Surgical drill with improved cutting and method of improving effectiveness of cutting

Abstract

A surgical drill for cutting bone includes a rod adapted to be selectively coupled to an attachment tube of a micro-drill instrument assembly and configured for selective rotation upon activation of the micro-drill instrument. The surgical drill includes a plurality of cutting slots disposed at the distal end of the shaft, the cutting slots defining a corresponding number of gap surfaces disposed therebetween. Each of the cutting flutes includes a cutting edge and a trailing edge. One or more push-away elements are defined in the gap surface between adjacent pairs of cutting slots of the plurality of cutting slots, the push-away element is configured to contact the bone during rotation of the surgical drill and to deflect the surgical drill relative to the bone and to optimize cutting efficiency and effectiveness of the surgical drill based on a rotational speed (RPM) of the surgical drill.

Description

Technical Field

[0001] The present disclosure relates to surgical systems for cutting or shaping bone, and more particularly to surgical drills for cutting and shaping bone. Background Art

[0002] Surgical instruments for cutting and shaping bones generally include a motor housing with a handle, a surgical attachment, and a surgical tool. The surgical attachment and the surgical tool are interchangeable with other surgical attachments and surgical tools. The surgical attachment is connected to the motor housing and engages with a motor disposed therein, which is configured to rotate, oscillate, or otherwise move the surgical tool when it is activated. The surgical tool generally includes an elongated shaft and a surgical cutting head or drill attached to (or integrally associated with) its distal end. The elongated shaft extends from the surgical drill, engages with the surgical attachment, and rotates, oscillates, or otherwise moves axially when the motor is actuated.

[0003] Surgical drills are used to dissect, cut and / or shape bones during surgical procedures. Various characteristics of surgical instruments or surgical drills are usually designed for specific purposes to improve surgical performance. These characteristics include cutting efficiency, stability, working length and visibility. Improving one of these characteristics usually adversely affects one or more of the other characteristics. For example, designing a surgical drill with a strong cutting groove can improve cutting efficiency, but at the same time, the same cutting groove may hinder another aspect of the surgical procedure, such as causing unacceptable vibration.

[0004] Such surgical instruments may include an elongated shaft coupled to a motor to provide torque to the tool to rotate the surgical drill during operation. The attachment assembly typically holds the tool relative to the motor via a chuck having various gears and connections that transfer torque from the motor to the tool. The attachment assembly may provide various features, such as hole diameter, length, angle, etc., to allow selection of the tool operated by the motor. In addition, the attachment assembly may include stiffness modifications and / or damping features, such as damping members, thickness, etc., to minimize and / or reduce vibrations at the tool tip (e.g., surgical drill) and vibrations caused by the tool that are felt and received by the user.

[0005] In some cases, uncontrolled vibrations, or vibrations commonly referred to as "tool chatter," can adversely affect the cutting performance of a surgical drill. Too little chatter can also cause the surgical drill to cut inefficiently. If properly tuned, a controlled amount of tool chatter can optimize the cutting effect of the surgical drill on tissue (e.g., bone or other hard tissue structures). This typically requires manual adjustment of the surgical drill within the tool holder, adjustment of one or more damping mechanisms, or other control mechanisms, which can be cumbersome for the surgeon and / or require multiple modifications during a given surgery.

[0006] Therefore, it would be a significant improvement in the art to produce a surgical drill with a means of self-adjusting tool vibration to cut bone more effectively and efficiently. Summary of the invention

[0007] According to aspects of the present disclosure, a surgical drill for cutting bone is provided, the surgical drill comprising a rod adapted to be selectively coupled to an attachment tube of a microdrill instrument assembly and configured to selectively rotate when the microdrill instrument is activated. A plurality of cutting grooves are disposed at the distal end of the rod, the plurality of cutting grooves defining a corresponding number of clearance surfaces disposed between the plurality of cutting grooves, each of the plurality of cutting grooves comprising a cutting edge and a trailing edge. One or more push-off elements are defined in the clearance surfaces between one or more adjacent pairs of cutting grooves in the plurality of cutting grooves. The push-off element is configured to contact the bone during rotation of the surgical drill, and is configured to deflect the surgical drill relative to the bone and optimize the cutting efficiency and effectiveness of the surgical drill based on the speed (RPM) of the surgical drill.

[0008] In various aspects according to the present invention, a corresponding plurality of push-off elements are provided between the plurality of cutting slots. In other aspects according to the present disclosure, the plurality of push-off elements are configured to deflect the surgical drill based at least on the rotation angle of the surgical drill or the oscillation angle of the surgical drill to optimize the cutting efficiency and effectiveness of the surgical drill based on the speed (RPM) of the surgical drill.

[0009] In aspects according to the present disclosure, a plurality of push-off elements are configured to deflect the surgical drill based at least on a rotation angle of the surgical drill or an oscillation angle of the surgical drill to optimize the cutting efficiency and effectiveness of the surgical drill based on a speed (RPM) of the surgical drill.

[0010] In aspects according to the invention, the plurality of push-off elements are non-cutting.

[0011] In various aspects according to the present invention, a series of push-off elements are provided between one or more adjacent pairs of cutting grooves in the plurality of cutting grooves.

[0012] In aspects according to the present invention, a series of push-off elements disposed between one or more adjacent pairs of cutting grooves among the plurality of cutting grooves are equally spaced between the cutting grooves.

[0013] In aspects according to the present invention, a series of push-off elements disposed between at least one adjacent pair of cutting grooves among the plurality of cutting grooves are unequally spaced between the cutting grooves.

[0014] In various aspects of the present disclosure, multiple push-off elements disposed between these adjacent pairs of cutting slots in the multiple cutting slots are synchronized so that the surgical drill does not completely bottom out when the next approaching cutting slot of rotation contacts the bone, thereby producing a more angular and powerful cut.

[0015] In various aspects of the present disclosure, multiple push-off elements disposed between these adjacent pairs of cutting slots in the multiple cutting slots are synchronized so that the surgical drill is pushed away from the bone laterally in the rotational direction rather than vertically in a direction orthogonal to the bone between each adjacent pair of slots.

[0016] According to various aspects of the present disclosure, a micro-drill instrument for cutting bone is provided, the micro-drill instrument includes a micro-drill assembly, the micro-drill assembly having: a motor housing, the motor housing including a motor disposed therein; an attachment tube, the attachment tube operably connected to the motor housing at its proximal end and configured to selectively receive a surgical drill for cutting bone therein; a chuck, the chuck operably receiving a rod of the surgical drill so that the surgical drill can be selectively rotated when the motor is activated. The surgical drill includes: a plurality of cutting grooves, the plurality of cutting grooves are disposed at the distal end of the rod, the plurality of cutting grooves define a corresponding number of gap surfaces disposed between the plurality of cutting grooves, each of the plurality of cutting grooves including a cutting edge and a trailing edge. One or more push-off elements are defined in the gap surfaces between one or more adjacent pairs of cutting grooves in the plurality of cutting grooves. The push-off element is configured to contact the bone during rotation of the surgical drill, and is configured to deflect the surgical drill relative to the bone and optimize the cutting efficiency and effectiveness of the surgical drill based on the speed (RPM) of the surgical drill.

[0017] In various aspects according to the present invention, a corresponding plurality of push-off elements are provided between the plurality of cutting slots. In other aspects according to the present disclosure, the plurality of push-off elements are configured to deflect the surgical drill based at least on the rotation angle of the surgical drill or the oscillation angle of the surgical drill to optimize the cutting efficiency and effectiveness of the surgical drill based on the speed (RPM) of the surgical drill.

[0018] In aspects according to the present disclosure, a plurality of push-off elements are configured to deflect the surgical drill based at least on a rotation angle of the surgical drill or an oscillation angle of the surgical drill to optimize the cutting efficiency and effectiveness of the surgical drill based on a speed (RPM) of the surgical drill.

[0019] In aspects according to the invention, the plurality of push-off elements are non-cutting.

[0020] In various aspects according to the present invention, a series of push-off elements are provided between one or more adjacent pairs of cutting grooves in the plurality of cutting grooves.

[0021] In aspects according to the present invention, a series of push-off elements disposed between one or more adjacent pairs of cutting grooves among the plurality of cutting grooves are equally spaced between the cutting grooves.

[0022] In aspects according to the present invention, a series of push-off elements disposed between at least one adjacent pair of cutting grooves among the plurality of cutting grooves are unequally spaced between the cutting grooves.

[0023] In various aspects of the present disclosure, multiple push-off elements disposed between these adjacent pairs of cutting slots in the multiple cutting slots are synchronized so that the surgical drill does not completely bottom out when the next approaching cutting slot of rotation contacts the bone, thereby producing a more angular and powerful cut.

[0024] In various aspects of the present disclosure, multiple push-off elements disposed between these adjacent pairs of cutting slots in the multiple cutting slots are synchronized so that the surgical drill is pushed away from the bone laterally in the rotational direction rather than vertically in a direction orthogonal to the bone between each adjacent pair of slots. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The above and other aspects and features of the present disclosure will become more apparent from the following detailed description when considered in conjunction with the accompanying drawings, in which like reference numerals identify similar or identical elements.

[0026] Figure 1 is a perspective view of a micro-drill surgical instrument according to aspects of the present disclosure;

[0027] Figure 1A is a perspective view of an angled attachment assembly including a surgical drill disposed therein for cutting bone;

[0028] Figure 2 is a plan view of an attachment assembly according to aspects of the present disclosure;

[0029] Figure 3A It is taken along line 3A-3A Figure 2 An internal cross-sectional view of an attachment assembly;

[0030] Figure 3B It is taken along line 3A-3A Figure 2 An internal cross-sectional view of an alternative attachment assembly;

[0031] Figure 3C It is taken along line 3A-3A Figure 2 An internal cross-sectional view of an alternative attachment assembly;

[0032] Figure 4 yes Figure 2 an exploded view of an attachment assembly of;

[0033] Figure 5 is an internal cross-sectional view of an attachment tube along a longitudinal axis of the attachment tube according to aspects of the present disclosure;

[0034] Figure 6 is an internal cross-sectional view of an attachment assembly according to aspects of the present disclosure;

[0035] Fig. 7A is an enlarged perspective view of a distal end of a surgical drill including a plurality of slots disposed thereabout for cutting bone;

[0036] Figure 7B It is taken along line 7B-7B Fig. 7A An enlarged cross-section of a surgical drill highlighting a push-off member disposed between two adjacent grooves; and

[0037] Figure 8 is configured according to aspects of the present disclosure for use with Figure 1 and Figure 1A Surgical instruments and Fig. 7A and Figure 7B Schematic diagram of an exemplary robotic surgical system for use with a surgical drill.

[0038] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. DETAILED DESCRIPTION

[0039] Example embodiments will now be described more fully with reference to the accompanying drawings and first with reference to Figure 1 , Figure 1A and Figure 2 , showing an instrument assembly 10. The instrument assembly 10 may be similar to one or more known instrument assemblies for removing tissue (e.g., bone or other hard tissue structures), such as the . M4 Micro Debrider Power Handpiece or Midas Legend EHS High speed surgical drills, which may be selectively used in ear, nose and throat (ENT) or neurosurgery. The instrument assembly 10 includes a motor housing 16 extending along an axis 20a and may have various angled or ergonomically shaped portions as described below.

[0040] The housing 16 includes a motor 17 disposed therein, the motor having a chuck assembly 18, the chuck assembly consisting of various gears and components to operably connect the motor 17 to a surgical tool (e.g., a surgical drill 20). The drill 20 includes a working end 22 and a rod 24. The working end 22 may include a surgical drill, a surgical drill bit, a resection tool, or other suitable working surgical tool. The motor 17 is configured to adjust the torque reaching the working end 22 through the shaft 24 via an interconnection within the chuck 18.

[0041] The instrument assembly 10 also includes an attachment assembly 40, which includes an attachment base or housing 30 and an attachment tube 34, which includes a hole 42 defined therethrough, which extends from the proximal end 35 to the distal end 37. The attachment base 30 and the attachment tube 34 can be selectively removed from the chuck 18 via any removable coupling known in the art during a selected surgery. The attachment tube 34 can include a proximal portion B and a distal portion A, which are arranged at an angle relative to each other depending on the specific surgical purpose. The angle between portion A and portion B can be selected based on the selected surgery, and a movable interconnect can also be included to provide power from the motor 17 to the tool 20 through the angled area. An example of how these interconnects can be formed is disclosed in co-owned U.S. Patent No. 10,527,478, the entire contents of which are incorporated herein by reference.

[0042] Continue to refer Figure 3A And also refer to Figure 3B , Figure 3C and Figure 4 , discussing the attachment assembly 40 in more detail. The attachment assembly 40 includes a generally cylindrical outer attachment tube 34 engaged within the attachment base 30. The inner bore 42 is formed by an inner annular wall that changes diameter along the length of the bore 42 at selected areas, for example, the proximal end 35 has a larger diameter than the distal end 37.

[0043] As described above, the attachment tube 34 includes a connection area 50 that is received within the receiving section 52 near the proximal end 35. The connection area 50 can have external threads to engage the internal threads in the receiving section 52. It is contemplated that other coupling mechanisms, such as press fit, brazing and / or welding, threaded connections, adhesives, stakes, or other suitable connections can be used to connect the attachment tube 34 to the attachment base 30. In addition, in various embodiments, the attachment tube 34 can be directly and indirectly coupled to the attachment base 30 ( Figure 3A ), may only be indirectly coupled to the attachment base 30 ( Figure 3B ), or may be directly coupled to the attachment base 30 ( Figure 3C ).

[0044] The receiving section 52 of the attachment base 30 may include a first inner diameter 58 that may be larger than the outer diameter 56 to receive an intermediate or damping member 70 (also located at Figure 4 ). The receiving section 52 may also include a second inner diameter 60 that may be substantially equal to or slightly larger than the outer diameter 56 of the tube connection section 50. The relationship of the inner diameter 58 and the outer diameter 56 of the damping member 70 may allow or form a press-fit connection between the damping member 70 and the attachment base 30. Thus, when assembled, the connection area 50 of the attachment tube 34 may be generally concentric with the receiving section 52 of the attachment base 30.

[0045] The tool 20 is configured to rotate about the axis 20a via torque transmitted to the tool 20 from the motor 17 within the motor assembly 16. What is commonly referred to as "tool chatter" can be caused by movement of the tool 20 and / or the instrument assembly 10 in a direction orthogonal to the axis 20a (see double-headed arrow 55). The rotation of the tool 20 can cause vibrations in any lateral direction relative to the axis 20a. Operating the tool 20 at a selected rotational speed can also reduce vibrations, such as lateral movement of the tool 20 and / or the attachment assembly 40 away from the axis 20a.

[0046] like Figure 3A As shown, the connection area 50 of the attachment tube 34 can extend to the direct bonding area 62 to allow the attachment tube 34 to be directly connected to the attachment base 30. For example, in the direct bonding area 62, the external threads on the tube connection section 50 can engage the internal threads formed on the inner diameter 60 of the connection area 52 at the direct bonding area 62. The attachment tube 34 can then be threaded to the attachment base 30 to allow the attachment tube 34 to be directly connected to the attachment base 30. However, it should be understood that other connections and bonding of the attachment tube 34 to the base 30 can be made. For example, a selected adhesive material, a press fit, and other connections can be formed between the attachment tube 34 and the attachment base 30.

[0047] Reference Figure 3B , it should be understood that the attachment tube 34 need not be directly connected to the attachment base 30. Instead, the attachment assembly 40x may have an attachment tube 34x. The attachment tube 34x may be substantially similar to the attachment tube 34 described above. The attachment tube 34 may have a connection portion 50 that may only contact the damping member 70 within the attachment base 30. Thus, the attachment tube 34 may be interconnected with the attachment base 30 via the damping member 70 and not directly contact the attachment base 30 at least within the connection area 52. However, the attachment tube 34 may contact the outer surface 53 of the attachment base 30.

[0048] like Figure 3C As shown, the attachment tube 34 need only directly contact and connect to the attachment base 30. Connecting the attachment tube 34 only directly to the attachment base 34 may be a selected alternative to including the damping member 70. The attachment assembly 40y may have an attachment tube 34y. The attachment tube 34y may be substantially similar to the attachment tube 34 described above. The attachment tube 34y may have a connection portion 50 that may only contact the attachment base 30, including at the outer surface 53 and the direct bonding area 62. Therefore, if the inner diameter 58 is maintained, a gap 71 may be formed. However, it should be understood that the connection area 52 may only include the inner diameter 60, so that there is no gap 71 ( Figure 4 ).

[0049] Continue to refer to Figures 1 to 3C And refer to Figure 4, the damping member 70 may extend a length 72 between an outer or distal end 74, which may include a lip or edge 76, and a proximal end 78. The damping member 70 may be generally cylindrical and have a generally annular wall forming an outer diameter 82 and an inner diameter 84. The outer diameter 82 may be substantially equal to or slightly less than the inner diameter 58 of the base connection area 52. Thus, the damping member 70 may be press-fit and retained in the connection area 52. However, it should also be understood that the damping member 70 may be coupled to the attachment base 30 by an adhesive, a threaded connection, or other suitable connection. The inner diameter 84 may be formed to receive the connection area 50 and may be substantially equal to or equal to the inner diameter 60 of the connection area 52.

[0050] It should also be understood that according to various embodiments, the damping member 70 can be molded or formed onto the attachment base 30, the attachment tube 34, or both. For example, the damping member 70 can be injection molded into the connection portion 50 of the attachment tube 34 or the connection portion 52 of the attachment base 30. Thus, the damping member 70 can be connected in a selected manner relative to the attachment assembly 40.

[0051] The damping member 70 may also have a thickness (formed by the difference between the inner diameter 84 and the outer diameter 82), a length 72, a material, or other characteristics selected based on the operating parameters of the attachment assembly 40. The operating parameters may include the rotational speed of the tool 20, the length of the attachment tube 34, the angle of the attachment tube 34', the diameter of the shaft 24, etc. Further, the damping member 70 may be selected from a material having a relatively high loss factor (i.e., a material that can absorb kinetic energy and / or convert kinetic energy into another form of energy), but is also suitable for the selected surgery. For example, a viscoelastic polymer can provide a selected loss factor while being able to withstand repeated heat and steam sterilization and / or chemical sterilization for surgical procedures on human patients. The damping member 70 may be formed, for example, of an elastomer, silicone rubber, FKM (determined by ASTM D1418) or similar fluoroelastomer, chlorobutyl elastomer, or other polymer or elastomeric material. An example includes EI du Pont de Nemours or The Chemours Company of Wilmington, Delaware. Fluoropolymer elastomer.

[0052] As described above, in various embodiments, the tube connection area 50 can fit within the inner diameter 84 of the damping member 70 and be placed within the connection area 52 of the attachment base 30. According to various embodiments, as described above, the tube connection area 50 can extend no longer than the length 72 of the damping member 70. However, it should be understood that the attachment tube 34 can be directly connected and connected only to the attachment base 30.

[0053] The damping member 70 may include the various characteristics discussed above to tune vibrations at the portion of the instrument assembly 70 such as at the base 30 or motor housing 16 held by the user and chatter at the tool tip 22. The damping member 70 may be tuned to dampen vibrations and / or tool chatter by a selected amount by selecting thickness, length, material, location, etc. Reduced vibration and tool chatter may ensure accurate resection or operation of the assembly 10.

[0054] The tuned vibration may occur without or in addition to the damping member 70 and the characteristics of the damping member 70. For example, the attachment area 50 of the attachment tube 34 may include a selected wall thickness 90 to help reduce vibration during operation of the tool 20. Figure 3A , Figure 3B and Figure 3C As shown, the tube connection region 50 may include a wall thickness 90 that may be selected based on various characteristics and constraints of the system. The thickness 90 of the connection region 50 may be formed by increasing the inner diameter of the attachment tube 34 over a selected portion of its length.

[0055] For example, Figure 3A , Figure 3B and Figure 3C As shown, the thickness 90 is formed by an inner diameter 92 in a first portion of the attachment tube 34, while the inner diameter 94 is formed in a second portion of the attachment tube 34. The attachment tube 34 may include other inner diameters, such as a distal inner diameter 95, where the tool 20 extends from the attachment tube 34 to near the working end 22 of the tool 20. It should be understood that the attachment tube 34 may be coupled to the attachment base 30 without the damping member 70. Therefore, the selected two inner diameters 92 and 94 that form the thickness may provide vibration damping characteristics alone.

[0056] Thus, vibration reduction can be produced using one or more of a selected thickness, an axial length of an area having a selected thickness, a damping member, etc. Selected vibration design limits (including vibration reduction through selected features) can be selected to be produced by reducing or forming a selected thickness at a selected location. The reduced or formed thickness can be achieved by cutting or forming an inner diameter or cutting into the outer surface of the attachment tube 34.

[0057] As briefly discussed above, during operation, the tool 20 can rotate about the axis 20a in a selected direction and can oscillate. During the rotation and oscillation of the tool 20, vibrations can be induced in the attachment assembly 40. The vibrations can be attributed to the rotation of the tool 20 or the operation of the motor 17 in the motor housing or motor assembly 16. The vibrations can be reduced by one or both (i.e., a combination) of the thickness 90 of the attachment tube 34 and the damping member 70. As described above, the reduction of vibrations and tool chatter can be achieved by forming a selected thickness 90 at any appropriate axial position along the attachment tube 34. The tool shaft 24 can ride in one or more bearings 100, which are connected within the inner diameter 94 of the attachment tube 34. Therefore, the rotation of the tool 20 can be radially guided by the attachment tube 34. This can transmit vibrations to the attachment housing 30, the attachment tube 34, and can be transmitted to the motor 16 or other parts grasped by the user.

[0058] Thus, the attachment tube 34 includes a selected thickness 90 and can be tuned relative to the operation of the tool 20 and the geometry and configuration of the attachment tube 34 and / or the attachment base 30. For example, when determining the selected thickness 90 of the attachment tube 34, the inner diameter 94 of the hole 33 extending through the attachment tube 34, the length of the attachment tube 34, the geometry of the attachment base 30, the geometry of the attachment tube 34, such as the angle of the attachment tube 34' can be considered. In addition, the size (including thickness, such as the difference between the inner diameter 84 and the outer diameter 82 of the damping member 70) can be selected to tune the vibration reduction of the attachment assembly 40 and / or the tool assembly 10. The tuning of the vibration felt by the user (such as a surgeon) and the tuning of the tool vibration (i.e., the lateral movement of the tool head 22) can be based on various features, as discussed herein. In addition, the details of the features (including size, placement, etc.) can be based on the details of the selected attachment assembly. As described above, various attachment assemblies can be provided in various configurations so that the details of the tuning features can vary between attachment assemblies.

[0059] Tuning, selecting the amount of vibration and tool chatter, or eliminating vibration and tool chatter may vary based on several considerations. For example and as Figure 5 As shown in , another embodiment of the attachment tube 34 may include a selected thickness as a vibration dampening or tuning feature distal to the end (including the proximal end 35). For example, the attachment tube 34" may include an inner diameter substantially along the entire length of the attachment tube 34". However, the vibration dampening or tuning feature 120 may be formed as a notch or groove inside or outside the attachment tube 34" to form at least an area having an inner diameter 122. The inner diameter 122 provides a selected thickness relative to the outer diameter of the attachment tube 34". The vibration dampening feature 120 may include a complete annular groove or may include a strut or connection formed therein.

[0060] In addition, the vibration damping feature 120 can provide selected flexibility at selected locations along the length of the attachment tube 34" to help reduce or eliminate selected vibrations during operation of the tool tip 20. For example, the vibration damping feature can have a length 120a. The vibration damping feature 120 can have a first end 120' spaced a distance 120b from the proximal end 35 and a second end 120" spaced a distance 120c from the distal end 120c. The selected lengths of 120a, 120b, and 120c can help tune the damping characteristics and can be selected based on the characteristics of the tube 34" and / or the tool 20 and / or the attachment base 30. In addition, the relationship of the inner diameters 122 and 94 can be further selected to tune the amount of damping. The inner diameters 122 and 94 and sections having them can also be selectively placed along the length of the attachment tubes 34, 34' and 34".

[0061] As described above, the bearing 100 may be positioned within the attachment tube 34", and the operation of rotating the tool 20 about the axis 20a may induce vibrations in the attachment assembly 40. The vibration reduction feature 120 including the inner diameter 122 relative to the inner diameter 94 of the attachment tube 34" may provide selected vibration reduction. The attachment tube 34" may be connected to the attachment base 30 in a manner substantially similar to Figure 3A , Figure 3B or Figure 3C , directly connected to the attachment base 30 , interconnected only through the damping member 70 , or a combination of interconnected to the damping member 70 and directly attached to the attachment base 30 .

[0062] Thus, it should be appreciated that the attachment tube 34" may be formed to include vibration reduction or tuning features, such as, alone or in combination with the damping member 70. Figure 5 The features shown in 120 or Figure 3A , Figure 3B or Figure 3C The thickness of the wall 90 shown in FIG. The vibration damping feature can help tune the vibration, which can include minimizing or eliminating the vibration generated by the operation of the instrument assembly 10 to rotate the tool 20 about the axis 20a. By reducing the vibration, the unselected movement of the instrument can be reduced, and the operation of the tool 20 can be smoother. This can allow for substantially precise operation of the tool 20, especially over a long period of time, to allow for speed of operation and selected results for the patient. Reducing vibration can also reduce user fatigue.

[0063] refer to Figure 6 , an attachment assembly 240 is shown. The attachment assembly 240 is similar to the attachment assembly 40 described above. Figure 6The attachment assembly 240 shown in the cross-sectional view of FIG. 2 is understood to include a hole that may include an inner diameter 92 and a second, different inner diameter 94. In addition, the attachment assembly 240 may include an attachment base 30 as described above and an attachment tube 234 connected to the attachment base 30 in at least one of a variety of ways. According to various embodiments including features of those embodiments discussed above, the attachment tube 234 may (1) be directly connected to the attachment base 30 only, (2) be connected to the damping member ( Figure 6 ) interconnected, or (3) connected to both the damping member and the attachment base 30 ( Figure 6 Attachment assembly 240 may also include a connection portion 52 to which base 30 is attached and a connection portion 50 to which tube 234 is attached.

[0064] The attachment tube 234 may include various interconnecting portions, such as a damping member 260 interconnecting a first rigid member 264 and a second rigid member 266. The rigid members 264, 266 may include selected outer dimensions, including those discussed above, and also include inner diameters 92 and / or 94. In addition, the damping member 260 may also define an inner diameter 94. However, it should be understood that the damping member 260 may have a selected axial position, mass, length, density, inner diameter, etc. on the attachment tube 234, as discussed above. In addition, the damping member 260 may be formed of various materials, including those discussed above.

[0065] The attachment tube 234 may be connected to the attachment base 30 as discussed above. However, the damping member 260 may be included as a feature of the attachment tube 234 or between a portion of the attachment tube 234 and the attachment base 30. Figure 6 As shown, the attachment base 30 can be connected to the first rigid portion 264, and the damping member 260 can be positioned between a portion of the attachment tube 234 (including the second rigid portion 266) and the attachment base 30. Therefore, the damping member 260 is positioned between at least a portion of the attachment tube 234 (i.e., the second rigid member 266) and the attachment base 30. In various configurations, those skilled in the art may consider the first rigid portion 264 to be a part of the attachment base 30 when connected to the attachment base 30. However, it should be understood that another damping member (such as the damping member 70) can be generally positioned near the connection portion and the areas 50, 52, such as positioned in the gap 71. Therefore, it should also be understood that according to various embodiments, the attachment assembly 240 may include multiple damping members. As Figure 6 As particularly shown in FIG. 2 , the damping member 260 is positioned a distance from the distal end 53 of the attachment base 30 and is fully integrated into the attachment tube 234 .

[0066] The damping member 260 can be connected to the rigid members 264, 266 according to various suitable bonding techniques. For example, the damping member 260 can be adhered, welded, molded directly to the rigid members 264, 266, or other suitable bonding or fixing techniques are used. However, the damping member 260 can dampen the movement between the second rigid member 266 and the first rigid member 264 and the attachment base 30. Therefore, the damping member 260 (including the various features of the damping member 260) can be used to help tune the vibration and vibration of the instrument 10, as discussed above.

[0067] As described above, the vibration dampening features may be individually or collectively tuned to a particular configuration of the tool assembly 10. For example, the configuration of the tool assembly may include the size of the bore, the length of the attachment tube 34, the angle of the attachment tube 34', etc. The tuning features may include selecting the thickness 90 of the wall, the length of the region having the thickness 90, the axial position of the wall having the thickness 90, the thickness and / or length or axial positioning of the damping member 70, and / or the axial position, length, or relative inner diameter of the damping feature 120.

[0068] The vibration response of the tool 20 and the attachment assembly 40 and the associated vibration reduction (e.g., by damping or increasing stiffness or decreasing stiffness) can be modeled by one or more structural dynamic techniques. The modeling techniques can include modal analysis, harmonic analysis, or transient dynamic analysis. Additionally or alternatively, various physical testing techniques can be used to determine the vibration response. These methods can predict the frequencies and displacements involved depending on the technique.

[0069] If properly tuned, a controlled amount of tool chatter can be effective in improving cutting efficiency or improving cutting effectiveness. Fig. 7A and Figure 7B As shown in , if the amount of vibration of the surgical drill 320 in contact with the bone is effectively controlled and properly tuned, the excess potential energy associated with each cutting flute 320 as it contacts the bone will improve the effectiveness of the cutting action during the cutting stroke.

[0070] More specifically and as in Figure 7BAs best seen in the enlarged view of , push-off elements (e.g., 323a) are disposed in clearance surfaces 325 (e.g., clearance surfaces 325a between each adjacent pair of cutting slots (e.g., cutting slots 322a and 322b)). As the surgical drill 320 rotates, each push-off element (e.g., push-off element 323a disposed between corresponding slots 322a and 322b) deflects or "bumps" the surgical drill 320 away from the bone by a small or controlled amount (e.g., depending, among other things, on the proportions and size of the push-off elements 323a, the rotational speed of the surgical drill 320, the depth of the clearance surfaces 325, the stiffness of the rod 324), thereby generating potential energy that is harnessed and timed to increase cutting efficiency and effectiveness. In other words, before the next slot (e.g., slot 322b) contacts the bone for cutting during rotational cutting, the stiffness of the system and the tuned potential energy provided by the push-off element 323a (as described above) quickly returns the surgical drill 320 into the bone and toward the bone, thereby forcing slot 322b to make a more powerful and efficient cut.

[0071] As can be appreciated, instead of relying on the surgeon to pre-tune or continuously tune the instrument assembly 10 during use to minimize tool chatter or relying on the surgeon's skill to try and more finely "dynamically" tune the instrument assembly 10 to more effectively and efficiently cut bone using tool chatter, customizing the surgical drill 320 with a push-off element (e.g., push-off elements 323a to 323b) allows the surgical drill 320 to "self-tune" as long as the instrument assembly 10 remains within pre-designed operating parameters (e.g., operating speed (RPM), torque, etc.).

[0072] In an embodiment, the size of the push-off element (hereinafter referred to as the push-off element 323a) can be designed according to a specific surgical purpose, or matched with the specific cutting characteristics of the cutting groove 322. In an embodiment, the push-off element 323a is non-cutting, but may include other features to enhance the cutting effect, such as scoring, filing, etc. In an embodiment, the geometry of the push-off element 323a can be synchronized so that when the approaching cutting groove 322 contacts the bone, the surgical drill 320 will not completely bottom out, thereby producing a more angled or smoother cut, rather than a strong cut. In this case, the size of the push-off element 323a can be set to push away from the bone along the rotational direction "R", rather than along the vertical axis "VV".

[0073] In other embodiments, more than one push-off element 323a may be disposed between adjacent slots (e.g., slots 322a and 322b). The spacing of the push-off elements 323a, 323b disposed within the gap surfaces 325a, 325b between adjacent slot pairs (e.g., slots 322a, 322b and slots 322b, 322c), respectively, may be the same or different, depending on a particular purpose or to achieve a particular tuning effect.

[0074] As described above, the tuning of the tool vibration depends on many factors, which can be designed to allow the surgical drill 320 to "self-tune" at a specific speed (RPM) and / or torque, thereby reducing the surgeon's manual tuning during use. These factors can be used to enhance the effectiveness and efficiency of the cutting effect and the efficiency combined with the push-off element 323a. These factors include: the number and quality of the cutting grooves 322, the geometry and quality (e.g., cross-sectional properties) of the tool shaft 324, the unsupported length of the tool shaft 324 away from the bearing 100, the number and location of the tool shaft support bearings 100 along the attachment length, the geometry and lateral stiffness (quality) of the attachment tube (e.g., the attachment tube 34), etc.

[0075] In addition, and as described above, the design of the geometry and mass of the surgical drill 320, the geometry and mass of the slot 322, the geometry and mass of the tool shaft 324, and / or the geometry and mass of the attachment tube 34 can also be used to control other vibration characteristics of the instrument assembly 10, including torsional vibration effects on other system components during activation. In an embodiment, the tool shaft 324 or the slot 322 can be provided with additional mass to improve the stability, stiffness, or smoothness / resonance of the surgical drill 320.

[0076] It has been demonstrated that utilizing a series of push-off elements (e.g., push-off elements 323a to 323b) between adjacent slots 322a, 322b and the surgical drill 320 operating within appropriate manufacturing parameters improves cutting efficiency (measured by the amount of material removed normalized by the reaction force of the bone supplied to the surgical drill) by as much as 2 to 3 times that of other known prior art designs.

[0077] Go to Figure 8 , shows a robotic surgical system 1000 configured for use in accordance with the present disclosure. Aspects and features of the robotic surgical system 1000 that are not germane to an understanding of the present disclosure are omitted to avoid obscuring the aspects and features of the present disclosure with unnecessary detail.

[0078] The robotic surgical system 1000 generally includes a plurality of robotic arms 1002, 1003; a control device 1004; and an operating console 1005 coupled to the control device 1004. The operating console 1005 may include a display device 1006, which may be particularly configured to display a three-dimensional image; and manual input devices 1007, 1008, through which a clinician (e.g., a clinician) may be able to remotely manipulate the robotic arms 1002, 1003 in a first operating mode. The robotic surgical system 1000 may be configured for a patient 1013 lying on a patient table 1012 for minimally invasive treatment. The robotic surgical system 1000 may further include a database 1014, particularly a database coupled to the control device 1004, in which preoperative data and / or anatomical maps, for example, from the patient 1013 are stored.

[0079] Each of the robotic arms 1002, 1003 may include a plurality of components connected by joints and mounted devices, which may be, for example, surgical tools "ST". The surgical tools "ST" may include, for example, the micro-drill instrument assembly 10 of the present disclosure, thereby providing any of the functions detailed above on the robotic surgical system 1000.

[0080] The robotic arms 1002, 1003 may be driven by an electric drive (e.g., a motor) connected to a control device 1004. The motor may be, for example, a rotary drive motor configured to provide a rotational input to accomplish one or more desired tasks. The control device 1004 (e.g., a computer) may be configured to activate the motor in a manner specifically with the aid of a computer program so that the robotic arms 1002, 1003 and thus the surgical tools "ST" mounted thereon perform desired movements and / or functions in accordance with corresponding inputs from manual input devices 1007, 1008, respectively. The control device 1004 may also be configured in such a manner that it adjusts the movement of the robotic arms 1002, 1003 and / or the motors.

[0081] More specifically, the control device 1004 can control one or more of the motors based on rotation, for example, using a rotational position encoder (or Hall effect sensor or other suitable rotational position detector) associated with the motor to control the rotational position to determine the rotational output from the motor and the rotational input provided thereby. Alternatively or in addition, the control device 1004 can control one or more of the motors based on torque, current, or in any other suitable manner.

[0082] Although various aspects of the disclosure have been shown in the accompanying drawings, it is not intended to limit the disclosure to these aspects, as the disclosure is intended to be as broad as the art allows and the specification should be read in the same manner. Therefore, the above description should not be interpreted as limiting, but merely as an illustration of specific aspects. Those skilled in the art will be able to envision other modifications within the scope and spirit of the claims appended hereto.

Claims

1. A surgical drill for cutting bone, the surgical drill comprising: a rod adapted to be selectively coupled to an attachment tube of a micro-drill instrument assembly and configured for selective rotation when the micro-drill instrument is activated; a plurality of cutting grooves disposed at a distal end of the rod, the plurality of cutting grooves defining a corresponding number of clearance surfaces disposed therebetween, each cutting groove of the plurality of cutting grooves comprising a cutting edge and a trailing edge; and At least one push-off element is defined in a gap surface between at least one adjacent pair of the plurality of cutting grooves, the at least one push-off element being configured to contact bone during rotation of the surgical drill and being configured to deflect the surgical drill relative to the bone and optimize the cutting efficiency and effectiveness of the surgical drill based at least on the rotational speed of the surgical drill.

2. The surgical drill for cutting bone according to claim 1, wherein a corresponding plurality of push-off elements are provided between the plurality of cutting grooves.

3. The surgical drill for cutting bone according to claim 2, wherein the plurality of push-off elements are configured to deflect the surgical drill based on at least a rotation angle of the surgical drill or an oscillation angle of the surgical drill.

4. A surgical drill for cutting bone according to claim 2, wherein the plurality of push-off elements are non-cutting.

5. A surgical drill for cutting bone according to claim 2, wherein a series of push-off elements are provided between at least one adjacent pair of cutting grooves in the plurality of cutting grooves.

6. A surgical drill for cutting bone according to claim 5, wherein the series of push-off elements disposed between at least one adjacent pair of cutting slots in the plurality of cutting slots are equally spaced between the cutting slots.

7. A surgical drill for cutting bone according to claim 5, wherein the series of push-off elements disposed between at least one adjacent pair of cutting slots in the plurality of cutting slots are unequally spaced between the cutting slots.

8. A surgical drill for cutting bones according to claim 2, wherein the plurality of push-off elements disposed between the adjacent pairs of cutting grooves in the plurality of cutting grooves are synchronized so that the surgical drill does not completely bottom out when the next approaching cutting groove of rotation contacts the bone.

9. A surgical drill for cutting bones according to claim 2, wherein the plurality of push-off elements arranged between the adjacent pairs of cutting grooves in the plurality of cutting grooves are synchronized so that the surgical drill is pushed away from the bone laterally in the rotation direction rather than vertically in the direction orthogonal to the bone between each adjacent pair of grooves.

10. A micro-drilling instrument for cutting bones, the micro-drilling instrument comprising: A micro-drill assembly, the micro-drill assembly comprising: a motor housing having a motor disposed therein; an attachment tube operably coupled to the motor housing at a proximal end thereof and configured to selectively receive a surgical drill therein for cutting bone; and a chuck for operably receiving a shaft of the surgical drill so that the surgical drill can selectively rotate when the motor is activated, wherein the surgical drill comprises: a plurality of cutting grooves disposed at a distal end of the rod, the plurality of cutting grooves defining a corresponding number of clearance surfaces disposed therebetween, each of the plurality of cutting grooves comprising a cutting edge and a trailing edge; and At least one push-off element is defined in a gap surface between at least one adjacent pair of the plurality of cutting grooves, the at least one push-off element being configured to contact bone during rotation of the surgical drill and being configured to deflect the surgical drill relative to the bone and optimize the cutting efficiency and effectiveness of the surgical drill based at least on the rotational speed of the surgical drill.

11. The micro-drill instrument for cutting bones according to claim 10, wherein a corresponding plurality of push-off elements are provided between the plurality of cutting grooves.

12. The micro-drill instrument for cutting bone according to claim 11, wherein the plurality of push-off elements are configured to deflect the surgical drill based on at least a rotation angle of the surgical drill or an oscillation angle of the surgical drill.

13. The micro-drill instrument for cutting bone of claim 11, wherein the plurality of push-off elements are non-cutting.

14. The micro-drill instrument for cutting bone according to claim 11, wherein a series of push-off elements are provided between at least one adjacent pair of cutting grooves in the plurality of cutting grooves.

15. The micro-drill instrument for cutting bone according to claim 14, wherein the series of push-off elements disposed between at least one adjacent pair of cutting grooves in the plurality of cutting grooves are equally spaced between the cutting grooves.

16. The micro-drill instrument for cutting bone of claim 14, wherein the series of push-off elements disposed between at least one adjacent pair of cutting grooves in the plurality of cutting grooves are unequally spaced between the cutting grooves.

17. The micro-drill instrument for cutting bones according to claim 11, wherein the plurality of push-off elements disposed between the adjacent pairs of cutting grooves in the plurality of cutting grooves are synchronized so that the surgical drill does not completely bottom out when the next approaching cutting groove of rotation contacts the bone.

18. A micro-drill instrument for cutting bones according to claim 11, wherein the plurality of push-off elements arranged between the adjacent pairs of cutting grooves in the plurality of cutting grooves are synchronized so that the surgical drill is pushed away from the bone laterally in the rotation direction rather than vertically in the direction orthogonal to the bone between each adjacent pair of grooves.

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