Rotary cutting tool and power handpiece adapter assembly, system, and methods of use

Abstract

An adapter assembly for coupling a cutting tool to a drill bit drive chuck such that driven rotation of the drive chuck is transmitted to the cutting tool by the adapter assembly. The adapter assembly includes a stem, a collet, and a housing. A proximal region of the stem provides an adapter male coupling configured to engage the drill bit drive chuck. A forward end of the collet provides an adapter female coupling configured to engage a surgical cutting tool shank. Further, the stem and the collet form complementary engagement features for coupling to one another. The housing rotatably retains the collet. Upon final assembly of the stem to the collet, rotation of the stem is transmitted to the collet. In use, the adapter assembly can facilitate coupling of a cutting tool to a powered handpiece in instances where the cutting tool is not compatible with the powered handpiece.

Description

Technical Field

[0001] This disclosure relates to rotary surgical cutting tools and powered handpieces (or drill bits). More specifically, this disclosure relates to interface devices for connecting rotary surgical cutting tools to powered handpieces. Background Technology

[0002] Powered surgical handpieces (also known as drills) are commonly used in many medical specialties to drive surgical instruments. For example, they are used to drive surgical drills, blades, or other cutting tools to perform a wide variety of different types of cuts, including drilling, opening, removing, dissecting, debridement, scraping, pulverizing, and shaping of anatomical tissue, including bone. Handpieces are typically configured to selectively engage and drive various rotary surgical cutting tools, each designed to perform specific procedures. During use, the surgeon selects the appropriate surgical tool based on the specific surgical procedure and mounts it onto the powered handpiece. Then, during the surgical procedure, the powered handpiece is operated to move (e.g., rotate, vibrate) the tool. Later, other procedural steps can be performed by mounting different types of tools onto the same powered handpiece.

[0003] The increased capabilities of powered surgical handpieces, coupled with the availability of a wide range of surgical cutting tools, have undoubtedly greatly increased the number of neurological, spinal, ENT / head / neck, and other procedures that surgeons can perform using a single surgical system (i.e., a single powered handpiece with multiple surgical cutting tools). The selective drive connection between the powered handpiece and each tool is typically achieved within the handpiece's housing. The housing houses an internal drive chuck configured to accommodate the handle or shank of the surgical cutting tool in a mating manner. Therefore, the handles of each surgical cutting tool that can be used with a particular handpiece generally share a common shape corresponding to the handpiece drive chuck (e.g., circular, hexagonal). The drive chuck is connected to (or formed as part of) a drive shaft; once the surgical cutting tool is engaged with the drive chuck, the powered rotation of the drive shaft causes the cutting tool to rotate.

[0004] Traditionally, cutting tools, including the shank, are typically shaped as elongated cylinders defining a single central axis about which the tool is driven and rotated during use. The handpiece drive chuck forms a corresponding, generally cylindrical passage for receiving the shank, thus achieving a coupling connection and subsequent drive interface at a point of contact formed only around the single central axis. The shank (or other areas of the cutting tool) may include notches, grooves, or other features deviating from a true cylindrical shape to achieve axial and / or rotational locking relative to the drive chuck. If the coupling features of the drive chuck and the shank of a particular surgical tool do not achieve a true match (e.g., due to wear at the drive chuck), the connection between the surgical tool and the powered handpiece may not be secure enough. Summary of the Invention

[0005] The inventors of this disclosure have recognized the need to solve one or more of the aforementioned problems. Details of one or more aspects of this disclosure are set forth in the accompanying drawings and description below. Other features, objects, and advantages of the technology described in this disclosure will become apparent from the specification, drawings, and claims.

[0006] Some aspects of this disclosure relate to an adapter assembly for coupling a surgical cutting tool to a drive chuck of a powered handpiece, such that driven rotation of the drive chuck is transmitted to the surgical cutting tool by the adapter assembly. The adapter assembly includes a lever, a collet, and a housing. The lever defines a proximal region opposite a distal region. The proximal region provides an adapter convex coupling configured to engage a drill drive chuck. The collet defines a tail region opposite a front end region. The front end region provides an adapter concave coupling configured to engage a shank of the surgical cutting tool. The distal region of the lever and the tail region of the collet form complementary engagement features for coupling the lever to the collet. Furthermore, the adapter convex coupling of the lever differs in form from the adapter concave coupling of the collet, making the adapter convex coupling incompatible with the adapter concave coupling. The housing rotatably holds the collet. After the lever is finally assembled onto the collet, driven rotation of the lever is transmitted to the collet. During use, in cases where the connection features provided with the cutting tool are incompatible with the connection features of the power handpiece, the adapter assembly facilitates the connection between the surgical cutting tool and the power handpiece. The adapter assembly connects to the power handpiece, establishing a secure connection between the rod and the drive chuck at the interface between the drill bit concave connection and the adapter convex connection. That is, the form of the adapter convex connection provided with the adapter assembly is compatible with the form of the drill bit concave connection provided with the drill bit chuck. The surgical cutting tool connects to the adapter assembly, establishing a secure connection between the surgical cutting tool shank and the chuck at the interface between the tool convex connection and the adapter concave connection. That is, the form of the adapter concave connection provided with the adapter assembly is compatible with the form of the tool convex connection provided with the surgical cutting tool.

[0007] Other aspects of this disclosure relate to a conversion device for coupling a drive mechanism including a chuck for receiving surgical cutting tools to a drive chuck of a powered handpiece, such that driven rotation of the drive chuck is transmitted to the chuck by the conversion device. The conversion device includes a lever and a cap. The lever defines a proximal region opposite a distal region. The proximal region provides an adapter convex coupling configured to engage a drill drive chuck. The distal region provides a conversion coupling configured to engage the chuck of the drive mechanism. The cap rotatably retains the lever and defines a first end opposite a second end. The first end is configured to selectively attach to the powered handpiece. The second end is configured to selectively attach to the drive mechanism.

[0008] Other aspects of this disclosure relate to a drive mechanism for coupling a surgical cutting tool to a conversion device mounted on a drive chuck of a powered handpiece, such that driven rotation of the conversion device's lever, realized by the drive chuck, is transmitted by the drive mechanism to the surgical cutting tool. The drive mechanism includes a chuck and a housing. The chuck defines a tail region opposite a front end region. The tail region provides a drive coupling configured to engage the lever of the conversion device. The front end region provides an adapter recessed coupling configured to selectively engage the shank of the surgical cutting tool. The housing rotatably holds the chuck and defines a proximal region. The proximal region is configured to selectively attach to the conversion device.

[0009] Other aspects of this disclosure relate to a surgical system for cutting tissue. The surgical system includes a powered handpiece, a surgical cutting tool, and an adapter assembly. The powered handpiece includes a housing and a drive chuck. The drive chuck is rotatably held by the housing and provides a drill bit concave engagement portion. The surgical cutting tool includes a shaft, a cutting head, and a shank. The shaft defines opposing first and second ends. The cutting head is disposed near the first end. The shank is disposed near the second end and provides a tool convex engagement portion. The adapter assembly includes a rod, a collet, and a housing. The rod defines a proximal region opposite a distal region. The proximal region provides an adapter convex engagement portion configured to engage the drill bit concave engagement portion. The collet defines a tail region opposite a front end region. The front end region provides an adapter concave engagement portion configured to engage the tool convex engagement portion. The distal region of the rod and the tail region of the collet form complementary engagement features for attaching the rod to the collet. The housing rotatably holds the collet. The form of the tool convex engagement portion differs from that of the drill bit concave engagement portion, making the tool convex engagement portion incompatible with the drill bit concave engagement portion. After the rod is finally assembled onto the chuck, the driven rotation of the chuck is transmitted to the surgical cutting tool by the adapter assembly. Attached Figure Description

[0010] Figure 1 An adapter component as part of a surgical system, based on the principles of this disclosure, is schematically shown;

[0011] Figure 2 Another adapter component as part of a surgical system, in accordance with the principles of this disclosure, is illustrated schematically;

[0012] Figure 3 This is a perspective view of a surgical system including an adapter assembly based on the principles of this disclosure;

[0013] Figure 4 yes Figure 3 Exploded stereoscopic view of the surgical system;

[0014] Figure 5 yes Figure 3 A three-dimensional view of a part of the surgical system, including the conversion device of the adapter assembly mounted on the powered handpiece;

[0015] Figure 6 yes Figure 3 A three-dimensional sectional view of a part of the surgical system, including the drive mechanism of the adapter assembly mounted on the conversion device and the surgical cutting tools;

[0016] Figure 7 yes Figure 3 A three-dimensional view of a part of a surgical system, including a portion of a conversion device mounted on a drive unit;

[0017] Figure 8 yes Figure 3 A three-dimensional view of the surgical system, showing an intermediate stage of assembly in which the adapter assembly's conversion device is mounted onto the power handpiece;

[0018] Figure 9 This is a simplified cross-sectional view of a power handpiece of an example drill chuck with a drill bit concave connection, used with the adapter assembly of this disclosure.

[0019] Figure 10 This is a perspective view of a rod component used with the adapter assembly of this disclosure and showing an example adapter convex connection portion;

[0020] Figure 11 yes Figure 10 End view of the rod;

[0021] Figure 12 It is assembled into Figure 9 On the drill chuck Figure 10 A simplified sectional view of the rod;

[0022] Figure 13 yes Figure 12 A three-dimensional view of a component;

[0023] Figure 14 This is a side view of an example surgical cutting instrument used with the adapter assembly of this disclosure and showing an example tool's convex coupling; and

[0024] Figure 15 It is assembled onto the adapter component disclosed herein. Figure 14 A simplified cross-sectional view of a surgical cutting instrument, including the engagement between a tool convex coupling of the surgical cutting tool and an example adapter concave coupling of the adapter assembly. Detailed Implementation

[0025] Specific embodiments of the present disclosure will now be described with reference to the accompanying drawings, wherein like reference numerals denote like or functionally similar elements. In the following description, the terms “distal” and “proximal” are used with respect to position or orientation relative to the treating clinician. “Distal” or “distally” means a position away from or in a direction away from the clinician. “Proximal” and “proximal” mean a position close to or toward the clinician.

[0026] It should be understood that the various aspects of this disclosure may be combined in combinations different from those specifically presented in the specification and drawings. It should also be understood that, depending on the example, the actions or events of any process or method described herein may be performed in a different order, and may be added, combined, or excluded entirely (e.g., all described actions and events may not be necessary for performing the technology). Furthermore, although some aspects of this disclosure are described for clarity as being performed by a single module or unit, it should be understood that the technology of this disclosure may be performed by a combination of units or modules associated with, for example, a medical device.

[0027] refer to Figure 1Some embodiments of this disclosure provide an adapter assembly 20 for coupling a surgical cutting tool 22 to a power handpiece or drill bit 24, such that the drill bit 24 rotates to drive the rotation of the cutting tool 22. The adapter assembly 20 of this disclosure can take various forms and, in some embodiments, facilitates indirect coupling between different coupling features provided together with the surgical cutting tool 22 and the power handpiece 24. For reference and as described in more detail below, the cutting tool 22 can take various forms and generally includes or defines a cutting head 30 opposite to a tool convex coupling (TMCP) 32. The power handpiece 24 can also take various forms and generally includes a drive chuck 34 forming or providing a drill bit concave coupling (DFCM) 36. With this in mind, the adapter assembly 20 includes or provides an adapter convex coupling 40 and an adapter concave coupling 42. The adapter convex coupling 40 is formed according to the drill bit concave coupling 36; the drill bit concave coupling 36 and the adapter convex coupling 40 have complementary engagement features. The adapter concave coupling 42 is formed according to the tool convex coupling 32; the adapter concave coupling 42 and the tool convex coupling 32 have complementary engagement features. While the complementary engagement features provided by the various couplings can take various forms, in some embodiments, the form of the tool convex coupling 32 is incompatible with the form of the drill concave coupling 36. That is, if an attempt is made to insert the cutting tool 22 into the drive chuck 34, the tool convex coupling 32 will not engage with the drill concave coupling 36 in a manner that would provide a secure connection suitable for safely serving as part of a surgical procedure in which the surgical cutting tool 22 is intended to be rotated by the power handpiece 24 to cut tissue. Accordingly, in some embodiments, the form of the adapter convex coupling 40 is different from and incompatible with the form of the adapter concave coupling 42.

[0028] In some embodiments, the adapter assembly 20 may include two or more separable components, such as a conversion device 50 and a drive device 52. The conversion device 50 forms or carries a convex adapter coupling portion 40, and the drive device 52 forms or carries a concave adapter coupling portion 42. The conversion device 50 and the drive device 52 may be configured to selectively attach to each other, for example by providing a conversion coupling portion (CCP) 54 of the conversion device 50 and a complementary drive coupling portion (DCP) 56 of the drive device 50. The conversion coupling portion 54 and the drive coupling portion 56 are formed to incorporate complementary engagement features (e.g., the conversion coupling portion 54 may be formed to have a convex configuration and the drive coupling portion 56 may be formed to have a concave configuration, or vice versa).

[0029] During use, the conversion device 50 can be selectively assembled to the power handpiece 24, including a secure engagement interface between the drill bit concave connection 36 and the adapter convex connection 40. The conversion device 50 can be selectively or permanently assembled to the drive unit 52, including a secure engagement interface between the conversion connection 54 and the drive connection 56. Finally, the cutting tool 22 can be selectively assembled to the drive unit 52, including a secure engagement interface between the adapter concave connection 42 and the tool convex connection 32. In this assembled state, the driven rotation of the drive chuck 34 (e.g., rotation or vibration in a single direction) is transmitted to the cutting tool 22 via the adapter assembly 20. Although... Figure 1 The conversion device 50 and the drive device 52 are separable from each other, but in other embodiments, a more persistent connection can also be established. For example, as Figure 2 As shown, in another embodiment of this disclosure, the adapter assembly 20' has an integral or homogeneous structure and includes the adapter convex connection portion 40 and the adapter concave connection portion 42 as described above.

[0030] refer to Figure 1 and Figure 2 Some aspects of this disclosure relate to a separate conversion device 50, a separate drive device 52, or an adapter assembly 20, 20' (which may or may include a separable conversion device and drive device). Other aspects of this disclosure relate to a surgical cutting system including a powered handpiece 24, adapter assemblies 20, 20', and a surgical cutting tool 22.

[0031] Figure 3 and Figure 4An example of an adapter assembly 80 of this disclosure as part of a surgical system, which also includes a powered handpiece 82 and a surgical cutting tool 84, is shown. The powered handpiece 82 and the cutting tool 84 can each take various forms that are obvious to a person skilled in the art. For example, although only a portion of the powered handpiece 82 is shown, in accordance with the above explanation, the powered handpiece 82 typically includes a drive chuck 90 that forms or carries a drill bit concave engagement 92. The drive chuck 90 is carried by or rotatable relative to a drill bit housing 94. Furthermore, the cutting tool 84 typically includes a shaft 100 that forms or carries a cutting head 102 opposite to a shank 104, or the shank 104 forms or carries a tool convex engagement 106. With this in mind, the adapter assembly 80 includes a conversion device 110 and a drive device 112. Details of the various components are provided below. Generally, the conversion device 110 is configured to selectively attach to the powered handpiece 82, including engagement with the drill bit concave engagement 92. The drive unit 112 can be attached (releasable or permanent) to the conversion unit 110 and is configured to selectively attach to the cutting tool 84, including engagement with the tool convex coupling 106. After final assembly, driven rotation of the drive chuck 90 (e.g., rotation or vibration in a single direction) is transmitted to the cutting tool 84 via the adapter assembly 80.

[0032] The conversion device 110 includes a rod 120 and a cover 122. The rod 120 is rotatably held within the cover 122 and defines a proximal region opposite to a distal region. The proximal region forms or carries an adapter convex connection 134 configured to engage a drill bit concave connection 92. The distal region forms or carries a conversion connection 136 configured to engage components of the adapter device 112. Non-limiting examples of possible connection forms contemplated in this disclosure are provided below. The cover 122 may take various shapes and sizes suitable for rotatably holding the rod 120 (e.g., a ball bearing assembly may be disposed within the cover 122 and mounted above the rod 120). In some embodiments, the cover 122 forms or defines a first end 140 opposite to a second end 142. Ends 140, 142 may be integrally formed or may be manufactured separately and subsequently assembled to each other. In any case, in some embodiments, the first end 140 includes or incorporates features adapted for selective attachment to the drill bit housing 94. For example, the first end 140 may be configured to engage the drill housing 94 with an interference fit. Other attachment forms may also be acceptable depending on the construction of the drill housing 94, as is known in the art (e.g., the first end 140 may form an internal thread for engagement with an external thread on the drill housing 94; ball and pawl forms may be used, etc.). The second end 142 includes or incorporates features configured to selectively attach to corresponding features of the drive mechanism 112, as described below. As a non-limiting example, the second end 142 may form or carry an external thread 144. In any case, in some embodiments and additionally referenced... Figure 5 The axial length of the rod 120 relative to the axial length of the cover 122 is selected such that after the cover 122 is finally assembled onto the drill bit housing 94 (including the engagement between the adapter convex connection 134 and the drill bit concave connection 92), the conversion connection 136 protrudes beyond the cover 122, for the reasons described below.

[0033] refer to Figure 3 and Figure 4 And refer to other sources Figure 6 (This figure also depicts a drive unit 112 assembled to the conversion device 110 and a cutting tool 84 assembled to the drive unit 112.) The drive unit 112 may include a chuck 150 and a housing 152. The chuck 150 is rotatably held within the housing 152 (e.g., via one or more bearing assemblies 154). Furthermore, the drive unit 112 forms or carries an adapter concave connection 156 (generally shown) for selectively engaging the tool convex connection 106 and a drive connection 158 (generally shown) for selectively engaging the conversion connection 136 of the conversion device 110, as described in more detail below.

[0034] The housing 152 can take various shapes and sizes suitable for rotatably holding the chuck 150 and selectively receiving the cutting tool 84. In some embodiments, the housing 152 forms or defines a proximal region 160 opposite the distal region 162. The end regions 160, 162 can be integrally formed or can be manufactured separately and subsequently assembled to each other. In any case, in some embodiments, the proximal region 160 includes or incorporates features adapted for selective attachment to the converter cover 122. For example, and as described above, in some non-limiting examples, the second end 142 of the converter cover 122 can form or carry external threads 144. In these and similar embodiments, the proximal region 160 can form or carry corresponding internal threads 164 to facilitate threaded engagement between the cover 122 and the housing 152. Other attachment forms (e.g., interference fit, ball and pawl, etc.) are also acceptable. The distal region 162 can form or carry features that facilitate rotatably supporting the shaft 100 of the cutting tool 84. For example, the size or diameter of the inlet hole 166 leading to the interior of housing 152 may be close to (e.g., slightly larger than) the intended diameter of the cutting tool spindle 100. Additionally or alternatively, one or more rotary support assemblies (e.g., ball bearing assemblies) may be carried by the distal region 162.

[0035] The complementary forms of the conversion coupling 136 and the drive coupling 158 can take various forms that facilitate a robust engagement between them, whereby the driven rotation of the lever 120 is transmitted to the chuck 150 (i.e., after engagement between the conversion coupling 136 and the drive coupling 158, the chuck 150 rotates with the rotation of the lever 120). In some embodiments, the conversion coupling 136 and the drive coupling 158 are configured to be assembled / disassembled axially. For example, relative to the longitudinal axis L defined by the chuck 150, the conversion coupling 136 engages the drive coupling 158 by axially guiding the chuck 150 toward the lever 120 in the direction of the longitudinal axis L (and / or vice versa). In these and related embodiments, the position of the drive coupling 158 relative to the longitudinal length of the housing 152 has a predetermined relationship with the known or predetermined longitudinal position of the transition coupling 136 relative to the cover 122 (in embodiments where the transition coupling 136 is located outside or beyond the cover 122); specifically, the drive coupling 158 is positioned such that, as the housing 152 is assembled onto the cover 122, the drive coupling 158 is longitudinally aligned with the transition coupling 136. The transition coupling 136 can be disengaged from the drive coupling 158 by guiding the chuck 150 axially away from the rod 120 (and / or vice versa) along the longitudinal axis L. In these and related embodiments, the transition coupling 136 and the drive coupling 158 can have complementary convex / concave configurations. Figure 6In a non-limiting example, the transition coupling 136 has a convex configuration whose dimensions and shape are designed to accommodate within a concave configuration of the drive coupling 158. In other embodiments, the transition coupling 136 may have a concave configuration and the drive coupling 158 may have a complementary convex configuration.

[0036] Figure 7 A non-limiting example of the construction of the transition coupling 136 (generally shown) and the drive coupling 158 (generally shown) in an engaged state is shown. The transition coupling 136, provided with or by the rod 120, has a convex form, thereby forming or defining one or more drive surfaces 170 (one of which is in…) Figure 7 (Identification mark). The drive coupling 158, provided with or by the chuck 150, has a concave shape, thereby forming or defining one or more driven surfaces 172 (one of which is in...). Figure 7 (Identified in Chinese). After the conversion coupling 136 is inserted into the drive coupling 158, the drive surface 170 slides in contact with or abuts one of the corresponding driven surfaces 172. In this engaged state, rotation or torque at the rod 120 is transmitted to the chuck 150 at the drive surface 170 / driven surface 172 interface. Those skilled in the art will understand that other complementary connection forms may or may not be used for the conversion coupling 136 and the drive coupling 158. Figure 7 Its characteristics.

[0037] During use, the conversion device 110 is assembled onto the power handheld component 82, such as... Figure 8 As shown. In some embodiments, the conversion device 110 may be permanently attached to the powered handpiece 82. In any case, the lever 120 is coupled to the drive chuck 90 ( Figure 4 The drive unit 112 is assembled onto the conversion unit 110, for example as described above and as follows: Figure 7 As shown, this completes the adapter assembly 80. Finally, the surgical cutting tool 84 is mounted to the adapter assembly 80 (e.g., at the drive unit 112), including a handle 104 that engages with the chuck 150. Figure 6 ). Figure 3 This indicates the final assembly of the surgical system. During the procedure, the powered handpiece 82 can be operated as needed, thereby rotating the cutting tool 84 via the adapter assembly 80.

[0038] refer to Figure 4The form of the adapter convex connection 134 can be selected based on any known or future drill bit concave connection 92. At this point, the power handpiece 82 can take any form suitable for driving rotary surgical cutting tools, such as those available from Medtronic, Inc. under the trade name Midas Rex. TM The obtained power handheld device or drill bit, such as Midas Rex TM Legend TM Surgical drill, Midas Rex TM MR7 TM Surgical drill, Midas Rex TM MR8 TM Surgical drills, etc. The power handpiece of this disclosure can employ various drive components or motors known in the art (e.g., pneumatic or pneumatically driven, electric or electrically driven, etc.) for achieving driven rotation at a desired speed, and generally includes a housing 94 holding a drive shaft that mechanically couples or links a motor (not shown) to a drive chuck 90 (e.g., similar to a collet) via a coupling assembly known in the art. The drive chuck 90 further forms or provides a drill bit concave engagement 92. The drill bit concave engagement 92 can take various forms, and this disclosure is by no means limited to a specific engagement configuration at the power handpiece 82. More generally, the drill bit concave engagement 92 is configured to selectively receive / load an inserted component in a manner that facilitates driven rotation of the loaded component.

[0039] As a non-restrictive example, Figure 9 This is a simplified representation of a part of the power handpiece 82, showing only one possible example of the drill bit concave connection 92 (generally shown). Figure 9 In the view, the power handpiece 82 includes a housing 94 and a drive chuck 90. ​​The drive chuck 90 may have an elongated tubular or hub-like configuration and its dimensions are designed to receive an internal passageway for a suitably shaped insertion component. In some embodiments, the peripheral shape of the internal passageway serves as a drill bit recessed connection 92. For example, the maximum diameter id of the internal passageway is defined by a guide surface 200. The internal geometry of the drive chuck 90 defines opposing drive pins or drive bodies 202a, 202b, which otherwise represent a radially inward protrusion from the guide surface 200. A first drive pin 202a defines a first drive surface 204a and a second drive surface 206a. The drive surfaces 204a, 206a do not directly intersect at a single corner; instead, a recessed surface 208a extends between the drive surfaces 204a, 206a. A second drive pin 202b similarly defines the first drive surface 204b, the second drive surface 206b, and the recessed surface 208b. The drive pins 202a and 202b have a symmetrical but offset arrangement.

[0040] Adapter convex connector 134 ( Figure 4 ) can be based on Figure 9 The drill bit concave connection portion 92 is formed. For example, a portion of the rod 120 in a non-limiting example is... Figure 10 and Figure 11 These figures illustrate possible forms of the adapter convex connection 134. The adapter convex connection 134 extends from the rod portion 220 to the proximal end 222. The adapter convex connection 134 includes a first interface structure 224a and a second interface structure 224b. In some embodiments (e.g., symmetrically offset), the interface structures 224a, 224b may be identical (or embody their mirror image) and may be formed or cut into an optional straight cylindrical initial shape of the rod 120.

[0041] The first interface structure 224a may include or define a deflection surface 230a, a first driven surface 232a, and a second driven surface 234a. The second interface structure 224b may have the same configuration. The deflection surface 230a is defined by a leading edge 240, first and second side edges 242, 244, and first and second intermediate or inserted connecting lateral edges 246, 248. In some non-limiting embodiments, the surface of the deflection surface 230a may be substantially planar (i.e., within 5% of a truly planar or flat surface). In some embodiments, surface features may be optionally incorporated into the deflection surface 230a such that the entire deflection surface 230a need not have a constant or uniform shape. However, the principal plane defined by the deflection surface 230a is oriented to be inclined to the central axis of the rod 120.

[0042] Driven surfaces 232a and 234a are effectively “opened” to the proximal end 222, extending from the connecting lateral edges 246 and 248, respectively. For example, the first driven surface 232a is effectively defined by the first connecting lateral edge 246, the first outer longitudinal edge 250, and the connecting longitudinal edge 252. The second driven surface 234a is effectively defined by the second connecting lateral edge 248, the second outer longitudinal edge 254, and the connecting longitudinal edge 252. The connecting longitudinal edge 252 may be formed by or include a longitudinal groove. In other embodiments, the connecting longitudinal edge 252 may be substantially straight (i.e., within 5% of a truly straight corner or edge).

[0043] The adapter convex connection 134 may further include or define opposing chamfered surfaces 260, 262 near the proximal end 222. The chamfered surfaces 260, 262 extend from corresponding guide surfaces 264, 266, or otherwise extend circumferentially between interface structures 224a, 224b, and reflect the taper of the outer diameter of the rod 120. The adapter convex connection 134 may also include an optional axial retaining feature in the form of a circumferential groove 270. The circumferential groove 270 is positioned away from the deflection surfaces 230a, 230b such that it interrupts the driven surfaces 232a, 234a of the first interface structure 224a and the driven surfaces 232b, 234b of the second interface structure 224b. The axial retaining feature may alternatively be one or more notches, planes, holes, slots, biasing mechanisms, etc. In other embodiments, the axial retaining feature is omitted.

[0044] Figure 12 and Figure 13 The diagram illustrates the engagement between the adapter convex coupling 134 and the drill bit concave coupling 92 after the rod 120 is inserted into the drive chuck 90. ​​The interface structures 224a and 224b of the adapter convex coupling 134 are aligned with a corresponding drive pin of the drive pins 202a and 202b. For example, the first driven surface 232a of the first interface structure 224a is aligned or in sliding contact with the first drive surface 204a of the first drive pin 202a, and the second driven surface 234a is aligned or in sliding contact with the second drive surface 206a. Similarly, the first driven surface 232b and the second driven surface 234b of the second interface structure 224b are aligned with the first drive surface 204b and the second drive surface 206b of the second drive pin 202b, respectively. Figure 13 Further reflecting that, in some alternative embodiments, one or more balls 280 (or other axially retaining members) can be held by the drive chuck 90 and arranged to engage the circumferential groove 270 of the rod 120, thereby achieving axial locking of the rod 120 relative to the drive chuck 90. ​​In any case, a driven interface is established between the drive chuck 90 and the rod 120. The input torque at the drive chuck 90 is transmitted to the rod 120 at interface structures 224a, 224b. The drive chuck 90 in the first direction (relative to...) Figure 11 and Figure 12Rotation in the clockwise direction transmits rotational force or torque to the lever 120 at the interface between the first driving surface 204a of the first drive pin 202a and the first driven surface 232a of the first interface structure 224a, and at the interface between the first driving surface 204b of the second drive pin 202b and the first driven surface 232b of the second interface structure 224b. Rotation of the drive chuck 90 in the opposite second direction (counterclockwise) transmits rotational force or torque to the lever 120 at the interface between the second driving surface 206a of the first drive pin 202a and the second driven surface 234a of the first interface structure 224a, and at the interface between the second driving surface 206b of the second drive pin 202b and the second driven surface 234b of the second interface structure 224b.

[0045] The adapter convex connection structure disclosed herein is not limited to the exemplary configuration of adapter convex connection structure 134. More generally, any configuration complementary to the configuration of the drill bit concave connection structure equipped with the discussed power handpiece (which may or may not be similar to the drill bit concave connection structure 92 described above) is acceptable.

[0046] Back Figure 6 The form of the adapter concave connection 156 can be selected based on any known or future developed tool convex connection 106. For reference, the most conventional surgical cutting tools typically include a shaft 100 forming or carrying a cutting head 102 opposite to the shank 104, or the shank 104 forming or carrying the tool convex connection 106. The shaft 100 can be formed of a surgically safe, rigid material (e.g., stainless steel) and defines opposing first and second (or distal and proximal) ends 300, 302. The cutting head or anatomical portion 102 is disposed (formed or assembled) adjacent to the distal end 300. The cutting head 102 can take various forms suitable for performing desired rotary surgical cutting procedures (e.g., cutting, debulking, excision, dissection, or removal of anatomical tissue including bone). As a non-limiting embodiment, the cutting head 102 can be a drill bit having any desired shape, size, flute pattern, etc. Although the elongated shaft 100 is illustrated as a straight line or straight line, in other embodiments, the shaft 100 may define one or more longitudinal bends or curves; in related embodiments, the surgical cutting tool of this disclosure may also include a curved outer sleeve (not shown) that supports the shaft 100 as it rotates.

[0047] The shank 104 and the tool convex coupling 106 formed or carried therefrom can be in various configurations. In this regard, the form of the shank 104 is by no means limited to this disclosure. In fact, any design known now or developed in the future suitable for establishing a connection with a chuck or the like in a manner that facilitates the rotation of the surgical cutting tool 84 as the chuck rotates is available. Therefore, the connection features provided by the tool convex coupling 106 may include one or more of the following: the peripheral shape of the shank 104 (e.g., cylindrical, conical, etc.), surface recesses (e.g., grooves, slots, etc.), surface protrusions or projections (e.g., flanges, ridges, etc.), one or more auxiliary components carried by the shank 104 (e.g., bias ball), etc. Regardless of the specific design, the adapter concave coupling 156 is formed to provide a complementary construction.

[0048] As a further explanation, Figure 14 The diagram illustrates one possible configuration of a surgical cutting tool 84. The cutting tool 84 includes an elongated shaft 100, a cutting head 102, and a shank 104, or otherwise forms or provides a tool convex connection 106 (generally shown). The tool convex connection 106 includes a plurality of driven surfaces 300. The driven surfaces 300 are substantially planar and extend substantially parallel to the longitudinal axis of the cutting tool 84. Figure 15 (The accompanying drawing also shows the engagement state between the cutting tool 84 and the chuck 150.) Further, the driven surfaces 300 are formed in a substantially hexagonal pattern to define a drive angle 302 between each driven surface 300. Alternatively, the tool convex coupling 106 may have eight, four, three, etc., drive surfaces. An annular groove 304 can be formed along the shank 104 using some cutting tools; in these and related embodiments, a locking ball, etc. (not shown), can be connected to the adapter assembly 80. Figure 4 Together, this includes providing axial locking with the cutting tool 84 at the annular groove. In any case, and as... Figure 15 As shown, the adapter concave coupling 156 (generally shown) is configured to engage the tool convex coupling 106 thus configured after the shank 104 is inserted into the chuck 150. For example, the adapter concave coupling 156 may include a drive surface 306, the size and shape of which are designed to contact a corresponding driven surface of the driven surfaces 300. The drive surface 306 may or may not have... Figure 15 The convex shape shown. When the shank 104 is inserted into the chuck 150, the driven surface 300 slidably contacts or abuts one of the corresponding drive surfaces 306. Figure 15 In the engaged state, the driven rotation of the chuck 150 transmits rotational force or torque to the cutting tool 84 at the interface between each drive surface 306 and driven surface 300.

[0049] It should be understood that Figure 14 The tool convex connecting part 106 and Figure 15 The adapter concave connector 156 shown is merely one example according to the principles of this disclosure. Surgical cutting tools usable with this disclosure can have a variety of other tool convex connector designs. Therefore, the adapter concave connector of this disclosure can also have… Figure 15 Several other configurations may or may not be involved. More generally, any concave connection form compatible with the convex connection of the surgical cutting tool of interest may be adopted.

[0050] The surgical system and adapter assembly disclosed herein offer significant improvements over previous designs. The adapter assembly facilitates the use of various rotary surgical cutting tools with powered handheld devices or drills that would otherwise be incompatible with the connection configuration of the cutting tools.

[0051] Although this disclosure has been described with reference to preferred embodiments, those skilled in the art will recognize that changes in form and detail may be made without departing from the spirit and scope of this disclosure.

Claims

1. An adapter assembly for connecting a surgical cutting tool to a drive chuck of a powered handpiece, such that driven rotation of the drive chuck is transmitted to the surgical cutting tool by the adapter assembly, the adapter assembly comprising: A rod defining a proximal region opposite to the distal region, wherein the proximal region provides an adapter convex connection configured to engage the drive chuck; A chuck defining a tail region opposite to the front end region, wherein the front end region provides an adapter concave connection configured to engage the handle of a surgical cutting tool; The distal region of the rod and the tail region of the chuck form complementary engagement features for attaching the rod to the chuck; Furthermore, the form of the adapter convex connection portion of the rod is different from the form of the adapter concave connection portion of the clamp, making the adapter convex connection portion incompatible with the adapter concave connection portion; as well as The housing of the chuck is rotatably held, and the housing completely surrounds the chuck along its length from the tail region to the front region; After the rod is finally assembled onto the chuck, the driven rotation of the rod is transmitted to the chuck.

2. The adapter assembly of claim 1, wherein the rod defines opposing first and second ends and a central axis, and further, wherein the adapter convex coupling extends from a first position spaced apart from the second end to a second position at the second end, the adapter convex coupling defining a leading edge, first and second intermediate edges connected to each other, first and second outer longitudinal edges connected to the first and second intermediate edges, and an inner longitudinal edge connected to the intersection of the first and second intermediate edges, wherein the adapter convex coupling comprises: A first deflection surface defined by the leading edge and the first and second intermediate edges, the first deflection surface extending obliquely to the central axis; as well as The first interface structure includes: A first driven surface connected to the deflection surface, the first driven surface being defined by the first intermediate edge, the first outer longitudinal edge, and the inner longitudinal edge; as well as A second driven surface is connected to the deflection surface and the first driven surface, the second driven surface being defined by the second intermediate edge, the second outer longitudinal edge and the inner longitudinal edge.

3. The adapter assembly of claim 2, wherein the first deflection surface is substantially planar.

4. The adapter assembly of claim 2, wherein the first deflection surface defines a main plane arranged at an angle ranging from 10 degrees to 70 degrees relative to the central axis.

5. The adapter assembly of claim 2, wherein at least a portion of the second driven surface is substantially planar.

6. The adapter assembly of claim 2, wherein at least a portion of the first driven surface is substantially planar.

7. The adapter assembly of claim 2, wherein the first intermediate edge and the second intermediate edge extend orthogonally to each other.

8. The adapter assembly of claim 2, wherein the angle defined by the first intermediate edge and the inner longitudinal edge is in the range of 30 degrees to 60 degrees.

9. The adapter assembly of claim 2, wherein the leading edge and the second intermediate edge are parallel to each other.

10. The adapter assembly of claim 2, wherein the intermediate portion of the rod defines the maximum outer diameter of the rod relative to the central axis, and the first outer longitudinal edge is located at a distance from the central axis equal to the maximum outer diameter.

11. The adapter assembly of claim 2, wherein the adapter convex connection further includes a circumferential groove between the first position and the second position.

12. The adapter assembly of claim 11, wherein the circumferential groove interrupts the first driven surface and the second driven surface.

13. The adapter assembly of claim 2, wherein a central plane divides the rod into a first half and a second half, the deflection surface, the first driven surface and the second driven surface are located within the first half, and the central plane includes the central axis.

14. The adapter assembly of claim 2, wherein the adapter convex coupling defines a maximum outer diameter from the central axis, and further wherein, for a central plane including the central axis and extending in a direction parallel to the central axis and from the first end to the second end, the second intermediate edge extends from the maximum outer diameter toward the central plane.

15. The adapter assembly of claim 2, wherein the adapter convex connection further includes a second deflection surface and a second interface structure having a first driven surface and a second driven surface, each of the second deflection surface and the second interface structure being formed on an axis opposite to the central axis of the first deflection surface and the first interface structure.

16. The adapter assembly of claim 1, further comprising a cover, wherein at least a portion of the rod is rotatably retained within the cover.

17. The adapter assembly of claim 16, wherein the cover defines a first end configured to selectively attach to the housing of the powered handpiece.

18. The adapter assembly of claim 17, wherein the cover defines a second end opposite to the first end, the second end being configured to selectively attach to the housing.

19. The adapter assembly of claim 17, wherein the rod is permanently fixed relative to the cover to jointly provide a conversion mechanism, and the clamp is permanently fixed relative to the housing to jointly provide a drive mechanism.

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