 The anchor system 10 is shown in a second retracted configuration according to an embodiment. From the first retracted configuration, the drill drive shaft 28 is moved further in the proximal direction until it is fully retracted in the second retracted configuration. The full proximal retraction of the drill drive shaft 28 is shown via the position of the drill pin 30 in the pin guide 58 of the input shaft 18. The drill pin 30 has been moved proximally within the pin guide 58 (to its proximal end 41) compared to its positioning in the first retracted configuration. In the second retracted configuration, the toothed gear 40 has been moved proximally, thereby engaging the spur gear 38. As shown in FIG. Figure 8As shown, the feature 43 (e.g., flange) of the toothed gear 40 engages the feature 45 (e.g., flange) of the spur gear 38. Due to the coupling of the toothed gear 40 to the spur gear 38, the spur gear 38 begins to rotate with the rotation of the drill drive shaft 28 (via the input shaft 18). The rotation of the spur gear 38 of the drill drive shaft 28 is translated to the spur gear 50 on the inserter drive shaft 42, causing the inserter drive shaft 42 to rotate through the square nut (or hub) 44 and within the second drive shaft recess 26.

[0042] Also like Figure 8 As shown, the spur gear 50 includes a square driver 52, and the inserter drive shaft 42 includes a distal square portion 35, thereby allowing rotation to be transferred from the spur gear 50 to the inserter drive shaft 42. Therefore, at the second (or fully) retracted configuration, the inserter drive shaft 42 begins to translate distally in the second drive shaft recess 26. Due to the thread 37 at the proximal end 46 of the inserter drive shaft 42, translation is allowed. In other words, the square nut 44 remains in place, and the inserter drive shaft 42 translates distally via the thread 37 in the square nut 44 and through the rotation of the square nut. When the inserter drive shaft 42 rotates, the thread 37 pushes the anchor driver (or inserter) 200 through the second guide tube 56. Throughout this process, the user is maintaining the rotation input from the handpiece or other power supply device (e.g., drill) on the input shaft 18.

[0043] Fig. 9 Anchor system 10 is shown in a first insertion configuration according to an embodiment. From the second retracted configuration, the user continues to input rotation to input shaft 18, and inserter drive shaft 42 continues to translate distally in second drive shaft recess 26 via square nut 44. Fig. 9 In the first insertion configuration shown, the inserter drive shaft 42 is rotated with the same pitch of the threads 37 thereon.

[0044] Fig.10 The anchor system 10 is shown in a second insertion configuration according to an embodiment. In the second insertion configuration, the anchor (not shown) on the anchor driver (or inserter) 200 has reached the desired insertion depth in the guide hole (not shown). As shown, once the desired insertion depth is reached, the inserter drive shaft 42 is disengaged from the square drive 52 of the spur gear 50. Since the threads 37 on the proximal end 46 of the inserter drive shaft 42 engage the square nut 44, the inserter drive shaft 42 remains at the desired insertion depth.

[0045] In the second insertion configuration, no additional translation is provided, no matter how much rotation is applied to the input shaft 18. This eliminates the risk of continuously driving or rotating the anchor into the guide hole even if the desired depth or predetermined depth has been reached. From this point on, an indicator (not shown) on the inserter drive shaft 42 or within the second drive shaft recess 26 will notify the user that the insertion is complete. The position of the indicator on the anchor system 10 can vary based on the type of anchor deployed. The user will remove the entire anchor system 10 from the positioning site, with the anchor inserted into the guide hole.

[0046] The automated anchor insertion system 10 ultimately increases user efficiency. It ensures that the anchor is inserted into the created guide hole. It enables the user to focus only on the location of the anchor rather than handling multiple devices. It also eliminates the risk of continuously driving the anchor into the guide hole beyond the desired depth. Most importantly, the anchor system 10 is a platform that can be used with both soft and rigid anchors.

[0047] Although embodiments of the present invention have been specifically shown and described with reference to certain exemplary embodiments, it will be understood by those skilled in the art that various changes in detail may be made therein without departing from the spirit and scope of the present invention as defined by the claims supported by the written description and the accompanying drawings. In addition, where exemplary embodiments are described with reference to a certain number of elements, it will be understood that the exemplary embodiments may be practiced with less than or greater than the certain number of elements.

Claims

1. An automatic anchor insertion system, comprising: a body having a first end and a second end; an input shaft that is hollow and extends from the first end of the body, and a guide tube that extends from the second end of the body; a first drive shaft recess and a second drive shaft recess, wherein the first drive shaft recess and the second drive shaft recess are located within the body; a drill drive shaft mounted within the input shaft and movable within the input shaft; a gear connected to a distal end of the input shaft; wherein in a first configuration, the input shaft and the drill drive shaft move together distally through the first drive shaft recess, and in a second configuration, the gear engages with threads in the first drive shaft recess and the drill drive shaft moves proximally relative to the input shaft; an inserter drive shaft movable within the second drive shaft recess; and wherein in a third configuration, the drill drive shaft is connected to a first gear and the inserter drive shaft extends through a second gear, and rotation of the first gear rotates the second gear such that movement of the drill drive shaft moves the inserter drive shaft, The guide tube is bifurcated, having a first guide tube extending into the first drive shaft recess and a second guide tube extending into the second drive shaft recess.

2. The system of claim 1, wherein in a fourth configuration, the inserter drive shaft is not within the second gear and does not move in response to rotation of the first gear.

3. The system of claim 1, further comprising a feature coupled to a distal end of the drill drive shaft, the feature configured to couple the drill drive shaft to the first gear.

4. The system of claim 1, wherein the inserter drive shaft has a distal square portion and threads at a proximal end, the distal square portion being sized and configured to extend through a square drive of the second gear.

5. The system of claim 1 further comprising a pin guide extending through the input shaft, wherein the feature of the drill drive shaft is movable within the pin guide.

Images