Surgical saw blade with bearing

Abstract

This invention relates to a surgical blade assembly having a gap between the outer sheath and the inner blade in order to minimize wear. [Solution] A covered blade assembly for minimizing or preventing contact between a movable inner blade 108 and an outer sheath. The assembly includes an outer sheath having a first portion 110 and a second portion 112 with an inner lumen 132 between them; an inner blade movable within the inner lumen of the outer sheath; a first pocket within the first surface of the inner blade; and a first ball bearing 148 within the first pocket. The first ball bearing creates a clearance between the first surface of the inner blade and the first portion of the outer sheath. The assembly may also include a second pocket for a second ball bearing 148 within the second surface of the inner blade. The second ball bearing creates a clearance between the second surface of the inner blade and the second portion of the outer sheath. The second pocket is configured to be offset from the first pocket.

Description

Technical Field

[0001] Cross-reference of related applications This application claims priority to U.S. Provisional Patent Application No. 62 / 639,040, filed on March 6, 2018, entitled "Sheathed Surgical Saw Blade and Bearings", and U.S. Provisional Patent Application No. 62 / 724,914, filed on August 30, 2018, entitled "Sheathed Surgical Saw Blade with Bearings and Universal Saw Handpiece for Sheathed and Standard Blades", the entire contents of which are incorporated herein by reference.

[0002] Field of Invention The present invention generally relates to surgical blade assemblies, and more specifically to a sheathed blade assembly having a gap amount between an outer sheath and an inner blade to minimize wear.

Background Art

[0003] Description of related technologies Surgical sheathed blades are composed of a movable inner member (blade) and an outer stationary member (sheath). During use, contact between the movable member and the stationary member is inevitable because a cantilever force is applied to the assembly to cause it to contact the movable and stationary parts. Due to the high linear speed of the blade, the assembly can become very hot and wear when the blade contacts the stationary sheath. Heating of the sheath and blade can cause osteonecrosis and damage to the patient or user. Further, wear created by the blade contacting the sheath generates metal particles that can fall into the surgical site.

[0004] The design requires different mechanisms for coated blade assemblies and uncoated (standard) blades to interact with the surgical saw handpiece, thus requiring different handpieces to operate one blade or the other. The need for two different saw handpieces, one to drive the coated blade assembly and the other the uncoated blade assembly, adds further cost to the surgical equipment and / or requires a choice between a single blade option (coated or uncoated).

[0005] Therefore, there is a need for a single surgical saw handpiece to drive both coated blade assemblies and uncoated (standard) blades, as well as for coated blade assemblies that prevent or minimize potential contact between the inner movable blade and the sheath.

[0006] Explanation of Disclaimers for Related Technical Sections: To the extent that specific patents / publications / products are discussed in this Related Technical Section or elsewhere in this disclosure, these discussions should not be taken as permission for the discussed patents / publications / products to be prior art for the purposes of patent law. For example, some or all of the discussed patents / publications / products may not be sufficiently early, may not reflect subject matter developed sufficiently early, and / or may not be sufficiently possible to constitute prior art for the purposes of patent law. To the extent that specific patents / publications / products are discussed above in this Related Technical Section and / or throughout the application, all such discussions / disclosures are incorporated herein by reference. [Overview of the Initiative]

[0007] The present invention relates to a single surgical saw that drives both a covered blade assembly and an uncovered (standard) blade, and to a covered blade that prevents potential contact between a movable inner blade and an outer sheath. According to one embodiment, the covered blade assembly includes an outer sheath having an upper and a bottom portion with an inner lumen between them, an inner blade movable within the inner lumen of the outer sheath, and at least one ball bearing within the inner lumen of the outer sheath. The ball bearing creates a clearance between the inner blade and at least one of the upper and bottom portions of the outer sheath.

[0008] In another embodiment, the covered blade assembly includes an outer sheath having a first part and a second part having an inner lumen between them, an inner blade movable within the inner lumen of the outer sheath, a first pocket within the first surface of the inner blade, and a first ball bearing within the first pocket. The first ball bearing creates a clearance between the first surface of the inner blade and the first part of the outer sheath.

[0009] In another embodiment, the present invention is a surgical saw. The surgical saw includes a saw head having a collet having an opening configured to receive a movable blade. The blade is removably connected within the collet. A handpiece is connected to the saw head and the handpiece has a drive mechanism for moving the blade.

[0010] These and other aspects of the present invention will become clear and clarified by referring to the embodiments described below. [Brief explanation of the drawing]

[0011] One or more aspects of the present invention are specifically pointed out and claimed at the end of this specification as examples of the claims. The aforementioned and other objects, features, and advantages of the present invention will be apparent from the following description in conjunction with the accompanying drawings.

[0012] [Figure 1] Figure 1 is a schematic top perspective view of a coated blade assembly according to one embodiment. [Figure 2] Figure 2 is a schematic exploded perspective view of a coated blade assembly according to one embodiment. [Figure 3] Figure 3 is a schematic distal view of a coated blade assembly according to one embodiment. [Figure 4] Figure 4 is a schematic side view of a coated blade assembly according to an alternative embodiment. [Figure 5] Figure 5 is a schematic top perspective view of a coated blade assembly according to an alternative embodiment. [Figure 6] Figure 6 is a schematic exploded perspective view of a coated blade assembly according to an alternative embodiment. [Figure 7] Figure 7 is a schematic side perspective view of a general-purpose saw head according to one embodiment. [Figure 8] Figure 8 is a schematic side perspective view of a covered blade assembly connected to a general-purpose saw head, according to one embodiment. [Figure 9] Figure 9 is a schematic side perspective view of an uncoated blade connected to a general-purpose saw head, according to an alternative embodiment. [Figure 10] Figure 10 is a schematic exploded view of the covered blade assembly connected to the general-purpose saw head shown in Figure 8. [Modes for carrying out the invention]

[0013] Aspects of the present invention, specific features, advantages, and details thereof are described more fully below with reference to non-limiting examples illustrated in the accompanying drawings. Descriptions of well-known structures are omitted so as not to unnecessarily obscure the details of the present invention. However, it should be understood that while illustrating aspects of the present invention, the detailed description and specific non-limiting examples are given by illustration only and are not limiting. The spirit and / or scope of the underlying concepts of the present invention Various substitutions, modifications, additions, and / or arrangements will be apparent to those skilled in the art from this disclosure.

[0014] Referring here to the drawings, similar reference numerals refer to the same parts throughout, and Figure 1 shows a schematic top perspective view of a covered blade assembly 100 according to one embodiment. The covered blade assembly 100 extends from a proximal end 102 to a distal end 104. As shown in the illustrated embodiment, the covered blade assembly 100 comprises a stationary outer sheath 106 having a movable inner blade 108 extending through it.

[0015] Referring now to Figure 2, a schematic exploded perspective view of a covered blade assembly 100 according to one embodiment is shown. In the illustrated embodiment, the covered blade assembly 100 comprises an outer sheath 106 having two parts, an upper portion 110 and a bottom portion 112. The upper portion 110 and the bottom portion 112 are made of a metal such as stainless steel. As shown in Figure 2, the upper portion 110 is an elongated rectangular plate. In the illustrated embodiment, the upper portion 110 has a straight proximal edge 114 and a curved distal edge 116. The bottom portion 112 is also an elongated rectangular plate having a straight proximal edge 118 and a curved distal edge 120. The bottom portion 112 also includes a distal end 122 including a circular opening 124. In the illustrated embodiment, the distal end 122 of the bottom portion 112 includes a pair of arms 126 (or prongs) extending therefrom. The arms 126 extend toward each other but do not touch, forming a gap 128 between them. The gap 128 extends into a circular opening 124, as shown in the figure.

[0016] Referring further to Figure 2, the outer sheath 106 further includes a track 130 extending along the bottom portion 112 between the straight proximal edge 118 and the curved distal edge 120. The track 130 defines an inner lumen 132 within the covered blade assembly 100 between the upper portion 110 and the bottom portion 112 of the outer sheath 106. The inner lumen 132 is sized and configured to fit the inner blade 108.

[0017] As shown in FIG. 2, the inner blade 108 includes a proximal cutting end 134 and a distal connecting end 136 (also referred to as the "hub" 164). In the illustrated embodiment, the inner blade 108 is elongated and tapered, narrowing towards the proximal cutting end 134. The proximal cutting end 134 of the inner blade 108 includes a head 138 having a plurality of cutting teeth 140. In the embodiment shown in FIG. 2, the head 138 of the proximal cutting end 134 is trapezoidal in shape and increases in width in the proximal direction. The distal connecting end 136 includes a circular disk 142 having a plurality of slots 144 and an opening 146 extending therethrough. The disk 142 is sized and configured to fit into an opening 124 at the distal end 122 of the bottom portion 112. Further, the opening 146 of the disk 142 is arranged to align with a gap 128 at the distal end 122 of the bottom portion 112. The purpose of the distal connecting end 136 of the inner blade 108 and the distal end 122 of the bottom portion 112 is to facilitate the connection of the coated blade assembly 100 to the saw head 160 (FIG. 7).

[0018] Also, as shown in FIG. 2, the coated blade assembly 100 further includes one or more ball bearings 148 between the upper portion 110 of the outer sheath 106 and the inner blade 108, and between the bottom portion 112 of the outer sheath 106 and the inner blade 108. The ball bearings 148 are seated or disposed on both sides of the inner blade 108 and rotate with respect to the inner blade 108 and the upper portion 110 and the bottom portion 112 of the outer sheath 106. Thus, the ball bearings 148 enable the movement of the inner blade 108 and enable minimizing the contact between the inner blade 108 and the outer sheath 106. The ball bearings 148 can be embedded in blind holes or slots (not shown) in the inner blade 108 or in the upper portion 110 and the bottom portion 112 of the outer sheath 106. The ball bearings 148 project beyond the surface of the inner blade 108 or the outer sheath 106 to maintain a gap between the inner blade 108 and the outer sheath 106. to protrude.

[0019] Referring now to FIGS. 3-4, a schematic distal view and a schematic side view of a coated blade assembly 100 according to one embodiment are shown. FIG. 3 shows the proximal end 102 of the coated blade assembly 100. In the illustrated embodiment, the inner blade 108 is shown positioned within the inner lumen 132 of the outer sheath 106 (between the upper portion 110 and the bottom portion 112). Also as shown in FIG. 3, the ball bearing 148 is positioned within a pocket 150 on the upper surface 152 of the inner blade 108.

[0020] FIG. 4 shows a side view of the coated blade assembly 100. In the illustrated embodiment, the inner blade 108 is positioned within the inner lumen 132 of the outer sheath 106. The inner blade 108 shown in FIG. 4 has two pockets 150A, 150B, one pocket 150A on the upper surface 152 of the inner blade 108 and one pocket 150B on the bottom surface 154 of the inner blade 108, and the ball bearing 148 is positioned within the pockets 150A, 150B. In the illustrated embodiment, the two pockets 150A, 150B are offset such that one pocket 150A is distal with respect to the proximal cut end 134 of the inner blade 108 compared to the other pocket 150B. The ball bearing 148 can be sized and configured to fit within the pockets 150A, 150B, although the coated blade assembly 100 does not require the pockets 150A, 150B. The ball bearing 148 can be constrained by the size of the outer sheath 106 and the width of the inner blade 108 within the outer sheath 106. The offset configuration of the ball bearing 148 provides a gap between the inner blade 108 and the outer sheath 106, greatly reducing friction within the assembly, thereby reducing heat, wear, and metal particle generation. Also, the gap allows fluid to lubricate the moving parts of the coated blade assembly 100.

[0021] Referring here to Figures 5 and 6, schematic top perspective views and schematic exploded perspective views of the covered blade assembly 100 according to an alternative embodiment are shown. In the alternative embodiment of the covered blade assembly 100 shown in Figures 5 and 6, the outer sheath 106 includes a plurality of notches 146 (i.e., openings or openings). As shown in Figure 5, the upper portion 110 of the outer sheath 106 includes three trapezoidal or triangular notches 156A extending through it. However, any number of notches 156A of any shape or configuration can be used.

[0022] In Figure 6, the bottom portion 112 of the outer sheath 106 further includes a plurality of notches 156B (i.e., openings or openings) extending through it. The bottom portion 112 of the outer sheath 106 also includes three trapezoidal or triangular notches 156B extending through it (however, any number of notches 156B of any shape or configuration can be used). In the illustrated embodiment, the notches 156B of the bottom portion 112 of the outer sheath 106 are aligned within the notches 156A of the upper portion 110 of the outer sheath 106. The notches 156A, 156B reduce the surface area of ​​contact between the inner blade 108 and the outer sheath 106, allowing fluid from the surgical site to lubricate the moving parts. Thus, the notches 156A, 156B reduce friction and wear within the covered blade assembly 100 and reduce heat and metal particle generation in the covered blade assembly 100. To further reduce friction, wear, and heat, any surface of the inner blade 108 and outer sheath 106 may also include a coating 158 such as a physical vapor deposition (PVD) coating, a diamond-like carbon coating, and / or a dry lubricating coating such as tungsten disulfide.

[0023] Referring now to Figure 7, a schematic side perspective view of a general-purpose saw head 160 according to one embodiment is shown. In the illustrated embodiment, the saw head 160 has a collet 162 (opening) for accommodating both a covered blade assembly 100 (Figure 1) and an uncovered (standard) blade 200. This includes (having 170). As shown in Figures 1-2, when using a coated blade 100, the collet 162 holds the outer sheath 106 in place while the inner blade 108 engages and drives using the hub 164 of the inner blade 108. When using an uncoated (standard) blade 200, the saw head 160 engages and drives the uncoated blade assembly 200 using the hub (not shown) of the uncoated blade assembly 200, as it has the same structure as the hub 164 of the coated blade assembly 100 (Figure 2), while the collet 162 provides sufficient clearance so that the standard blade 200 does not come into contact with any of the mechanisms associated with securing the outer sheath 106. Since the saw head 160 can accommodate both the coated blade assembly 100 (Figure 1) and the uncoated (standard) blade assembly 200, the need for two different types of saw handpieces is eliminated, reducing purchase costs and inventory. Logistics for hospitals and surgical centers are also improved. As shown in Figure 7, the single general-purpose saw head 160 also provides users (e.g., physicians) with greater flexibility in selecting blade types for various surgical resections during orthopedic surgery.

[0024] Referring briefly to Figures 8 and 9, schematic side perspective views are shown of a covered blade assembly 100 and an uncovered blade 200, respectively, connected to a general-purpose saw head 160. As shown in both Figures 8 and 9, the general-purpose saw head 160 of Figure 7 can be mounted on a handpiece 166. The handpiece 166 can be any handpiece with a drive mechanism, such as a battery-operated handpiece or a pneumatic handpiece.

[0025] In Figure 8, in an embodiment in which the covered blade assembly 100 is used, the collet 162 captures the arm 126 at the distal end 122 (Figure 2) of the bottom portion 112 of the outer sheath 106. In particular, as shown in Figure 10, one or more raised regions 172 on the collet 162 clamp (or capture) the outer sheath 106 of the covered blade assembly 100, holding the outer sheath 106 stationary while the inner blade 108 essentially floats within the outer sheath 106. Thus, as also shown in Figure 10, the collet 162 connects to the stationary outer sheath 106 without contacting the movable inner blade 108.

[0026] As shown in Figure 9, when an uncoated (standard) blade 200 is used, the collet 162 connects to the hub of the uncoated blade 200 (similar to the hub 164 of the coated blade assembly 100 (Figure 2)), but a gap 168 is left between the blade 200 and the collet 162 to prevent contact, overheating, and damage. The gap 168 in Figure 9 can be created within the collet 162 by a recess 174, such as that shown in Figure 10. The recess 174 provides a gap 168 between the collet 162 and the uncoated blade 200 (Figure 9).

[0027] Figure 10 also shows various other components of the collet 162 and saw head 160. In the illustrated embodiment, the covered blade assembly 100 is attached to the collet 162 (and saw head 160) via a cap 176 and a conventional connector 178. In the illustrated embodiment, the connector 178 is attached to the cap 176 and extends through the hub 164 and collet 162 of the covered blade assembly 100. As shown in Figure 10, the saw head 160 includes a drive hub 180. The drive hub 180 is a movable component of the saw head 160. When the stationary outer sheath 106 is clamped by the raised region 172 of the collet 162, the inner blade 180 is driven, moved, or actuated by the drive hub 180, which is connected to a drive mechanism (not shown) in the handpiece 166.

[0028] All definitions defined and used herein should be understood to control dictionary definitions, definitions within documents incorporated by reference, and / or the ordinary meanings of the defined terms.

[0029] Various embodiments have been described and illustrated in this specification, but those skilled in the art will know that the embodiments described in this specification are not described. A person skilled in the art will readily recall various other means and / or structures for performing the function and / or obtaining the result and / or one or more advantages, and each of such variations and / or modifications will be considered within the scope of the embodiments described herein. More generally, a person skilled in the art will readily understand that all parameters, dimensions, materials and configurations described herein are illustrative, and that actual parameters, dimensions, materials and / or configurations depend on one or more specific uses in which the teaching is used. A person skilled in the art can recognize or confirm numerous equivalents to specific embodiments described herein simply by ordinary experimentation. Thus, the embodiments described herein are presented merely illustratively, and it will be understood that within the scope of the appended claims and their equivalents, the embodiments can be performed in other ways other than those specifically described and claimed. Embodiments of this disclosure cover individual features, systems, articles, materials, kits and / or methods described herein. Furthermore, any combination of two or more such features, systems, articles, materials, kits and / or methods is included within the scope of this disclosure, provided that they are not mutually inconsistent.

[0030] The terms used herein are for the purpose of describing only specific embodiments and are not intended to limit the invention. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural form unless the context explicitly indicates otherwise. The terms “comprise” (and any form of “comprise,” such as “comprises” or “comprising”), “have” (and any form of “have,” such as “has” or “having”), “include” (and any form of “include,” such as “includes” or “including”), and “contain” (and any form of “contains” or “containing”) are open-ended linking verbs. As a result, a method or device that “comprises,” “have,” “include,” or “contains” one or more steps or elements. Similarly, a step in a method of “comprise,” “have,” “include,” or “contain” one or more features, or an element of a device, is not limited to having, but possessing, only, one or more of those features. Furthermore, a device or structure configured in a particular way may be configured in at least that way, but in ways not listed.

[0031] All means or step-plus-functional elements of the following claims, along with their corresponding structures, materials, actions, and equivalents, are intended to include structures, materials, or actions for performing a function, in combination, if any, with other elements of the claims specifically claimed. While the description of the present invention has been presented for illustrative and explanatory purposes, it is not exhaustive or limiting to the forms disclosed herein. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the invention. The embodiments have been selected and described to best illustrate the principles and practical applications of one or more aspects of the invention, and to enable those skilled in the art to understand one or more aspects of the invention in terms of various embodiments with various modifications suitable for specific conceivable applications.

Claims

1. A coated blade assembly, Between them is an outer sheath having an inner lumen, an upper portion and a bottom portion, The inner blade is movable within the inner lumen of the outer sheath, The ball bearing in the inner lumen of the outer sheath, A covered blade assembly comprising a ball bearing that creates a clearance between the inner blade and at least one of the upper and bottom portions of the outer sheath.

2. The assembly according to claim 1, wherein the outer sheath is stationary relative to the movable inner blade.

3. The assembly according to claim 1, wherein the inner blade is tapered toward the proximal cutting end.

4. The assembly according to claim 3, wherein the inner blade is further provided with a head at the proximal cutting end, and the head has a plurality of cutting teeth extending therefrom.

5. The assembly according to claim 4, wherein the head has a width that increases proximally.

6. The assembly according to claim 1, wherein the inner blade has a distal connecting end comprising a circular disc having a plurality of openings extending therefrom.

7. The assembly according to claim 6, further comprising an opening extending within the circular disc.

8. The assembly according to claim 7, wherein the bottom portion of the outer sheath includes a distal end having an opening that aligns with the opening of the circular disc.

9. A coated blade assembly, Between them, an outer sheath having a first part and a second part, with an inner lumen, The inner blade is movable within the inner lumen of the outer sheath, The first pocket in the first surface of the inner blade, The first ball bearing in the first pocket, A covered blade assembly comprising a first ball bearing which creates a gap between the first surface of the inner blade and the first portion of the outer sheath.

10. The assembly according to claim 9, further comprising a second pocket within the second surface of the inner blade, wherein the second surface faces the first surface.

11. The assembly according to claim 10, further comprising a second ball bearing in the second pocket.

12. The assembly according to claim 11, wherein the second ball bearing creates a gap between the second surface of the inner blade and the second portion of the outer sheath.

13. The assembly according to claim 10, wherein the second pocket is configured to be offset from the first pocket.

14. The assembly according to claim 9, further comprising a plurality of first notches extending through the first portion.

15. The assembly according to claim 14, further comprising a second plurality of notches extending through the second portion, wherein the second plurality of notches are aligned with the first plurality of notches.

16. The assembly according to claim 9, further comprising a coating on at least one of the inner blade and the outer sheath, wherein the coating is composed of at least one of a physically vapor-deposited (PVD) coating, a carbon coating, and a dry lubricating coating.

17. It is a surgical saw, A saw head including a collet having an opening configured to receive a movable blade, The saw head, in which the blade is removably connected within the collet, A handpiece connected to the saw head, wherein the handpiece has a drive mechanism, A surgical saw comprising a handpiece, the drive mechanism for moving the blade.

18. The surgical saw according to claim 17, wherein the movable blade includes a stationary outer sheath having a pair of arms.

19. The surgical saw according to claim 18, wherein the pair of arms are connected to the movable blade in the collet.

20. The surgical saw according to claim 17, further comprising a gap between the blade and the collet.

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