Surgical handpiece and associated accessories for driving orthopedic pins

Abstract

A surgical power tool assembly is provided. The assembly includes a handpiece and a pin driver attachment coupled to the handpiece. The handpiece includes a motor and a controller for operating the motor. A trigger is movably coupled to a housing of the handpiece. The controller controls the speed of the motor based on an actuation position of the trigger. An output drive is coupled to the motor and is rotated about an axis by the motor. An actuation surface of the trigger is movable relative to the housing such that the actuation surface is closer to the axis in the actuated position than in the inactuated position. The pin driver attachment includes a housing for coupling to the handpiece. The pin driver attachment can include a lever for clamping the surgical pin to drive the surgical pin into bone.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to and the benefit of all U.S. Provisional Patent Application No. 63 / 457,941, filed April 7, 2023, and Provisional Patent Application No. 63 / 486,924, filed February 24, 2023, and Provisional Patent Application No. 63 / 396,506, filed August 9, 2022, and Provisional Patent Application No. 63 / 396,499, filed August 9, 2022, the entire contents of which are expressly incorporated herein by reference. [Background technology]

[0002] Conventional medical and surgical procedures routinely involve the use of surgical tools and instruments that allow surgeons to access and manipulate a surgical site. As a non-limiting example, rotary instruments for driving surgical pins, such as surgical handpiece assemblies, are commonly utilized in connection with orthopedic surgical procedures to drive surgical pins into bone. Conventional surgical handpiece assemblies have a "pistol grip" configuration. In procedures in which such surgical handpiece assemblies are used, it can be difficult for a user to accurately orient the surgical handpiece to drive a surgical pin into bone without repositioning the surgical handpiece itself or the patient.

[0003] While surgical handpiece assemblies for driving surgical pins are routinely utilized to assist in the performance of a variety of different types of medical and / or surgical procedures, there remains a need in the art for continuing improvements in such surgical handpiece assemblies. Summary of the Invention

[0004] A first aspect of the present disclosure provides a surgical power tool assembly for driving surgical pins, such as orthopedic pins. The surgical power tool assembly includes a surgical handpiece having a handpiece housing, an electric motor positioned within the handpiece housing, a controller positioned within the handpiece housing, a battery removably coupled to the handpiece housing and configured to power the controller, a trigger movably coupled to the handpiece housing and having an actuation surface movable between an actuated position and an inactuated position, the controller configured to control the speed of the motor based on the actuation position of the trigger, and an output drive coupled to the electric motor and configured to be rotated about an axis by the electric motor, the actuation surface being closer to the axis in the actuated position than in the inactuated position. The assembly also includes a pin driver attachment including an attachment housing removably coupled to the handpiece housing, an actuator movably coupled to the attachment housing, and a collet operable in clamping and unclamping states and operable to engage the surgical pin when in the clamping state, the actuator being operably coupled to the collet by movement of the actuator between a first position and a second position, the collet being in the clamping state when the actuator is in the first position and the collet being in the unclamping state when the actuator is in the second position.

[0005] A second aspect of the present disclosure provides a surgical power tool assembly for driving a surgical pin. The surgical power tool assembly includes a surgical handpiece having a handpiece housing, an electric motor positioned within the handpiece housing, a controller positioned within the handpiece housing, a battery removably coupled to the handpiece housing and configured to power the controller, a trigger movably coupled to the handpiece housing and having an actuation face movable between an actuated position and an inactuated position, the controller configured to control the speed of the motor based on the actuation position of the trigger, and an output drive coupled to the electric motor and configured to be rotated about an axis by the electric motor, the actuation face being closer to the axis in the actuated position than in the inactuated position. The assembly also includes a pin driver attachment for driving the surgical pin.

[0006] A third aspect of the present disclosure provides a surgical power tool assembly including a surgical handpiece having a handpiece housing, an electric motor positioned within the handpiece housing, a controller positioned within the handpiece housing, a battery removably coupled to the handpiece housing and configured to power the controller, a trigger pivotally coupled to the handpiece housing, the controller configured to turn on the electric motor when the trigger is depressed and adjust a speed of the electric motor based on how far the trigger is depressed, and an output drive coupled to the electric motor and configured to be rotated about an axis by the electric motor. The assembly also includes a pin driver attachment having an attachment housing removably coupled to the handpiece housing, an operating member movably coupled to the attachment housing, and a collet operable in clamping and unclamping states and operable to engage the surgical pin when in the clamping state, the operating member operably coupled to the collet by movement of the operating member between a first position and a second position, the collet being in the clamping state when the operating member is in the first position and the collet being in the unclamping state when the operating member is in the second position.

[0007] A fourth aspect of the present disclosure provides a surgical power tool assembly for driving a surgical pin. The surgical power tool assembly includes a surgical handpiece having a handpiece housing, an electric motor positioned within the handpiece housing, a controller positioned within the handpiece housing, a battery removably coupled to the handpiece housing and configured to power the controller, a trigger pivotally coupled to the handpiece housing, the controller configured to turn on the electric motor when the trigger is depressed and adjust the speed of the electric motor based on how far the trigger is depressed, and an output drive coupled to the electric motor and configured to be rotated about an axis by the electric motor. The surgical power tool assembly also includes a pin driver attachment for driving the surgical pin.

[0008] A fifth aspect of the present disclosure provides a method for inserting a surgical pin with a surgical power tool assembly. The method includes inserting the surgical pin into a coupler. The method also includes grasping the housing with a user's hand so that the user's thumb is closer to the battery than the coupler. The method also includes applying a trigger with the user's finger while the user's thumb is closer to the battery than the coupler. The method also includes driving the included surgical pin into bone with the surgical power tool assembly.

[0009] A sixth aspect of the present disclosure provides a method for inserting a pin with a surgical power tool. The method includes grasping a housing of the surgical power tool with a user's hand. The method also includes engaging an index finger of the user's hand on a lever to clamp the surgical pin with a collet. The method also includes engaging a finger other than the index finger of the user's hand on a trigger. The method also includes driving the surgical pin into bone with the surgical power tool.

[0010] A seventh aspect of the present disclosure provides a method for driving a pin in a robotic-assisted total knee replacement procedure. The method also includes providing a battery-powered surgical tool. The method also includes coupling a surgical attachment to the battery-powered surgical tool. The method also includes drilling a hole in at least one bone selected from the femur, tibia, and patella with a drill bit using a first drive portion of the surgical attachment. The method also includes driving a first pin into one of the femur, tibia, or patella with a second drive portion of the surgical attachment. The method also includes driving a second pin having a different diameter than the first pin into another of the femur, tibia, or patella with a third drive portion of the surgical attachment.

[0011] An eighth aspect of the present disclosure provides a powered surgical instrument. The powered surgical instrument includes a housing defining an internal cavity, the housing including a handle portion. The instrument also includes a body portion extending distally from the handle portion. The instrument also includes a tool assembly disposed at a distal end of the body portion. The instrument also includes a control circuit and a drive motor disposed within the internal cavity, the drive motor mechanically coupled to the tool assembly, the control circuit configured to control operation of the drive motor, and the control circuit including a plurality of field effect transistors. The instrument also includes a potting material disposed within the internal cavity encapsulating at least a portion of the field effect transistors of the control circuit.

[0012] A ninth aspect of the present disclosure provides a powered surgical instrument. The powered surgical instrument also includes a housing defining an internal cavity, the housing including a handle portion. The instrument also includes a body portion extending distally from the handle portion. The instrument also includes a tool assembly disposed at a distal end of the body portion. The instrument also includes a control circuit and a drive motor disposed within the internal cavity, the drive motor mechanically coupled to the tool assembly, the control circuit configured to control operation of the drive motor, the control circuit including a plurality of field effect transistors. The instrument also includes a metal heat sink in contact with at least two of the plurality of field effect transistors.

[0013] A tenth aspect of the present disclosure provides a method for manufacturing a powered surgical device. The method includes providing a housing for the powered surgical device, the housing defining a cavity, and a control circuit disposed within the housing. The method also includes injecting a liquid potting material into the cavity of the sealed housing to hermetically seal the housing, the control circuit including a circuit board, a motor controller coupled to the circuit board, and optionally one or more field-effect transistors coupled to the circuit board, and optionally another trigger sensor and one or more motor sensors, e.g., one or more Hall sensors. The method also includes solidifying the potting material to encapsulate at least a portion of the control circuit, e.g., the another field-effect transistor, the motor controller, the motor sensor, the trigger sensor, and / or the circuit board.

[0014] An eleventh aspect of the present disclosure provides a surgical power tool. The surgical power tool includes a housing. The tool also includes an electric motor positioned within the housing. The tool also includes a coupler operably actuated by the electric motor. The tool also includes a controller positioned within the housing. The tool also includes a battery configured to provide power to the controller and coupled to the housing. The tool also includes a trigger movably coupled to the housing, the controller configured to turn on the electric motor when the trigger is depressed and adjust the speed of the electric motor based on how far the trigger is depressed. The coupler defines an axis. The trigger defines an actuation surface and moves between an actuated position and an inactuated position. The actuation surface is closer to the axis defined by the coupler in the actuated position than in the inactuated position.

[0015] A twelfth aspect of the present disclosure provides a surgical power tool. The surgical power tool includes a housing including a barrel portion and a handle portion. The tool also includes an electric motor positioned within the housing. The tool also includes a coupler operably actuated by the electric motor. The tool also includes a controller positioned within the housing. The tool also includes a battery configured to provide power to the controller and coupled to the housing. The tool also includes a trigger movably coupled to the handle portion of the housing, the controller configured to turn on the electric motor when the trigger is depressed. The handle portion defines a longitudinal axis. The barrel portion of the housing is operable to rotate about the longitudinal axis of the handle portion.

[0016] A thirteenth aspect of the present disclosure provides a surgical power tool. The surgical power tool includes a housing including a barrel portion and a handle portion. The tool also includes an electric motor positioned within the housing. The tool also includes a coupler operably actuated by the electric motor. The tool also includes a controller positioned within the housing. The tool also includes a battery configured to provide power to the controller and coupled to the housing. The tool also includes a trigger movably coupled to the handle portion of the housing, the controller configured to turn on the electric motor when the trigger is depressed. The handle portion defines an axis. The barrel portion of the housing is operable to rotate about the axis of the handle portion.

[0017] A fourteenth aspect of the present disclosure provides a surgical power tool. The surgical power tool includes a housing. The housing may include a proximal region and a distal region. The housing may include a first attachment coupler in the proximal region and a second attachment coupler in the distal region. The tool also includes an electric motor positioned within the housing. The tool also includes a controller positioned within the housing. The tool also includes a battery configured to provide power to the controller and coupled to the housing. The tool also includes a trigger movably coupled to the housing, the controller configured to turn on the electric motor when the trigger is depressed. The tool also includes a mode switch movably coupled to the housing and movable between a first position and a second position, the controller operable to control the motor in a first mode when the mode switch is in the first position and to control the motor in a second mode when the mode switch is in the second position. The tool also includes a first attachment configured to be driven from the motor when engaged with the first attachment coupler. The tool also includes a second attachment configured to be driven from the motor when engaged with the second attachment coupler, wherein the motor is operable to drive the first attachment when the motor is in a first mode and the motor is operable to drive the second attachment when the motor is in a second mode.

[0018] A fifteenth aspect of the present disclosure provides a surgical power tool. The surgical power tool includes a housing. The tool also includes an electric motor positioned within the housing. The tool also includes a coupler operably actuated by the electric motor. The tool also includes a controller positioned within the housing. The tool also includes a battery configured to provide power to the controller and coupled to the housing. The tool also includes a first trigger movably coupled to the housing, the controller configured to turn on the electric motor when the first trigger is depressed. The tool also includes a second trigger movably coupled to the housing, the controller configured to turn on the electric motor when the second trigger is depressed. The first trigger is accessible from a different grip than the second trigger.

[0019] A sixteenth aspect of the present disclosure provides a surgical power tool. The surgical power tool includes a housing. The tool also includes an electric motor positioned within the housing. The tool also includes a coupler operably actuated by the electric motor. The tool also includes a controller positioned within the housing. The tool also includes a battery configured to provide power to the controller and coupled to the housing. The tool also includes a trigger movably coupled to the housing, the controller configured to turn on the electric motor when the trigger is depressed and adjust the speed of the electric motor based on how far the trigger is depressed. The coupler defines an axis. The trigger defines an actuation surface, the trigger is movable between an actuated position and an inactuated position. The actuation surface is closer to the axis defined by the coupler in the actuated position than in the inactuated position.

[0020] A seventeenth aspect of the present disclosure provides a powered surgical tool. The powered surgical tool includes a handpiece defining a cavity. The tool also includes an electric motor disposed within the cavity. The tool also includes a rigid first printed circuit board disposed within the cavity, the first circuit board including a trigger sensor and a motor control sensor. The tool also includes a rigid second printed circuit board disposed within the cavity. The tool also includes a rigid third circuit board disposed within the cavity. The tool also includes the first circuit board, the second circuit board, and the third circuit board each defining a plane, the planes of the first, second, and third circuit boards being parallel to one another. The tool also includes a controller configured to adjust power drawn from the power source based on user input, the controller mounted on one of the second printed circuit board and the third circuit board.

[0021] An eighteenth aspect of the present disclosure provides a surgical power tool assembly for driving a surgical pin. The surgical power tool assembly includes a surgical handpiece having a handpiece housing. The assembly also includes an electric motor positioned within the handpiece housing. The assembly also includes a controller positioned within the handpiece housing. The assembly also includes a trigger movably coupled to the handpiece housing and having an actuation surface movable between an actuated position and an inactuated position, the controller being configured to control the speed of the motor based on the actuation position of the trigger. The assembly also includes an output drive coupled to the electric motor and configured to be rotated about an axis by the electric motor. The actuation surface is closer to the axis in the actuated position than in the inactuated position. The assembly also includes a pin driver attachment for driving the surgical pin.

[0022] Advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0023] [Figure 1] FIG. 1 is a perspective view of a surgical system including a surgical handpiece and a surgical attachment. [Figure 2] FIG. 1 is another perspective view of a surgical system including a surgical handpiece and a surgical attachment. [Figure 3] FIG. 1 is an elevational view of a surgical system. [Figure 4] FIG. 1 is a cross-sectional view of a surgical system with a lever of a surgical attachment shown in a first position. [Figure 5] FIG. 1 is a cross-sectional view of the surgical system, with the lever of the surgical attachment shown in a second position. [Figure 6] 1 is a cross-sectional view of a surgical handpiece of a surgical system with a trigger in a first position. [Figure 7] 1 is a cross-sectional view of a surgical handpiece of a surgical system with a trigger in a second position. [Figure 8] FIG. 2 is an exploded view of the surgical handpiece. [Figure 9] FIG. 1 is a perspective view of a surgical attachment and pin of a surgical system. [Figure 10] FIG. 10 is a cross-sectional view of the surgical attachment and pin from FIG. 9. [Figure 11] FIG. 10 is a cross-sectional view of the surgical attachment from FIG. 9. [Figure 12] 10A-10C are cross-sectional views of alternative implementations of surgical attachments for surgical systems. [Figure 13] FIG. 1 is an elevational view of a pin driver attachment of a surgical system. [Figure 14] FIG. 1 is a cross-sectional view of a first implementation of a pin driver attachment. [Figure 15] FIG. 10 is a cross-sectional view of a second implementation of the pin driver attachment. [Figure 16] FIG. 10 is a cross-sectional view of a third implementation of the pin driver attachment. [Figure 17A] FIG. 1 is a perspective view of a printed circuit board assembly. [Figure 17B] FIG. 2 is another perspective view of the printed circuit board assembly. [Figure 18] FIG. 2 is another perspective view of the printed circuit board assembly. [Figure 19] FIG. 10 is an elevational view of a printed circuit board assembly in another configuration. [Figure 20] FIG. 1 is a perspective view of a printed circuit board assembly including a heat sink. [Figure 21] FIG. 1 is a perspective view of a printed circuit board assembly including another heat sink. [Figure 22] FIG. 10 is a perspective view of another configuration of a printed circuit board assembly including potting material. [Figure 23] FIG. 1 is a side view of one configuration of a printed circuit assembly disposed within a housing of a surgical handpiece. [Figure 24] FIG. 10 is a perspective view of another implementation of a surgical power tool assembly having multiple surgical attachments. [Figure 25] FIG. 10 is a perspective view of another implementation of a surgical power tool assembly having multiple surgical attachments that can be configured in different orientations. [Figure 26] FIG. 10 is a perspective view of another implementation of a surgical power tool assembly having multiple surgical attachments that can be configured in different orientations. [Figure 27A] FIG. 1 is a perspective view of another implementation of a surgical power tool assembly in a first configuration. [Figure 27B] 27B is a perspective view of an implementation of the surgical power tool assembly of FIG. 27A in a second configuration. [Figure 27C] FIG. 27C is a perspective view of an implementation of the surgical power tool assembly of FIGS. 27A and 27B in a third configuration. [Figure 28] FIG. 10 is a perspective view of another surgical power tool assembly. [Figure 29A] FIG. 10 is an elevational view of another surgical power tool assembly. [Figure 29B] FIG. 10 is an elevational view of another surgical power tool assembly. [Figure 30A] FIG. 10 is a side view of another configuration of a surgical power tool assembly. [Figure 30B] FIG. 10 is a side view of another configuration of a surgical power tool assembly. [Figure 31] 10 is a perspective view of another configuration of a surgical power tool assembly. FIG. [Figure 32] FIG. 32 is a cross-sectional view of the surgical power tool assembly of FIG. 31. [Figure 33] 10 is a perspective view of another configuration of a surgical power tool assembly. FIG. [Figure 34] FIG. 34 is a cross-sectional view of the surgical power tool assembly of FIG. 33. DETAILED DESCRIPTION OF THE INVENTION

[0024] Referring to FIG. 1 , a surgical power tool assembly 98 of a surgical system 96 is contemplated. The surgical power tool assembly 98 may be referred to as a surgical handpiece assembly. An exemplary surgical power tool assembly is described in U.S. Patent Publication No. 2016 / 0206327. The power tool assembly may include a surgical handpiece having a housing 100, an electric motor 102 positioned within the housing 100, and an output drive 104 operably coupled to and actuated by the electric motor 102, the output drive 104 being rotated by the motor 102 about an output drive axis AX. The output drive 104 may be configured to engage any suitable surgical end effector, such as a surgical pin or wire, a drill bit, or a driver. The power tool assembly may further include a controller 106. The controller 106 may optionally be positioned within the housing 100. The surgical power tool assembly can optionally include a removable battery 108 configured to power the controller and electric motor 102. One battery that can be used with this aspect of the invention is described in U.S. Patent Application Publication No. 2007 / 0090788, published April 26, 2007, which is incorporated herein by reference. The battery 108 can be configured to couple to the housing via a twist-lock design. One suitable example of such a battery is described in U.S. Patent No. 11,534,181, issued December 27, 2022, which is incorporated herein by reference in its entirety. A trigger 110 can be movably coupled to the housing 100, a suitable trigger sensor can be included within the tool, and the controller 106 can be configured to turn on the electric motor 102 and / or adjust the speed of the motor 102 and, in turn, the output drive 104 based on the extent to which the trigger 110 is actuated and / or depressed. The output drive 104 may include a gear set 112 disposed between the motor 102 and a tool coupling 114 of the output drive 104 to increase the torque available at the tool coupling 114 .In some configurations, tool coupler 114 can be used to secure surgical pins and / or drill bits to the handpiece, while in other configurations tool coupler 114 can be used to secure one or more of the surgical attachments to the handpiece. In one configuration, controller 106 is configured to regulate power drawn from the power source (e.g., a battery) based on user input to trigger 110. In some configurations, trigger 110 is pivotally coupled to housing 100.

[0025] The handpiece housing 100 may define a cavity for receiving the motor 102. A printed circuit board assembly 115 may be disposed within the cavity. The printed circuit board assembly 115 may include a first printed circuit board 116, a second printed circuit board 118, and a third printed circuit board 120. The first circuit board 116 may include a trigger sensor and a motor control sensor. Each of the first printed circuit board 116, the second printed circuit board 118, and the third printed circuit board 120 may be rigid. Furthermore, each of the first circuit board 116, the second circuit board 118, and the third circuit board 120 may define a plane. The planes of each of the first circuit board 116, the second circuit board 118, and the third circuit board 120 may be parallel to one another and may be disposed on separate planes; therefore, the printed circuit boards 116, 118, 120 may not be considered coplanar. The controller 106 can be mounted on one of the second printed circuit board 118 and the third printed circuit board 120. The first printed circuit board 116, the second printed circuit board 118, and the third printed circuit board 120 can be connected to each other via one or more flex connectors. In other configurations (see FIGS. 6-8), the printed circuit board assembly 115 can include only the first printed circuit board 116 and the second printed circuit board 118.

[0026] A wide variety of surgical attachments can be used with the surgical power tool assembly 98 contemplated herein. One such surgical attachment is a pin driver attachment 122. The pin driver attachment 122 includes an attachment housing 124 that is removably coupled to the power tool housing 100. The pin driver attachment 122 can also include an operating member 126 movably coupled to the attachment housing 124. The operating member 126 can be embodied as a lever or a twist collar. The pin driver attachment 122 can further include a collet 128 attached to the attachment housing. The collet 128 is operable in a clamped state ( FIG. 5 ) and an unclamped state ( FIG. 4 ). The collet is operable to engage a surgical pin 130 when in the clamped state and to allow the pin 130 to move relative to the collet 128 when in the unclamped state. The operating member 126 is operably coupled to the collet 128. The operating member 126 is movable between a first position and a second position. In the first position, the collet 128 is clamped. In the second position, the collet 128 is unclamped. A suitable example of a pin driver attachment 122 having a similar collet design for gripping a pin in response to movement of the operating member is described in International Patent Application No. PCT / US2019 / 054093, which is incorporated herein by reference in its entirety.

[0027] 4 and 5, collet 128 can include one or more jaws 129 movably coupled to the attachment housing. The one or more jaws can be movable relative to attachment housing 124 in response to the position of an operating member 126 (e.g., a lever) such that the one or more jaws 129 in a clamped state of collet 128 are closer to output drive shaft AX for engaging a surgical pin than the one or more jaws 129 in an unclamped state of the collet.

[0028] As described above, the operating member 126 may be embodied as a lever 126. The lever 126 may define a recess 132. The trigger 110 may be aligned with the lever 126 and the recess 132 such that actuation of the trigger 110 within the recess 132 and actuation of the lever 126 occur on a single reference plane. The lever 126 may define a pivot end 134 and a free end 136. The lever 126 may also include a first bend 138, a second bend 140, and a third bend 142. The first bend 138 and the second bend 140 may be located closer to the pivot end 134 than the free end 136. The first bend 138 and the second bend 140 may be acute angles. The first bend 138 facilitates establishment of the recess 132 for placement of a portion of the user's hand. The second bend 140 facilitates bringing the free end 136 of the lever 126 closer to the housing 100, thereby allowing a user to easily grasp and actuate the lever 126. The third bend 142 may have an obtuse angle. The third bend 142 provides easy movement for one or more of a user's fingers while holding the housing 100 in the palm of the hand. The lever 126 may further include a fourth bend 144. The fourth bend 144 may be closer to the free end 136 than the third bend 142. The fourth bend 144 may have an obtuse angle. The fourth bend 144 may curve away from the housing 100 to prevent a user's fingers from slipping off the lever 126 between the third bend 142 and the fourth bend 144. Collectively, bends 138, 140, 142, 144 in lever 126 help to facilitate placement of a portion of a user's hand within recess 132 of lever 126, thereby allowing the user to simultaneously operate trigger 110 and lever 126 in a natural hand placement that is more ergonomic than traditional pistol grip designs.

[0029] 30A and 30B, an alternative configuration for lever 126 is shown. Lever 126 in FIG. 30A corresponds to the configuration of lever 126 shown in FIGS. 1-5. Specifically, free end 136 of lever 126 is positioned proximal to trigger 110. In comparison, lever 126 in FIG. 30B is shorter. In FIG. 30B, at least a portion of trigger 110 is positioned proximal to the free end of lever 126.

[0030] A method of inserting a pin with the surgical power tool assembly 98 is also disclosed. The method includes depressing a lever 126 with an index finger and depressing a trigger 110 with a finger other than the index finger. Operation of the electric motor 102, and subsequently the output drive 104, of the power tool 98 can be controlled based on the position of the trigger 110. The collet 128 can be operable between a clamped and an unclamped state based on the position of the lever 126. A user grasps the housing 100 of the surgical power tool assembly 98 with a hammer grip. In other words, the user can grasp the housing 100 so that the user's thumb is closer to the proximal end of the tool 98 and / or the battery 108 than to the distal end of the tool 98.

[0031] The trigger 110 can define an actuation surface 146 on which one or more fingers of a user's hand can rest. The actuation surface 146 moves between an actuated position ( FIG. 7 ) and an inactive position ( FIG. 8 ) during use of the trigger 110. In the actuated position, the controller 106 is configured to control the speed of the motor 102 or otherwise energize the motor 102 to rotate the output drive 104. In the inactive position, the controller 102 can be configured to turn off the motor 102, so that the output drive 104 is not rotationally driven by the motor 102. The surgical power tool assembly 98 is constructed such that the actuation surface 146 is closer to the coupler and / or output drive axis AX in the actuated position than in the inactive position. This in-line trigger configuration can provide more convenient hand positioning while the surgical tool 98 is being used for different surgical applications, such as surgical pin placement. The trigger 110 can be rotatable about the trigger axis TX. The trigger axis TX may optionally be defined by a trigger mounting pin 148. The trigger 110 may include a pivot end connected to the mounting pin and a free end pivotable about the trigger axis TX.

[0032] Another configuration of surgical handpiece assembly 198 is shown in FIGS. 33 and 34. In this configuration, surgical handpiece assembly 198 includes a first trigger 210a and a second trigger 210b. First trigger 210a has a first actuation surface 246a. First trigger 210a is configured to cause electric motor 202 to rotate output drive 204 about axis AX in a first direction. Second trigger 210b has a second actuation surface 246b. Second trigger 210b can be configured to cause electric motor 202 to rotate output drive 204 about axis AX in a second direction opposite the first direction. In the configuration shown in FIGS. 33 and 34, first trigger 210a and second trigger 210b are slidably coupled to housing 200. In other configurations, the first trigger 210 a and the second trigger 210 b can be pivotally coupled to the housing 200 .

[0033] 1-8 , the trigger 110 can include a run-safe switch 150 operably connected to the controller 106. The run-safe switch 150 can be displaceable between at least a first position and a second position. In the first position, actuation of the trigger 110 pivoting about the trigger axis TX does not activate the motor 102 and subsequently the output drive 104 to rotate the pin. In the second position, actuation of the trigger 110 pivoting about the trigger axis TX can activate the motor 102 and subsequently the output drive 104 to rotate the pin. In other configurations, the run-safe switch 150 can be movable to a third position to rotate the pin in the opposite direction.

[0034] The housing 100 may include a base 152 and a protrusion 154 extending from the base 152. The protrusion 154 may be positioned adjacent to the trigger 110 and may extend further away from the coupler axis AX than the actuation surface 146 does away from the coupler axis AX when the trigger 110 is in the actuated or unactuated position. The protrusion 154 may prevent accidental actuation of the trigger 110 when the surgical power tool assembly 98 is stationary on a work surface; for example, if a user sets down the surgical tool 98 and the tool rotates slightly, the protrusion 154 prevents the trigger 110 from moving under the weight of the surgical tool 98 or an external force. The protrusion 154 may define a cutout 156 for receiving the runsafe switch 150 in one or more positions so that the runsafe switch 150 does not interfere with movement of the trigger 110 relative to the housing 100.

[0035] 9-11, another configuration of the pin driver attachment 322 is shown. The pin driver attachment can include an input shaft 358 defining features for receiving torque from the output drive 304 of the handpiece 298. The pin driver attachment can include a first drive portion having a first bore 360, a second drive portion having a second bore 362, and a third drive portion having a third bore 363. The first bore 360 can be coaxial with the second bore 362 and the third bore 363. The first bore 360 can be smaller (e.g., have a different or smaller cross-sectional area) than the second bore 362, and the second bore 362 can be smaller than the third bore 363. One or more tool couplers 364a, 364b can be coupled to the input shaft 358. The tool couplers 364a, 364b are movable between an engaged position and a disengaged position. In the configuration shown in FIG. 11 , one of the tool couplers 364a comprises a collar for securing a pin in the third bore 363, and the other tool coupler 364b comprises one or more magnets off-center in the first and second bores 360, 362 for securing a pin comprising a ferrous material to the pin driver attachment 322 within the first and second bores 360, 362. In the engaged position, a drill bit or pin can be secured within the tool couplers 364a, 364b. The third driver portion can be used to drive a twist drill. The first and second drive portions can be used to drive two different surgical pins. In the disengaged position, a drill bit or pin can be released from the tool couplers 364a, 364b. The first bore 360 can include multiple flats for driving a drill bit or surgical pin. The second bore 362 can include multiple flats for driving a drill bit or surgical pin. 31 and 32, a pin drive attachment 322 is shown coupled to the surgical power tool assembly 98 rather than the pin drive attachment 122 shown in FIG.

[0036] Referring to FIG. 12 , another pin driver attachment 422 is provided. The pin driver attachment 422 may include an input shaft 458 defining features for receiving torque from the output drive 404 of the handpiece 398. The pin driver attachment may also include a first bore 460 and a second bore 462. The first bore 460 is coaxial with the second bore 462. The first bore 460 is smaller than the second bore 462. One or more tool couplers 464 a, 464 b are secured to the input shaft 458. The tool couplers 464 a, 464 b are movable between an engaged position and a disengaged position. One of the tool couplers 464 a comprises a collar for securing a pin in the second bore 462, and the other tool coupler 464 b comprises an O-ring for securing a pin disposed within the first bore 460. In the engaged position, a drill bit or pin can be secured within the tool couplers 464a, 464b. In the disengaged position, a drill bit can be released from the tool couplers 464a, 464b. The first bore 460 can include multiple flats. The second bore can include multiple flats. A surgical pin including at least six flats can be received by the second bore.

[0037] 13-16 illustrate various pin driver attachments having identical input shafts 558, 658, 758 and different bores for receiving pins having different diameters and / or coupling configurations. The use of these attachments promotes better workflow by providing uniform coupling of the identical input shafts 558, 658, 758 of the different pin driver attachments while allowing for the attachment of different pins to the different pin driver attachments shown in FIGS. 13-16. The input shafts 558, 658, 758 can be coupled to the surgical attachments 322, 422 or tool coupler 114 described above.

[0038] A method for driving pins in a robotic-assisted total knee replacement procedure is also contemplated. The method includes providing a battery to a surgical power tool assembly 98. A surgical attachment 122, such as a pin driver attachment 122, is coupled to the surgical power tool assembly 98. Using the surgical attachment 122, a hole is drilled in the patient's femur, tibia, or patella with a first drill bit. The surgical attachment drives a first pin into the femur, tibia, or patella. The surgical attachment drives a second pin into one of the other bones of the femur, tibia, and patella. The first pin can have a different diameter than the second pin. These pins can be used to secure a navigation tracker (not shown) to the patient's bone. Using the same surgical attachment 122 for each of these pins helps make workflow more efficient by eliminating the need for multiple surgical attachments and saving time during the procedure by reducing the number of components requiring sterilization. Additionally, there is less overlap of components, reducing the distance between where the pin / tool / drill bit is coupled to the surgical power tool assembly 98 and where the user grips the surgical power tool assembly 98.

[0039] Another method of inserting a pin is also contemplated. This method includes grasping housing 100 of surgical power tool assembly 98 with a user's hand. The user can grasp housing 100 with a hammer grip. The user can grasp housing 100 so that the user's thumb is closer to the proximal end of surgical power tool assembly 98 than the distal end of surgical power tool assembly 98. This method further includes engaging an index finger of the user's hand on lever 126 to clamp the surgical pin with collet 128. This method further includes engaging (e.g., by depressing) trigger 110 with a finger other than the index finger. This method also includes driving the surgical pin into the bone with surgical power tool assembly 98. The user can engage index finger on lever 126 with the user's thumb closer to battery 108 of surgical power tool assembly 98 than the distance of the index finger from battery 108.

[0040] Another method of inserting the pin is also contemplated. This method can include inserting the surgical pin into a coupler of the surgical power tool assembly 98. This method can further include gripping the housing 100 of the power tool 98 so that the user's thumb is closer to the battery 108 than the tool coupler 114. This method can further include engaging (e.g., depressing) the trigger 110 with the user's hand while the user's thumb is closer to the battery 108 than the tool coupler 114. This method can further include driving the surgical pin into the bone with the surgical power tool assembly. This method can further include depressing the lever 126 with the user's finger while the user's thumb is closer to the battery 108 than the coupler. The steps of depressing the lever 126 and depressing the trigger 110 can be performed with different fingers. 45. The step of gripping the housing can further include gripping the housing 100 so that the battery 108 is positioned above the user's hand during use (see FIG. 24).

[0041] Although the methods described above refer to the surgical power tool assembly 98 described above, it will be understood that these methods may also be applied to the other surgical power tool assemblies described herein.

[0042] The motor 102 can be a brushless DC motor. The surgical tool 98 can include a three-phase H-bridge that commutates the brushless DC motor. The H-bridge can control the speed and direction of the power motor.

[0043] Referring to FIG. 20 , one or more of the printed circuit boards 116, 118, and 120 can include a field-effect transistor 121 (FET). The FET 121 can be driven by a general-purpose gate driver. The gate driver can have a maximum gate sink and source current of 2 amperes. The gate driver provides a gate-source voltage of 5 volts so as not to exceed the gate-source rating of the FET 121. The gate driver can also have an internal bootstrap capacitor for driving the high-side FET 121. The FET 121 can comprise a gallium nitride FET. These FETs 121 have characteristically low input capacitance, which enables high switching speeds. The printed circuit board or boards can be fabricated from a fiberglass material such as FR-4 or other suitable construction.

[0044] In certain motor applications, the end user desires a surgical tool 98 where the space available for the motor control electronics is significantly limited. This may be due to the location of the motor or other application-specific limitations. However, when the surgical power tool assembly 98 is used under heavy power loads, a significant amount of heat can be generated due to the high current required to maintain the application of high torque.

[0045] The various components of the printed circuit boards 116, 118, 120 may be soldered. An exemplary solder may be a high-temperature solder having a melting point below 280, 290, or 300 degrees Celsius. In some cases, one or more of the printed circuit boards 116, 118, 120 may include one or more metal heat sinks 123 to absorb heat resulting from heavy power loads. The metal heat sinks 123 may be selected from a variety of metals and metal alloys. For example, the metal heat sink may include one or more materials selected from the group consisting of Aluminum 1050, Aluminum 1070, Aluminum 1100, Aluminum 1200, or Aluminum 1370. Exemplary aluminum alloys include alloys containing copper, manganese, zirconium, and / or titanium. The heat sink material may be a material rated at least 200 W / mK, or at least 220 W / mK, or at least 230 W / mK.

[0046] 20 and 21, the metal heat sink 123 can be located below the substrate including the FET 121, above the substrate including the FET 121, or the metal heat sink 123 can be located above and below the substrate including the FET 121.

[0047] The printed circuit board assembly 115 can include a dual heat sink solution including aluminum heat sinks 123 that directly contact the high-side and low-side transistors, respectively. In one particular implementation, the dual heat sink solution includes two 16.05 mm x 2.3 mm x 1 mm Aluminum 1370 heat sinks that directly contact the GaN FETs. The surgical power tool assembly 98 can include a metal heat sink 123 for each of the three FETs 121. In other implementations, the heat sinks 123 can have other dimensions and still be in direct contact with the FETs 121.

[0048] One or more of the metal heat sinks 123 can be used in combination with a thermally conductive potting material, such as a silicone elastomer potting material. The potting material can be positioned between two of the printed circuit boards so that the potting material is in direct contact with the printed circuit board containing the FETs. Exemplary potting materials can include one or more materials selected from the group consisting of Sylgard 184, Sylgard 3-6605, Sylgard 160, DowSil TC-6020, or DowSil TC4025. In some implementations, suitable potting materials can have a thermal conductivity of at least 0.25, at least 0.5, at least 0.75, a minimum of 1, or at least 2.5 W / mK.

[0049] The potting material may include a thermally conductive additive, which may be selected from the group consisting of abrasive ceramics, lubricating ceramics, boron nitride, aluminum oxide, aluminum nitride, and combinations thereof.

[0050] Referring to one exemplary implementation shown in FIG. 23 , the housing of the surgical handpiece 98 can define an internal cavity, such as a separate enclosure 125, in which the control circuitry (such as one or more of the printed circuit boards) and / or the motor and other components of the instrument are disposed. A potting material can be injected into this cavity, causing the potting material to flow into the cavity and thereby coat and encapsulate one or more internal components of the instrument (e.g., the control circuitry or its components). The potting material can be injected such that the cavity is partially or completely filled with the potting material. Encapsulation of the internal components can reduce voids within the internal cavity. Furthermore, the potting material can seal the components, thereby providing protection from moisture, chemical compounds (e.g., cleaning agents), steam, gases, and biological contaminants. This sealing method also allows for sterilization of the instrument, providing the option for multiple use of the instrument.

[0051] Before the potting material is injected into the housing or enclosure, the housing or enclosure can be suitably sealed to withstand the pressure of the potting process and to hermetically seal the housing. The potting material can be any material that solidifies when injected into the cavity, and can be any liquid or amorphous material. After solidification, the material can have a relatively high stiffness to protect the components from shock, vibration, maintain elasticity, and reduce stress under extreme temperatures and other environmental conditions. The potting material can also be in solid form in some configurations.

[0052] 23, one or more printed circuit boards can be provided within a control housing 125. The housing can be a control module for regulating the operation of a motor integrated with a powered surgical tool. The housing can define a shell formed with an opening, and the control circuitry can be disposed within the shell. One or more conductive pins can extend through corresponding openings in the housing.

[0053] The one or more printed circuit boards can include one or more sensors that monitor the state of the externally mounted triggers. A magnet is attached to each trigger and disposed within the tool housing. Optionally, a magnetic field sensor is located within the control module. Each sensor generates a signal that varies as a function of the proximity of an associated one of the trigger magnets. Manual displacement of the trigger results in a similar displacement of the magnet within the tool. When the trigger and magnet are so displaced, the complementary sensor generates a signal indicating that movement has occurred. Upon receiving this signal, the control circuit generates the necessary signal to enable application of an excitation current to the motor. Conductive components of the tool's circuit board can be shielded from the supersaturated steam of an autoclave environment. Once the tool is sterilized, these components are not adversely affected.

[0054] One or more of the printed circuit boards may also include one or more sensors, such as one or more Hall sensors, that monitor the status of the tool motor. To facilitate sensor responsiveness, some portions of the shell may be formed from a material through which the physical quantity(s) monitored by the sensor(s) can pass. For example, if one or more of the sensors monitor a magnetic field(s), some adjacent portions of the shell may be formed from a combination of magnetic and non-magnetic materials that focus the magnetic field(s). If the sensor(s) monitor photon energy (light), the shell may have a panel or panel portions that are transparent to the wavelength of light being monitored.

[0055] Another configuration of a surgical power tool assembly 798 is shown in FIG. 24. The surgical power tool assembly 798 includes various surgical attachments 822a, 822b, 822c, and 822d that can be coupled to a housing 800. The surgical attachments 822a, 822b, 822c, and 822d can each include an input shaft for receiving torque from a motor of the surgical power tool assembly 798. Actuation of a trigger 810 can power the motor via a battery 808 to drive the coupled surgical attachments 822a, 822b, 822c, and 822d. The surgical attachments 822a, 822b, 822c, and 822d can be used for driving pins, sawing, drilling, and other surgical procedures.

[0056] Another configuration of a surgical power tool assembly 898 is shown in FIG. 25. The surgical power tool assembly 898 includes various surgical attachments 922a, 922b, 922c that can be coupled to a housing 900. The surgical attachments 922a, 922b, 922c can each include an input shaft for receiving torque from a motor of the surgical power tool assembly 898. Actuation of one of the triggers 910a, 910b can power the motor by a battery 908 to drive the coupled surgical attachment 922a, 922b, 922c. The surgical attachments 922a, 922b, 922c, 922d can be used for driving pins, sawing, drilling, and other surgical procedures. The surgical attachments 922a, 922b, 922c can be configured such that the input shafts of the surgical attachments 922a, 922b, 922c are offset from the tool coupler by at least 45 degrees, at least 60 degrees, or about 90 degrees. This feature will be further understood when the input shafts define an input axis and the tool coupler also defines an axis, and the input axis is offset from the axis of the tool coupler by at least 45 degrees, at least 60 degrees, or about 90 degrees. The lever 926 can be offset from the input axis to allow for better access to the lever during pin placement.

[0057] Another configuration of a surgical power tool assembly 998 is shown in FIG. 26. The surgical power tool assembly 998 includes various surgical attachments 1022a, 1022b, 1022c, and 1022d that can be coupled to a housing 1000. The surgical attachments 1022a, 1022b, 1022c, and 1022d can each include an input shaft for receiving torque from a motor of the surgical power tool assembly 998. Actuation of one of the triggers 1010a, 1010b can power the motor via a battery 1008 to drive the coupled surgical attachment 1022a, 1022b, 1022c, and 1022d. The surgical attachments 1022a, 1022b, 1022c, and 1022d can be used for driving pins, sawing, drilling, and other surgical procedures. The housing 1000 includes a handle portion 1003 and a barrel portion 1001. The handle portion 1003 extends along an axis, and the barrel portion is configured to articulate about the handle portion to achieve a plurality of possible orientations of the surgical attachments 1022a, 1022b, 1022c, 1022d relative to the housing 1000. In other words, in this configuration, the barrel portion 1001 can articulate at various angles relative to the handle portion 1003. The housing portions 1001, 1003 can include a suitable detent mechanism, such as a spring-loaded pin that engages a preset hole, to fix the position of the barrel portion 1001 relative to the handle portion 1003.

[0058] Another configuration of a surgical power tool assembly 1098 is shown in FIG. 27. The surgical power tool assembly 1098 can include various surgical attachments that can be coupled to the housing 1000. Each surgical attachment can include an input shaft for receiving torque from a motor of the surgical power tool assembly 1098. Actuation of one of the triggers can power the motor via a battery 1108 to drive the coupled surgical attachment. The surgical attachment can be used for driving pins, sawing, drilling, and other surgical procedures. The housing 1100 includes a handle portion 1103 and a barrel portion 1101. The handle portion 1103 extends along an axis, and the barrel portion 1101 is configured to pivot relative to the handle portion 1103 to achieve multiple possible orientations of the surgical attachment relative to the housing 1100. In other words, in this configuration, the barrel portion 1101 can be tilted at various angles relative to the handle portion 1001. The housing portions 1101 , 1103 may include a suitable detent mechanism, such as a spring-loaded pin that engages a preset hole, to fix the position of the barrel portion 1101 relative to the handle portion 1103 .

[0059] Another configuration of the surgical power tool assembly 1198 is shown in FIG. 28. The surgical power tool assembly 1198 includes various surgical attachments 1222a, 1222b, 1222c, 1222d that can be coupled to a housing 1200. The surgical attachments 1222a, 1222b, 1222c, 1222d can each include an input shaft for receiving torque from a motor of the surgical power tool assembly 1198. Actuation of one of the triggers 1210a, 1210b can power the motor via the battery 1208 to drive the coupled surgical attachment 1222a, 1222b, 1222c, 1222d. The surgical attachments 1222a, 1222b, 1222c, 1222d can be used for driving pins, sawing, drilling, and other surgical procedures. The surgical power tool assembly 1198 can include a mode switch 1205 movably coupled to the housing 1200 and movable between a first position and a second position. As implemented, the mode switch 1205 generally surrounds the barrel of the housing 1200 and includes a ring-shaped member movable around the barrel portion of the housing 1200 to switch modes. The barrel portion can include a Hall effector sensor to determine the position of the mode switch 1205. Alternatively, the mode switch 1205 can be located elsewhere on the surgical power tool assembly 1198 or on a separate device, such as a tablet, connected to the surgical power tool assembly 1198.

[0060] The controller is operable to control the motor in a first mode when the mode switch 1205 is in a first position and to control the motor in a second mode when the mode switch 1205 is in a second position. The barrel portion of the housing 1200 can include a proximal region and a distal region. The housing 1200 includes a first attachment coupler 1214b in the proximal region and a second attachment coupler 1214a in the distal region.

[0061] The surgical power tool assembly 1198 can be designed to simultaneously engage (e.g., couple to) two of the surgical attachments 1222a, 1222b, 1222c, 1222d. The first surgical attachment 1222a, 1222b, 1222c, 1222d can be configured to be driven from the motor when the first attachment is engaged with the first attachment coupler 1214b. The second surgical attachment 1222a, 1222b, 1222c, 1222d can be configured to be driven from the motor when the second attachment is engaged with the second attachment coupler 1214a. The motor is operable to drive the first attachment when in the first mode, and the motor is operable to drive the second attachment when in the second mode. The motor can include a transmission selectively coupled to two or more separate output shafts. A first motor mode can drive the first output shaft, and a second motor mode can drive the second output shaft. The first output shaft can be configured to drive a first attachment, and the second output shaft can be configured to drive a second attachment. Alternatively, the tool can include two motors, and the mode switch 1205 controls which motor is engaged depending on the position of the mode switch 1205.

[0062] First attachment coupler 1214b is located on an opposite side of housing 1200 from second attachment coupler 1214a. The second attachment can be operable to drive a surgical pin and the first attachment can be operable to drive a surgical saw blade or drill bit or screwdriver.

[0063] An alternative surgical power tool assembly 1298, 1398 is shown in Figures 29A and 29B. The tool assembly 1298, 1398 may include a housing 1300, 1400, an electric motor positioned within the housing 1300, 1400, a coupler operably actuated by the electric motor, and optionally a controller positioned within the housing 1300, 1400. The tool assembly may also include a removable battery configured to power the controller and / or the electric motor. The power tool may further include a first trigger 1310a, 1410a and a second trigger 1310b, 1410b movably coupled to the housing 1300, 1400, wherein the controller is configured to turn on the electric motor when either the first trigger 1310a, 1410a or the second trigger 1310b, 1410b is depressed. The surgical power tool assembly 1298, 1398 can further include a third trigger 1310c, 1410c movably coupled to the housing 1300, 1400, and the controller is configured to turn on the electric motor when the third trigger 1310c, 1410c is depressed and / or contacted. In some implementations, actuation of any of the triggers causes the electric motor to rotate in a first direction, i.e., the same direction. In other implementations, one of the triggers can cause the electric motor to rotate in a different direction than one of the other triggers. The first trigger 1310a, 1410a and the second trigger 1310b, 1410b are positioned on the power tool assembly 1298, 1398 so as to be accessible from a different grip than the third trigger 1310c, 1410c.

[0064] The housing 1300, 1400 can include a barrel portion and a handle portion, and the first trigger 1310 a, 1410 a and the second trigger 1310 b, 1410 b can be located on a first region of the handle portion, and the third trigger 1310 c, 1410 c can be located on a second region of the handle portion. The first region can be located opposite the second region relative to the handle portion, such that the triggers are located on both sides of the handle portion. In some cases, the first region can be located closer to the barrel portion than the second region.

[0065] Several configurations have been discussed in the above description. However, the configurations discussed herein are not intended to be exhaustive or to limit the invention to any particular form. The terminology used is intended to be descriptive in nature rather than limiting. Certain inventive aspects of the present disclosure have been made with reference to the following exemplary clauses:

[0066] I. A pin driver attachment system, the pin driver attachment comprising: an attachment housing removably coupled to a handpiece housing including a motor; an input shaft having features for receiving torque from the handpiece and defining a first bore and a second bore, the first bore being coaxial with and smaller than the second bore; and a coupler coupled to the input shaft, the coupler being movable between an engaged position and a disengaged position, wherein the engaged position allows a drill bit to be secured within the coupler and the disengaged position allows the drill bit to be released from the coupler.

[0067] II. The pin drive attachment system of clause I, further comprising a surgical pin including at least six flat surfaces, wherein the first hole includes a plurality of flat surfaces and the second hole includes a plurality of flat surfaces.

[0068] III. The pin driver attachment system of clause II, further comprising a surgical pin comprising a ferrous material.

[0069] IV. A powered surgical instrument comprising: a housing defining an internal cavity, the housing including a handle portion; a body portion extending distally from the handle portion; a tool assembly disposed at a distal end of the body portion; a control circuit and a drive motor disposed within the internal cavity, the drive motor mechanically coupled to the tool assembly, the control circuit configured to control operation of the drive motor, the control circuit including a plurality of field effect transistors; and a potting material disposed within the internal cavity encapsulating at least a portion of the field effect transistors of the control circuit.

[0070] V. The powered surgical instrument of clause IV, further comprising a metal heat sink in contact with at least two of the plurality of field effect transistors.

[0071] VI. The powered surgical instrument of clause IV, wherein the potting material is a polymer selected from the group consisting of polyester, silicone, rubber, epoxy, nylon, polyphthalamide, liquid crystal polymer, and combinations thereof.

[0072] VII. The powered surgical instrument of clause VI, wherein the potting material includes a thermally conductive additive.

[0073] VIII. A powered surgical instrument comprising: a housing defining an internal cavity, the housing including a handle portion; a body portion extending distally from the handle portion; a tool assembly disposed at a distal end of the body portion; a control circuit and a drive motor disposed within the internal cavity, the drive motor mechanically coupled to the tool assembly, the control circuit configured to control operation of the drive motor, the control circuit including a plurality of field effect transistors; and a metal heat sink in contact with at least two of the plurality of field effect transistors.

[0074] IX. The powered surgical instrument of clause VIII, further comprising a potting material disposed within the interior cavity encapsulating at least a portion of the field effect transistor of the control circuit.

[0075] X. A method of manufacturing a powered surgical device, the method including: providing a housing for the powered surgical device, the housing defining a cavity, and a control circuit disposed within the housing; injecting a liquid potting material into the cavity of the sealed housing to hermetically seal the housing, the control circuit including a circuit board, a motor controller coupled to the circuit board, and optionally one or more field effect transistors coupled to the circuit board, and optionally another trigger sensor and one or more motor sensors, e.g., one or more Hall sensors; and solidifying the potting material to encapsulate at least a portion of the control circuit, e.g., the another field effect transistor, the motor controller, the motor sensor, the trigger sensor, and / or the circuit board.

[0076] XI. A surgical power tool assembly comprising: a housing; an electric motor positioned within the housing; a coupler operably actuated by the electric motor; a controller positioned within the housing; a battery configured to provide power to the controller and coupled to the housing; and a trigger movably coupled to the housing, the controller configured to turn on the electric motor when the trigger is depressed and to adjust the speed of the electric motor based on how far the trigger is depressed, the coupler defining an axis, the trigger defining an actuation surface, and moving between an actuated position and a non-actuated position, the actuation surface being closer to the axis defined by the coupler in the actuated position than in the non-actuated position.

[0077] XII. The surgical power tool assembly of clause XI, further comprising a surgical attachment, the surgical attachment including an input shaft and a tool coupler, the input shaft being offset from the tool coupler by at least 45 degrees, at least 60 degrees, or about 90 degrees.

[0078] XIII. The surgical power tool assembly of clause XII, wherein the input shaft defines an input axis, the input axis being offset from the tool coupler by at least 45 degrees, at least 60 degrees, or about 90 degrees.

[0079] XIV. The surgical power tool assembly of clause XIII, wherein the tool coupler is operable to engage the surgical pin, and wherein the tool coupler includes a lever operable to move the tool coupler between a locked configuration and an unlocked configuration, the lever offset from the input shaft.

[0080] XV. A surgical power tool assembly comprising: a housing including a barrel portion and a handle portion; an electric motor positioned within the housing; a coupler operably actuated by the electric motor; a controller positioned within the housing; a battery configured to power the controller and coupled to the housing; and a trigger movably coupled to the handle portion of the housing, the controller configured to turn on the electric motor when the trigger is depressed; wherein the handle portion defines a longitudinal axis and the barrel portion of the housing is operable to rotate about the longitudinal axis of the handle portion.

[0081] XVI. The surgical power tool assembly of clause XV, wherein the barrel portion defines an attachment coupler configured to receive a surgical attachment.

[0082] XVII. The surgical power tool assembly of clause XV, wherein the barrel portion includes a coupler for engaging a surgical end effector.

[0083] XVIII. A surgical power tool assembly comprising: a housing including a barrel portion and a handle portion; an electric motor positioned within the housing; a coupler operably actuated by the electric motor; a controller positioned within the housing; a battery configured to power the controller and coupled to the housing; and a trigger movably coupled to the handle portion of the housing, the controller configured to turn on the electric motor when the trigger is depressed; wherein the handle portion defines an axis and the barrel portion of the housing is operable to rotate about the axis of the handle portion.

[0084] XIX. The surgical power tool assembly of clause XVIII, wherein the axis is perpendicular to the longitudinal axis of the handle portion.

[0085] XX. A housing including a proximal region and a distal region, the housing including a first attachment coupler in the proximal region and a second attachment coupler in the distal region; an electric motor positioned within the housing; a controller positioned within the housing; a battery configured to power the controller and coupled to the housing; a trigger movably coupled to the housing, the controller configured to turn on the electric motor when the trigger is depressed; and a mode switch movably coupled to the housing and movable between a first position and a second position, the controller configured to turn on the electric motor when the mode switch is in the first position. a mode switch operable to control the motor in a first mode when the mode switch is in a first position and operable to control the motor in a second mode when the mode switch is in a second position; a first attachment configured to be driven from the motor when engaged with the first attachment coupler; and a second attachment configured to be driven from the motor when engaged with the second attachment coupler, wherein the motor is operable to drive the first attachment when the motor is in the first mode and the motor is operable to drive the second attachment when the motor is in the second mode.

[0086] XXI. The surgical power tool assembly of clause XX, wherein the first attachment coupler is located on an opposite side of the housing from the first attachment coupler.

[0087] XXII. The surgical power tool assembly of clause XX, wherein the second attachment is operable to drive a surgical pin and the first attachment is operable to drive a surgical saw blade or a drill bit.

[0088] XXIII. The surgical power tool assembly of clause XX, wherein the mode switch is a ring switch operable to rotate relative to the housing to toggle between a first position and a second position.

[0089] XXIV. A surgical power tool assembly comprising: a housing; an electric motor positioned within the housing; a coupler operably actuated by the electric motor; a controller positioned within the housing; a battery configured to power the controller and coupled to the housing; a first trigger movably coupled to the housing, wherein the controller is configured to turn on the electric motor when the first trigger is depressed; and a second trigger movably coupled to the housing, wherein the controller is configured to turn on the electric motor when the second trigger is depressed, wherein the first trigger is accessible from a different grip than the second trigger.

[0090] XXV. A surgical power tool assembly as described in clause XXIV, wherein the housing includes a barrel portion and a handle portion, the first trigger being on a first region of the handle portion, and the second trigger being on a second region of the handle portion.

[0091] XXVI. The surgical power tool assembly of clause XXV, wherein the first region is positioned opposite the second region.

[0092] XXVII. The surgical power tool assembly of clause XXV, wherein the first region is located closer to the barrel portion than the second region.

[0093] XXVIII. The surgical power tool assembly of clause XXIV, further comprising: a mode switch movably coupled to the housing and movable between a first position and a second position, wherein the controller is operable to control the motor in a first mode when the mode switch is in the first position and to control the motor in a second mode when the mode switch is in the second position, the housing including a proximal region and a distal region, the housing including a first attachment coupler in the proximal region and a second attachment coupler in the distal region; a first attachment configured to be driven from the motor when engaged with the first attachment coupler; and a second attachment configured to be driven from the motor when engaged with the second attachment coupler, wherein the motor is operable to drive the first attachment when the motor is in the first mode and the motor is operable to drive the second attachment when the motor is in the second mode.

[0094] XXIX. The surgical power tool assembly of clause XXVIII, wherein the first trigger is operable to control the speed of the motor when the motor is in the first mode, and the second trigger is operable to control the speed of the motor when the motor is in the second mode.

[0095] XXX. A surgical power tool assembly comprising: a housing; an electric motor positioned within the housing; a coupler operably actuated by the electric motor; a controller positioned within the housing; a battery configured to power the controller and coupled to the housing; and a trigger movably coupled to the housing, the controller configured to turn on the electric motor when the trigger is depressed and to adjust a speed of the electric motor based on how far the trigger is depressed; the coupler defining an axis; the trigger defining an actuation surface; the trigger movable between an actuated position and an inactuated position; the actuation surface being closer to the axis defined by the coupler in the actuated position than in the inactuated position.

[0096] XXXI. The surgical power tool assembly of clause XXX, wherein the housing defines a trigger axis, the trigger has a pivot end and a free end, and the trigger is pivotable about the trigger axis at its free end.

[0097] XXXII. The surgical power tool assembly of clause XXX, wherein the housing includes a base and a protrusion extending from the base, the protrusion extending to the actuation surface when the trigger is in the actuated and unactuated positions.

[0098] XXXIII. The surgical power tool assembly of clause XXX, wherein the trigger includes a runsafe switch.

[0099] XXXIV. The surgical power tool assembly of clause XXX, wherein the trigger includes first and second magnets.

[0100] XXXV. A powered surgical tool comprising: a handpiece defining a cavity; an electric motor disposed within the cavity; a rigid first printed circuit board disposed within the cavity, the first printed circuit board including a trigger sensor and a motor control sensor; a rigid second printed circuit board disposed within the cavity; a rigid third circuit board disposed within the cavity, the first circuit board, the second circuit board, and the third circuit board each defining a plane, the planes of the first, second, and third circuit boards being parallel to one another; and a controller configured to adjust power drawn from a power source based on user input, the controller mounted on one of the second printed circuit board and the third circuit board.

[0101] XXXVI. A surgical power tool assembly for driving a surgical pin, comprising: a surgical handpiece housing; an electric motor positioned within the handpiece housing; a controller positioned within the handpiece housing; a trigger movably coupled to the handpiece housing, the trigger having an actuation surface movable between an actuated position and an inactive position, the controller configured to control the speed of the motor based on the actuation position of the trigger; and an output drive coupled to the electric motor and configured to be rotated about an axis by the electric motor, the actuation surface being closer to the axis in the actuated position than in the inactive position; and a pin driver attachment for driving a surgical pin.

[0102] XXXVII. A method of driving a pin in a robotic-assisted total knee replacement procedure, the method comprising: providing a battery-powered surgical tool; coupling a surgical attachment to the battery-powered surgical tool; drilling holes with a drill bit at at least two locations using a first drive portion of the surgical attachment; driving the first pin at one of the at least two locations with a second drive portion of the surgical attachment; and driving a second pin having a different diameter than the first pin at another of the at least two locations with a third drive portion of the surgical attachment.

Claims

1. 1. A surgical power tool assembly for driving a surgical pin, comprising: A surgical handpiece, comprising: Handpiece housing, an electric motor positioned within the handpiece housing; a controller positioned within the handpiece housing; a battery removably coupled to the handpiece housing and configured to power the controller; a trigger movably coupled to the handpiece housing and having an actuation surface movable between an actuated position and an inactuated position, the controller configured to control the speed of the motor based on the actuated position of the trigger; and an output drive coupled to the electric motor and configured to be rotated by the electric motor about an axis; the actuating surface is closer to the shaft in the actuated position than in the non-actuated position; A surgical handpiece; 1. A pin driver attachment, comprising: an attachment housing removably coupled to the handpiece housing; an operating member movably coupled to the attachment housing; and a collet operable in a clamped state and an unclamped state, the collet operable to engage the surgical pin when in the clamped state; the operating member is operably coupled to the collet by movement of the operating member between a first position and a second position, the collet being in the clamped state when the operating member is in the first position, and the collet being in the unclamped state when the operating member is in the second position; Pin driver attachment and 1. A surgical power tool assembly comprising:

2. The surgical power tool assembly of claim 1 , wherein the trigger is pivotally coupled to the handpiece housing.

3. The surgical power tool assembly of claim 2 , wherein the trigger defines a trigger pivot end pivotally coupled to the handpiece housing and a trigger free end disposed proximally from the trigger pivot end.

4. The surgical power tool assembly according to any one of claims 1 to 3, wherein the operating member is selected from the group consisting of a threaded collar and a lever.

5. 5. The surgical power tool assembly of claim 1, wherein the operating member comprises a lever pivotally coupled to the attachment housing, the lever defining a lever pivot end pivotally coupled to the attachment housing and a lever free end disposed proximally from the lever pivot end.

6. The surgical power tool assembly of claim 5 , wherein the lever defines a recess and the trigger is aligned with the recess.

7. A surgical power tool assembly according to claim 5 or 6, wherein the lever free end is located proximally from the trigger.

8. A surgical power tool assembly according to any one of claims 5 to 7, wherein at least a portion of the trigger is located proximally from the lever free end.

9. 9. A surgical power tool assembly according to claim 5, wherein the lever has a first bent portion, a second bent portion, and a third bent portion, the first bent portion and the second bent portion being closer to the lever pivot end than the lever free end, each of the first bent portion and the second bent portion being at an acute angle, and the third bent portion being at an obtuse angle.

10. 10. The surgical power tool assembly of claim 9, wherein the lever further comprises a fourth bend, the fourth bend being closer to the lever free end than the third bend, and the fourth bend being at an obtuse angle.

11. The surgical power tool assembly of claim 10 , wherein the lever includes exactly four bends.

12. 12. The surgical power tool assembly of claim 1, wherein the trigger is further defined as a first trigger having a first actuation surface, the first trigger configured to cause the electric motor to rotate the output drive about the axis in a first direction, and the surgical handpiece further comprises a second trigger having a second actuation surface, the second trigger configured to cause the electric motor to rotate the output drive about the axis in a second direction opposite the first direction.

13. 13. The surgical power tool assembly of claim 1, wherein the collet includes jaws coupled to the attachment housing, the jaws being movable relative to the attachment housing in response to the position of the operating member such that the jaws in the clamped state are closer to the shaft for engaging the surgical pin than the jaws in the unclamped state.

14. 1. A surgical power tool assembly for driving a surgical pin, comprising: A surgical handpiece, comprising: Handpiece housing, an electric motor positioned within the handpiece housing; a controller positioned within the handpiece housing; a battery removably coupled to the handpiece housing and configured to power the controller; a trigger movably coupled to the handpiece housing and having an actuation surface movable between an actuated position and an inactuated position, the controller configured to control the speed of the motor based on the actuated position of the trigger; and an output drive coupled to the electric motor and configured to be rotated by the electric motor about an axis; the actuating surface is closer to the shaft in the actuated position than in the non-actuated position; A surgical handpiece; a pin driver attachment for driving the surgical pin; 1. A surgical power tool assembly comprising:

15. 15. The surgical power tool assembly of claim 14, wherein the pin driver attachment comprises a first drive portion for connecting to a twist drill, a second drive portion for connecting to a first surgical pin having a first diameter, and a third drive portion for connecting to a second surgical pin having a second diameter different from the first diameter.

16. 16. The surgical power tool assembly of claim 15, wherein the first drive portion defines a first cross-sectional area, the second drive portion defines a second cross-sectional area different from the first cross-sectional area, and the third drive portion defines a third cross-sectional area different from the first and second cross-sectional areas.

17. A surgical power tool assembly according to any one of claims 14 to 16, wherein the trigger is pivotally coupled to the handpiece housing.

18. 18. The surgical power tool assembly of claim 17, wherein the trigger defines a trigger pivot end pivotally coupled to the handpiece housing and a trigger free end disposed proximally from the trigger pivot end.

19. 19. The surgical power tool assembly of any one of claims 14 to 18, wherein the trigger is further defined as a first trigger having a first actuation surface, the first trigger configured to cause the electric motor to rotate the output drive about the axis in a first direction, and the surgical handpiece further comprises a second trigger having a second actuation surface, the second trigger configured to cause the electric motor to rotate the output drive about the axis in a second direction opposite the first direction.

20. A surgical handpiece, comprising: Handpiece housing, an electric motor positioned within the handpiece housing; a controller positioned within the handpiece housing; a battery removably coupled to the handpiece housing and configured to power the controller; a trigger pivotally coupled to the handpiece housing, the controller configured to turn on the electric motor when the trigger is depressed and to adjust the speed of the electric motor based on how far the trigger is depressed; and an output drive coupled to the electric motor and configured to be rotated about an axis by the electric motor; A surgical handpiece; 1. A pin driver attachment, comprising: an attachment housing removably coupled to the handpiece housing; an operating member movably coupled to the attachment housing; and a collet operable in a clamped state and an unclamped state, the collet operable to engage the surgical pin when in the clamped state; the operating member is operably coupled to the collet by movement of the operating member between a first position and a second position, the collet being in the clamped state when the operating member is in the first position, and the collet being in the unclamped state when the operating member is in the second position; Pin driver attachment and 1. A surgical power tool assembly comprising:

21. 21. The surgical power tool assembly of claim 20, wherein the trigger defines a trigger pivot end pivotally coupled to the handpiece housing and a trigger free end disposed proximally from the trigger pivot end.

22. 22. A surgical power tool assembly according to claim 20 or 21, wherein the operating member is selected from the group consisting of a threaded collar and a lever.

23. 23. The surgical power tool assembly of claim 20, wherein the operating member comprises a lever pivotally coupled to the attachment housing, the lever defining a lever pivot end pivotally coupled to the attachment housing and a lever free end disposed proximally from the lever pivot end.

24. 24. The surgical power tool assembly of claim 23, wherein the lever defines a recess, and the trigger is aligned with the recess.

25. 25. A surgical power tool assembly according to claim 23 or 24, wherein the lever free end is located proximally from the trigger.

26. A surgical power tool assembly according to any one of claims 23 to 25, wherein at least a portion of the trigger is located proximally from the lever free end.

27. 27. A surgical power tool assembly according to any one of claims 23 to 26, wherein the lever has a first bent portion, a second bent portion, and a third bent portion, the first bent portion and the second bent portion being closer to the lever pivot end than the lever free end, each of the first bent portion and the second bent portion being at an acute angle, and the third bent portion being at an obtuse angle.

28. 28. The surgical power tool assembly of claim 27, wherein the lever further comprises a fourth bend, the fourth bend being closer to the lever free end than the third bend, the fourth bend being at an obtuse angle.

29. 30. The surgical power tool assembly of claim 28, wherein the lever includes exactly four bends.

30. 30. The surgical power tool assembly of any one of claims 20 to 29, wherein the trigger defines an actuation surface and moves between an actuated position and an inactuated position, the actuation surface being closer to a longitudinal axis defined by the collet in the actuated position than in the inactuated position.

31. 31. The surgical power tool assembly of claim 30, wherein the trigger is further defined as a first trigger having a first actuation surface, the first trigger configured to cause the electric motor to rotate the output drive about the axis in a first direction, and the surgical handpiece further comprises a second trigger having a second actuation surface, the second trigger configured to cause the electric motor to rotate the output drive about the axis in a second direction opposite the first direction.

32. 32. The surgical power tool assembly of claim 31, wherein the collet includes jaws coupled to the attachment housing, the jaws being movable relative to the attachment housing in response to the position of the operating member such that the jaws in the clamped state are closer to the shaft for engaging the surgical pin than the jaws in the unclamped state.

33. 1. A surgical power tool assembly for driving a surgical pin, comprising: A surgical handpiece, comprising: Handpiece housing, an electric motor positioned within the handpiece housing; a controller positioned within the handpiece housing; a battery removably coupled to the handpiece housing and configured to power the controller; a trigger pivotally coupled to the handpiece housing, the controller configured to turn on the electric motor when the trigger is depressed and to adjust the speed of the electric motor based on how far the trigger is depressed; and an output drive coupled to the electric motor and configured to be rotated about an axis by the electric motor; A surgical handpiece; a pin driver attachment for driving the surgical pin; 1. A surgical power tool assembly comprising:

34. 34. The surgical power tool assembly of claim 33, wherein the pin driver attachment comprises a first drive portion for connecting to a twist drill, a second drive portion for connecting to a first surgical pin having a first diameter, and a third drive portion for connecting to a second surgical pin having a second diameter different from the first diameter.

35. 35. The surgical power tool assembly of claim 34, wherein the first drive portion defines a first cross-sectional area, the second drive portion defines a second cross-sectional area different from the first cross-sectional area, and the third drive portion defines a third cross-sectional area different from the first and second cross-sectional areas.

36. 36. The surgical power tool assembly of claim 33, wherein the trigger defines a trigger pivot end pivotally coupled to the handpiece housing and a trigger free end disposed proximally from the trigger pivot end.

37. 37. The surgical power tool assembly of any one of claims 33-36, wherein the trigger is further defined as a first trigger having a first actuation surface, the first trigger configured to cause the electric motor to rotate the output drive about the axis in a first direction, and the surgical handpiece further comprises a second trigger having a second actuation surface, the second trigger configured to cause the electric motor to rotate the output drive about the axis in a second direction opposite the first direction.

38. 1. A method of inserting a surgical pin with a surgical power tool assembly, the surgical power tool assembly including a housing, an electric motor positioned within the housing, a coupler operably actuated by the electric motor, a controller positioned within the housing, a battery removably coupled to the housing and configured to power the controller, and a trigger movably coupled to the housing, the method comprising: inserting the surgical pin into the coupler; grasping the housing with a user's hand so that the user's thumb is closer to the battery than the coupler; placing a user's finger on the trigger with the user's thumb closer to the battery than the coupler; and driving the surgical pin into bone with the surgical power tool assembly.

39. 39. The method of claim 38, further comprising drilling a hole in the bone with a twist drill coupled to the coupler.

40. 40. The method of claim 38 or 39, wherein the step of applying the trigger further comprises depressing the trigger to adjust the speed of the electric motor.

41. 41. The method of claim 40, wherein the surgical power tool assembly further includes a surgical attachment for engaging the surgical pin, the surgical attachment including a lever separate from the trigger, the method further comprising depressing the lever with the user's finger while the user's thumb is closer to the battery than the coupler.

42. 42. The method of claim 41, wherein the steps of depressing the lever and depressing the trigger are performed by different fingers.

43. 43. The method of claim 42, wherein the steps of depressing the lever and depressing the trigger are performed simultaneously.

44. 44. The method of any one of claims 41 to 43, wherein the surgical attachment comprises a collet having jaws, and wherein the step of depressing the lever further comprises depressing the lever to move the jaws from a non-clamped state to a clamped state, wherein the jaws engage the surgical pin in the clamped state.

45. 45. The method of any one of claims 38 to 44, wherein the step of gripping the housing further comprises gripping the housing such that the battery is positioned above the user's hand during use.

46. The method of any one of claims 38 to 45, wherein the step of depressing the trigger further comprises pivoting the trigger relative to the housing.

47. 1. A method of inserting a pin with a surgical power tool, the surgical power tool including a trigger and a lever coupled to a collet, the method comprising: grasping the housing of the surgical power tool with a user's hand; a step of fastening the surgical pin with the collet by hooking the index finger of the user's hand on the lever; placing a finger of the user's hand other than the index finger on the trigger; and driving the surgical pin into bone with the powered surgical tool; A method comprising:

48. 48. The method of claim 47, further comprising gripping the housing of the surgical power tool handpiece with a hammer grip.

49. 49. The method of claim 48, wherein the step of gripping is further defined by gripping the housing such that a user's thumb is closer to a proximal end of the surgical power tool than to a distal end of the surgical power tool.

50. 50. The method of any one of claims 47 to 49, wherein the step of engaging the trigger further comprises depressing the trigger and adjusting a speed of an electric motor based on the position of the trigger.

51. 51. The method of claim 50, further comprising hooking the index finger over the lever with the user's thumb closer to a battery of the surgical power tool assembly than the index finger.

52. 52. The method of any one of claims 47 to 51, wherein the steps of depressing the lever and depressing the trigger are performed simultaneously.

53. 53. The method of claim 51 or 52, wherein the collet includes jaws, and wherein the step of depressing the lever further includes depressing the lever to move the jaws from an unclamped state to a clamped state, wherein the jaws engage the surgical pin in the clamped state.

54. 54. The method of any one of claims 47 to 53, wherein the step of gripping the housing further comprises gripping the housing such that a battery is positioned above the user's hand during use.

55. 1. A method of driving a pin in a robotic-assisted total knee replacement procedure, comprising: providing a battery-powered surgical tool; coupling a surgical attachment to the battery-powered surgical tool; using a first drive portion of the surgical attachment to drill a hole with a drill bit into at least one bone selected from the femur, the tibia, and the patella; driving a first pin in one of the femur, the tibia, or the patella with a second drive portion of the surgical attachment; and driving a second pin having a different diameter than the first pin in another bone of the femur, the tibia, or the patella with a third drive portion of the surgical attachment; A method comprising:

56. 56. The method of claim 55, further comprising attaching a first navigation tracker to the femur using the first pin.

57. 57. The method of claim 55 or 56, further comprising attaching a second navigation tracker to the tibia using the second pin.

58. 58. The method of any one of claims 55 to 57, wherein at least one of the steps of driving a first pin and driving a second pin occurs before the step of drilling a hole.

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