Rotary Surgical Cutting Tools and Related Accessories

Abstract

The surgical handpiece system includes a high-speed surgical burr assembly and a surgical handpiece assembly. The high-speed surgical burr assembly has a nose tube and a drive shaft at least partially disposed within the nose tube. A cutting tool is coupled to a distal region of the drive shaft. The cutting tool and drive shaft are configured to rotate relative to the nose tube. The surgical handpiece system includes a hub and a rotatable drive chuck for alignment with and coupling to the nose tube and drive shaft. A motor is configured to rotate the rotatable drive chuck, the drive shaft, and the cutting tool when the drive shaft is coupled to the rotatable drive chuck.

Description

[Technical field]

[0001] Related Applications The subject patent application claims priority to and the entire benefit of U.S. Provisional Patent Application No. 62 / 857,959, filed June 6, 2019, and Provisional Patent Application No. 62 / 972,354, filed February 10, 2020, which are incorporated by reference in their entireties. [Background technology]

[0002] High speed burrs often include a motor and a separate disposable component that must be coupled to the motor so that torque can be transferred from the motor through a drive shaft to rotate the cutting burr at high speeds to erode and / or wear surfaces. It is an object of the present disclosure to improve this coupling. Summary of the Invention

[0003] The present disclosure generally relates to a surgical handpiece system. An exemplary configuration provides a surgical handpiece system having a high speed surgical burr assembly. The high speed surgical burr assembly includes a nose tube defining a lumen extending between a proximal end and a distal end of the nose tube. The nose tube has a proximal portion extending along an axis. The proximal portion of the nose tube has an outer surface defining a nose tube recess. The nose tube also includes a protrusion disposed proximally of the nose tube recess. The high speed surgical burr assembly also includes a drive shaft disposed at least partially within the lumen of the nose tube and configured to rotate relative to the nose tube. The high speed surgical burr assembly also includes a cutting tool coupled to a distal region of the drive shaft. The cutting tool is configured to rotate with the drive shaft relative to the nose tube. The system also includes a surgical handpiece assembly including a hub having a bore defining a cavity for receiving a proximal portion of the nose tube of the high speed surgical burr assembly. The surgical handpiece assembly also includes a biasing member disposed within the cavity of the hub. The biasing member is configured to be received by a nose tube recess of the nose tube to constrain a depth of the nose tube of the high speed surgical burr assembly within the cavity of the hub relative to the hub. The surgical handpiece assembly also includes a radial alignment member disposed within the cavity of the hub proximal to the biasing member. The radial alignment member defines a notch for receiving the protrusion to constrain a radial orientation of the nose tube relative to the hub.

[0004] Another exemplary configuration provides a surgical handpiece system including a high speed surgical burr assembly. The high speed surgical burr assembly includes a nose tube defining a lumen extending between a proximal end and a distal end of the nose tube. The high speed surgical burr assembly also includes a drive shaft disposed at least partially within the lumen of the nose tube and configured to rotate relative to the nose tube. The drive shaft has a proximal region extending along a drive shaft axis. The high speed surgical burr assembly also includes a cutting tool coupled to a distal region of the drive shaft. The cutting tool is configured to rotate with the drive shaft relative to the nose tube. The system also includes a surgical handpiece assembly including a hub having a bore defining a cavity for receiving a proximal end of the nose tube and a proximal region of the drive shaft of the high speed surgical burr assembly. The surgical handpiece assembly also includes a rotatable drive chuck configured to rotate by a motor about a hub axis. The rotatable drive chuck is disposed within the cavity of the hub and configured to rotate relative to the hub. The rotatable drive chuck defines an opening for receiving a proximal region of the drive shaft. The rotatable drive chuck includes a drive portion disposed proximate the opening. The drive portion has at least two drive surfaces configured to engage the drive shaft in a drive direction to rotate the drive shaft. The rotatable drive chuck also includes an alignment portion disposed between the drive portion and the opening of the rotatable drive chuck. The alignment portion has an alignment edge extending distally from the drive portion of the rotatable drive chuck toward the opening of the rotatable drive chuck. The alignment edge tapers away from the hub axle as the alignment edge extends distally from the drive portion of the rotatable drive chuck. The drive shaft is configured to engage the alignment edge of the alignment portion of the rotatable drive chuck to orient the drive shaft in a drive direction such that the drive shaft engages the at least two drive surfaces of the drive portion of the rotatable drive chuck.

[0005] Yet another exemplary configuration provides a high speed surgical burr assembly configured to cut tissue and be coupled to a surgical handpiece assembly. The high speed surgical burr assembly includes a nose tube defining a lumen extending between a proximal end and a distal end of the nose tube. The nose tube has a proximal portion extending along an axis. The proximal portion of the nose tube has an outer surface defining a recess for receiving a biasing member of the surgical handpiece assembly to constrain a depth of the nose tube relative to the surgical handpiece assembly. The nose tube includes a protrusion disposed proximal of the recess. The protrusion is configured to constrain a radial orientation of the nose tube relative to the surgical handpiece assembly. The high speed surgical burr assembly also includes a drive shaft disposed at least partially within the lumen of the nose tube and configured to rotate relative to the nose tube. The drive shaft has a drive portion at a proximal region of the drive shaft for engaging a rotatable drive chuck of the surgical handpiece assembly. The high speed surgical burr assembly also includes a cutting tool coupled to a distal region of the drive shaft opposite the drive portion. The cutting tool is configured to rotate with the drive shaft relative to the nose tube in response to rotation of a rotatable drive chuck of the surgical handpiece assembly.

[0006] Another exemplary configuration provides a high speed surgical burr assembly configured to cut tissue and be coupled to a surgical handpiece assembly. The high speed surgical burr assembly includes a nose tube defining a lumen extending between a proximal end and a distal end of the nose tube. The nose tube has a proximal portion configured to be coupled to a surgical handpiece assembly. The proximal portion of the nose tube includes a protrusion configured to constrain a radial orientation of the nose tube relative to the surgical handpiece assembly. The high speed surgical burr assembly also includes a drive shaft disposed at least partially within the lumen of the nose tube and configured to rotate relative to the nose tube. The drive shaft has a proximal region extending along an axis. The proximal region of the drive shaft includes a drive portion for engaging a rotatable drive chuck of the surgical handpiece assembly in a drive direction. The drive shaft also includes an alignment portion proximal to the drive portion of the drive shaft. The alignment portion has an outer surface that tapers toward the axis as the alignment portion extends from the drive portion to a proximal end of the drive shaft. The alignment portion is configured to engage the rotatable drive chuck to align the drive portion of the drive shaft in a drive direction for engagement with the rotatable drive chuck. The alignment portion defines a notch extending distally from a proximal end of the drive shaft to mitigate contact between the alignment portion of the drive shaft and the rotatable drive chuck during engagement of the alignment portion with the rotatable drive chuck. The high speed surgical burr assembly also includes a cutting tool coupled to a distal region of the drive shaft opposite the proximal region of the drive shaft. The cutting tool is configured to rotate with the drive shaft relative to the nose tube in response to rotation of the rotatable drive chuck of the surgical handpiece assembly.

[0007] Yet another exemplary configuration provides a high speed surgical burr assembly for connecting to a surgical handpiece assembly. The high speed surgical burr assembly includes a drive shaft having a proximal end and a distal end. The high speed surgical burr assembly also includes a nose tube having a first region defining a lumen for at least partially receiving the drive shaft between the proximal end and the distal end. The high speed surgical burr assembly also includes a second region extending monolithically from the first region for coupling the drive shaft to the surgical handpiece assembly at the proximal end. The second region includes an alignment feature configured to radially align the nose tube to the surgical handpiece assembly. The second region also includes a retention feature configured to axially retain the nose tube to the surgical handpiece assembly. The high speed surgical burr assembly also includes a cutting tool coupled to the drive shaft at a distal end of the drive shaft.

[0008] Another exemplary configuration provides a surgical handpiece assembly configured to be coupled to a high speed surgical burr assembly having a nose tube and a drive shaft rotatably coupled to the nose tube. The surgical handpiece assembly includes a hub having a bore defining a cavity for receiving a proximal portion of the nose tube. The surgical handpiece assembly also includes a biasing member disposed within the cavity of the hub. The biasing member is configured to engage the nose tube to constrain a depth of the nose tube within the cavity of the hub relative to the hub. The surgical handpiece assembly also includes a radial alignment member disposed within the cavity of the hub proximal to the biasing member. The radial alignment member defines a notch for receiving a protrusion of the nose tube to constrain a radial orientation of the nose tube relative to the hub. The radial alignment member has an alignment wall extending distally from the notch to engage the protrusion of the nose tube and radially position the nose tube such that the notch can receive the protrusion of the nose tube.

[0009] Advantages of the present disclosure 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, in which: [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 is a perspective view of a surgical handpiece system including a hub coupled to a nose tube assembly. [Diagram 2] 2 is a cross-sectional view of a nose tube assembly coupled to a hub taken along line 2-2 of FIG. 1. [Diagram 3] 3 is a partial cross-sectional view of the proximal end of the nose tube assembly coupled to the hub taken along line 3-3 of FIG. 1. [Figure 4] FIG. 2 is an exploded perspective view of the proximal end of the nose tube assembly, the hub, and the surgical handpiece. [Diagram 5] FIG. 2 is a perspective view of a portion of the nose tube assembly. [Figure 6] FIG. 13 is a perspective view of a portion of the nose tube assembly positioned for insertion into the collet of the hub. [Figure 7] FIG. 13 is a perspective view of a proximal portion of the drive shaft of the nose tube assembly. [Figure 8] FIG. 13 is a front view of the alignment portion of the drive shaft. [Figure 9] FIG. 2 is a perspective view of another configuration of a surgical handpiece system. [Figure 10] FIG. 10 is a perspective view of a high speed surgical burr assembly of the surgical handpiece system of FIG. [Figure 11] FIG. 11 is a cross-sectional view of the high speed surgical burr assembly of FIG. 10 taken along line 11-11 of FIG. [Figure 12] FIG. 11 is an elevational view of a proximal portion of the high speed surgical burr assembly of FIG. [Figure 13] FIG. 11 is a perspective view of a proximal region of a drive shaft of the high speed surgical burr assembly of FIG. [Figure 14]10 is a perspective view of a surgical handpiece assembly of the surgical handpiece system of FIG. 9. [Figure 15] FIG. 15 is an exploded view of the surgical handpiece assembly of FIG. 14. [Figure 16] 16 is a cross-sectional view of the surgical handpiece assembly of FIG. 14 taken along line 16-16 of FIG. 14. [Figure 17] FIG. 10 is a partial cross-sectional view of the surgical handpiece system of FIG. [Figure 18] 15 is a perspective view of a radial alignment member of the surgical handpiece assembly of FIG. 14. [Figure 19] 15 is a plan view of a radial alignment member of the surgical handpiece assembly of FIG. 14. [Figure 20] FIG. 15 is a detailed cross-sectional view of the surgical handpiece assembly of FIG. 14 before the high speed surgical burr assembly is inserted into a cavity in the hub of the surgical handpiece assembly. [Figure 21] FIG. 15 is a detailed cross-sectional view of the surgical handpiece assembly of FIG. 14 with the high speed surgical burr assembly partially inserted into a cavity in the hub of the surgical handpiece assembly. [Figure 22] FIG. 15 is a detailed cross-sectional view of the surgical handpiece assembly of FIG. 14 with the high speed surgical burr assembly fully inserted into a cavity in the hub of the surgical handpiece assembly. [Diagram 23] FIG. 15 is a perspective view of a rotatable drive chuck of the surgical handpiece assembly of FIG. 14. [Figure 24] 24 is a perspective cross-sectional view of the rotatable drive chuck of FIG. 23 taken along line 24-24 of FIG. 24. [Diagram 25] FIG. 24 is a top view of the rotatable drive chuck of FIG. 23. [Figure 26] FIG. 13 is a plan view of another configuration of the rotatable drive chuck. [Figure 27] FIG. 13 is a perspective view of another configuration of a drive shaft of a high speed surgical burr assembly. [Figure 28] FIG. 28 is an elevational view of a drive shaft of the high speed surgical burr assembly of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] FIG. 1 illustrates a perspective view of a surgical handpiece system 10. The surgical handpiece system 10 includes a motor 12, a hub 14, and a nose tube assembly 16. The motor 12 is connected to the hub 14, and the nose tube assembly 16 is connected to the motor 12 via the hub 14. The nose tube assembly 16 includes a nose tube 17, a drive shaft 24 (see FIG. 2), and a cutting tool 18 coupled to the drive shaft 24. The motor 12 is configured to provide torque to the nose tube assembly 16 via the hub 14. Specifically, the motor 12 transmits torque via the hub 14 to the drive shaft 24 of the nose tube assembly 16, which rotates the cutting tool 18 of the nose tube assembly 16 disposed at a distal end 21 of the nose tube assembly 16. The motor 12 is configured to transmit torque to the cutting tool 18 via the hub 14 and the nose tube assembly 16. In some configurations, the motor 12 is configured to rotate the cutting tool 18 at speeds in excess of 50,000 revolutions per minute. The high speed torque transfer from the motor 12 to the cutting tool 18 enables the nose tube assembly 16 to precisely and efficiently abrade the nasal passages, for example. The nose tube assembly 16 can also be adapted for spinal, neuro, and endoscopic applications.

[0012] The hub 14 may include a variety of different configurations. The hub 14 may be straight or curved depending on the application. For example, in a curved configuration, the hub 14 may define a seamless curve of 20 degrees away from the horizontal axis 20 of the hub 14, or the hub 14 may define a straight length along the horizontal axis 20. Additionally, the nose tube assembly 16 may also be curved or straight depending on the application of the nose tube assembly 16. More specifically, the nose tube 17 may be curved or straight. For example, the nose tube assembly 16 may include a bend at the proximal end 22 or may include a bend at the distal end 21 of the nose tube assembly 16. A transnasal application of the nose tube assembly 16 may use a bend at the distal end 21, and a spinal application of the nose tube assembly 16 may use a bend at the proximal end 22 of the nose tube assembly 16. A bushing (not shown) aligns drive shaft 24 within lumen 26 (see FIG. 2) of nose tube 17 such that drive shaft 24 does not contact the inside surface of nose tube 17. This allows drive shaft 24 to rotate independently of nose tube 17 when motor 12 transmits torque through drive shaft 24.

[0013] Shown in FIG. 1 is a curved hub 14. The curved hub 14 differs from a straight hub based on the desired surgical application of the surgical handpiece system 10. As noted above, the degree to which the hub 14 and / or nose tube assembly 16 can be bent can be influenced by the surgical application. It is contemplated that the hub 14 and / or nose tube assembly 16 can be straight and not utilize any bends. Specifically, the curved hub 14 can include a number of ball bearings (not shown) or other torque transmission mechanisms used to support rotatable components that enable the curved hub 14 to transmit torque to the nose tube assembly 16. The bearings provide alignment for a shaft (not shown) interconnected by a gear set (not shown) that transmits torque from the motor 12 through the hub 14 to the nose tube assembly 16.

[0014] As described above, the hub 14 is attached to the motor 12. The hub 14 may include features to aid in aligning and locking the hub 14 to the motor 12 of the surgical handpiece system 10. For example, the hub 14 may include a visual indicator, such as a dot (not shown) that corresponds to another dot (not shown) on the motor 12 such that alignment between the dots allows the hub 14 to be coupled to the motor 12. Additionally, the hub 14 may include an anti-rotation pin (not shown) at the proximal end 22 of the hub 14 to allow for a specific orientation between the hub 14 and the motor 12. An external c-clip (not shown) and an O-ring (not shown) may further aid in establishing a secure connection between the hub 14 and the motor 12 so that the motor 12 transmits torque through the hub 14 to the nose tube assembly 16. The hub 14 may also include a knurled portion (not shown). The knurled portion corresponds to a location on the hub 14 where an operator can place their fingers to hold the surgical handpiece system 10.

[0015] FIG 2 illustrates a cross-sectional view of the surgical handpiece system 10 taken along line 2-2 of FIG 1. Specifically, FIG 2 illustrates a cross-section of the nose tube assembly 16 and the hub 14. The motor 12 is not shown in FIG 2. The nose tube assembly 16 is shown having a drive shaft 24 that extends through a lumen 26 defined in the nose tube 17. The drive shaft 24 extends within the hub 14, which is configured to transfer torque from the motor 12 to the drive shaft 24. The drive shaft 24 is shown extending between and beyond the proximal and distal ends 22, 21 of the nose tube assembly 16.

[0016] As shown in FIGS. 2 and 3 , the drive shaft 24 is at least partially disposed within the lumen 26. The drive shaft 24 also includes an alignment portion 28. The alignment portion 28 is configured to align a drive portion 30 of the drive shaft 24 for engagement with a rotatable drive chuck 34 disposed within the hub 14. The rotatable drive chuck 34 is disposed in alignment with the drive shaft 24 and the hub 14 of the nose tube assembly 16 to transmit torque from the motor 12 through the drive shaft 24. As described in more detail below, the alignment portion 28 of the drive shaft 24 is disposed at the proximal end 22 of the nose tube assembly 16. To align the drive shaft 24 with the hub 14, the rotatable drive chuck 34 engages a leading edge 36 of the alignment portion 28 of the drive shaft 24 when the nose tube assembly 16 is forced toward the hub 14. Specifically, alignment portion 28 defines one or more leading edges 36 to engage one or more angled surfaces 38 of rotatable drive chuck 34 to align drive portion 30 of drive shaft 24 within rotatable drive chuck 34. As described in further detail below, the configuration of angled surfaces 38 of rotatable drive chuck 34 and leading edge 36 of alignment portion 28 enable drive shaft 24 to self-align. In other words, as nose tube assembly 16 is forced toward hub 14, leading edge 36 of alignment portion 28 engages angled surfaces of rotatable drive chuck 30 to rotate drive shaft 24. This engagement and continued force of nose tube assembly 16 against hub 14 rotates drive shaft 24 in a direction that causes drive portion 30 to engage rotatable drive chuck 34 to enable torque transfer between drive shaft 24 and rotatable drive chuck 34. Regardless of the initial radial orientation of alignment portion 28, the configuration of ramped surface 38 of rotatable drive chuck 34 and leading edge 36 of alignment portion 28 ensures that drive portion 30 of drive shaft 24 is oriented to engage with rotatable drive chuck 34 when nose tube assembly 16 is pressed toward hub 14.The self-aligning feature is beneficial in certain embodiments because drive shaft 24 is invisible when nose tube assembly 16 is coupled to hub 14 and because drive shaft 24 cannot move axially within nose tube assembly 16. Thus, a user grasps the exterior surface of nose tube 17 and presses it toward hub 14. With only axial movement, engagement between alignment portion 28 of drive shaft 24 and rotatable drive chuck 34 results in rotation of drive shaft 24 without the user having to rotate cutting tool 18 of nose tube assembly 16 to obtain proper orientation of drive portion 30 into rotatable drive chuck 34.

[0017] Proper alignment between the hub 14 and the drive shaft 24 may be indicated by tactile feedback. More specifically, when the leading edge 36 of the alignment portion 28 engages the ramp 38 of the rotatable drive chuck 34, tactile feedback, such as, for example, a vibration from contact between the leading edge 36 and the ramp 38, may be felt through the surgical handpiece system 10. The tactile feedback may indicate proper alignment between the nose tube assembly 16, the hub 14, and the motor 12.

[0018] As shown in FIG. 3, when aligned in the proper orientation, the drive portion 30 of the drive shaft 24 mates with a flat surface 40 in the drive chamber 42 of the rotatable drive chuck 34. This allows torque to be transferred from the motor 12 through the hub 14 to the drive shaft 24. In other words, when the drive portion 30 is aligned with the flat surface 40 in the drive chamber 42 of the rotatable drive chuck 34, the motor 12 transfers torque through the hub 14 and the rotatable drive chuck 34 rotates independently of the hub 14. The bearings 44 disposed within the hub 14 help align the drive shaft 24 and the rotatable drive chuck 34 along the horizontal axis 20 of the surgical handpiece system 10. Thus, the bearings 44 enable efficient torque transfer along the horizontal axis 20 by aligning the rotatable drive chuck 34 and the drive shaft 24 within the hub 14, as well as the nose tube assembly 16, respectively.

[0019] FIG. 3 illustrates a partial cross-sectional view of the drive shaft 24 disposed within the hub 14 taken along line 3-3 shown in FIG. 1. Specifically, FIG. 3 illustrates the drive portion 30 of the drive shaft 24 aligned within a drive chamber 42 of a rotatable drive chuck 34. A bearing 44 is shown engaging the drive shaft 24 and the rotatable drive chuck 34 to align the drive shaft 24 and the rotatable drive chuck 34 along the horizontal axis 20 and allow the drive shaft 24 and the rotatable drive chuck 34 to rotate independently of the hub 14. The independent rotation of the drive shaft 24 and the rotatable drive chuck 34 relative to the hub 14 allows the motor 12 to transmit torque through the hub 14 to a cutting tool 18, such as a bur.

[0020] 3, the nose tube 17 of the nose tube assembly 16 defines a recess 48 disposed at the proximal end 22 of the nose tube 17 and adjacent the bearing 44 when the nose tube assembly 16 is coupled to the hub 14. Specifically, the nose tube 17 has an outer surface 56 that defines a recess 48 for receiving a biasing member 46, such as a C-clip, to constrain the depth of the nose tube assembly 16 relative to the surgical handpiece system 10. The biasing member 46 is held axially in place using the hub 14. When the nose tube assembly 16 is inserted into the hub 14, the biasing member 46 expands as the nose tube assembly 16 is inserted such that the biasing member 46 seats within the recess 48 when the nose tube assembly 16 is fully inserted into the hub 14.

[0021] The biasing member 46 is disposed within the recess 48 to hold the nose tube assembly 16 in position along the horizontal axis 20 during use of the surgical handpiece system 10. Thus, the recess 48 may also be referred to as a retaining feature 48, and the biasing member 46 is disposed within the retaining feature 48 to maintain axial alignment of the nose tube assembly 16 and the drive shaft 24 relative to the hub 14 during use of the surgical handpiece system 10. In other words, as the nose tube assembly 16 is pressed into the hub 14, the biasing member 46 opens and grips the recess 48. Because the biasing member 46 functions to retain the depth of the nose tube assembly 16 relative to the hub 14 by engaging the retaining feature, the biasing member 46 may also be referred to as a retaining element. The biasing member 46 prevents axial movement of the nose tube assembly 16 relative to the hub 14. More specifically, the biasing member 46 prevents the nose tube assembly 16 from inadvertently separating from the hub 14 when the biasing member 46 engages the recess 48. The engagement between the biasing member 46 and the recess 48 can be overcome in response to a user applying sufficient force (e.g., by pulling) to expand the biasing member 46 from the recess 48 and separate the nose tube assembly 16 from the hub 14.

[0022] As mentioned above, the biasing member 46 helps restrain the nose tube assembly 16 along the horizontal axis 20 relative to the hub 14. As shown in FIG. 3, the recess 48 may define a chamfered edge 50 that may be disposed adjacent a protrusion 52 of the nose tube 17 that extends radially away from the lumen 26 of the nose tube 17 such that the biasing member 46 is adjacent the protrusion 52. The chamfered edge 50 of the recess 48 may reduce the force required by a user to remove the nose tube assembly 16 from the hub 14.

[0023] As shown in FIG. 3, the drive shaft 24 includes a retaining portion 27 disposed distally of the alignment portion 28 and a drive portion 30 of the drive shaft 24. The retaining portion 27 of the drive shaft 24 can be disposed within a lumen 26 of the nose tube 17. Specifically, the retaining portion 27 extends partially into the nose tube assembly 16 and is configured adjacent a shelf 33 on an inner surface of the nose tube 17 that defines the lumen 26 to restrain the drive shaft 24 relative to the nose tube 17. In some configurations, such as shown in FIG. 3, a bearing can be interposed between the shelf 33 and the retaining portion 27 of the drive shaft 24. The retaining portion 27 defines a diameter 29 that is greater than a diameter 31 of the lumen 26 to enable the retaining portion 27 to restrain the drive shaft 24 relative to the nose tube assembly 16. This configuration prevents the drive shaft 24 from being axially removed distally from the nose tube 17. In one configuration, the relative diameter of the cutting tool 18 to the lumen 26 and / or distal bushing 35 (see FIG. 2 ) coupled to the distal end 21 of the nose tube 17 prevents the drive shaft 24 from being axially removed from the nose tube 17 in the proximal direction.

[0024] 4-6, partial perspective views of the nose tube assembly 16 and the rotatable drive chuck 34 are shown. FIG. 4 shows a partial perspective exploded view of the nose tube assembly 16 and the hub 14 of the surgical handpiece system 10. FIG. 4 is shown as exploded along a horizontal axis 20, with the nose tube assembly 16 and the hub 14 spaced apart along the horizontal axis 20. Specifically, FIG. 4 shows an exploded perspective view of the nose tube assembly 16 having a projection 52 extending radially from a surface 56. FIG. 5 shows a partial perspective view of the nose tube assembly 16 removed from the hub 14. FIG. 6 shows a partial perspective view of the nose tube assembly 16 defining the recesses 48 and projections 52 on the surface 56 and the rotatable drive chuck 34.

[0025] With reference to FIG. 4 , the hub 14 has a proximal end 62 and a distal end 60 opposite the proximal end 62. The hub 14 has an inner surface defining a bore 58 extending from the distal end 60 to the proximal end 62. The inner surface also defines a channel 54 in communication with the bore 58 extending from the distal end 60 toward the proximal end 62. The protrusion 52 of the nose tube 17 is adapted to radially align the nose tube 17 during insertion of the nose tube assembly 16 into the bore 58 of the hub 14. In this manner, the protrusion 52 functions as a radial alignment feature 52 of the nose tube 17. Stated another way, the protrusion 52 functions as a keyed alignment feature 52, where the protrusion 52 fits into a channel 54 defined in the hub 14. The channel 54 is sized to accommodate the protrusion 52 such that radial movement of the nose tube 17 is reduced when the channel 54 receives the protrusion 52. Mitigate this radial movement to allow for precise coupling of the nose tube assembly 16 to the hub 14. In this manner, the protrusions 52 slide within the channels 54 to radially align the nose tube 17 with respect to the hub 14. There may be two channels 54 and two protrusions 52, the channels 54 and protrusions 52 being diametrically spaced apart from one another across the longitudinal axis. In another configuration, there may be two channels 54 and one protrusion 52, such that the hub 14 allows the nose tube assembly 16 to be coupled to the hub 14 in two different orientations. Such a configuration may be advantageous when the hub 14 and / or the nose tube assembly 16 utilizes bends as described above.

[0026] As noted, protrusions 52 extend radially from nose tube 17. Specifically, protrusions 52 extend perpendicularly from surface 56 of nose tube 17. By extending from surface 56 of nose tube 17, protrusions 52 are able to engage channels 54 defined in hub 14 such that radial movement of protrusions 52 within channels 54 is prevented from, for example, rotating nose tube 17 relative to hub 14. Engagement of protrusions 52 within channels 54 also serves to roughly align drive portion 30 of drive shaft 24 within drive chamber 42 of rotatable drive chuck 34. In this manner, protrusions 52 provide efficient and precise alignment.

[0027] The projection 52 extends from the surface 56 of the nose tube 17 to a peak 66. The peak 66 defines a height of the projection 52. The height of the projection 52 can be based on the dimensions of the hub 14. The peak 66 of the projection 52 can be formed from at least one first angled surface 72. As will be described in more detail, the projection 52 can also be formed from two first and second angled surfaces 72, 74. The peak 66 can extend from the first angled surface 72 to the second angled surface 74.

[0028] The first sloping surface 72 can extend from the chamfered edge 50 of the recess 48 to the peak 66 of the projection 52. The second sloping surface 74 can be disposed along the alignment portion 28 of the drive shaft 24 and can extend to the peak 66 of the projection 52. The first and second sloping surfaces 72, 74 can also define opposite slopes such that the first and second sloping surfaces 72, 74 peak at the peak 66 of the projection 52. The angles forming the slopes of the first and second sloping surfaces 72, 74 can vary or be equal based on the optimum extension and movement of the projection 52 as it slides within the channel 54. Stated another way, the peak 66 can extend between the first and second sloping surfaces 72, 74 to interconnect the first and second surfaces 72, 74 that define the height of the projection 52. The first and second angled surfaces 72, 74 also aid in allowing the projection 52 to slide into the channel 54 of the hub 14. The first and second angled surfaces 72, 74 facilitate assembly by reducing frictional forces as the projection 52 slides through the channel 54. Additionally, the peak 66 may define a radius between the first and second angled surfaces 72, 74. For example, the peak 66 may be rounded between the first angled surface 72 and the second angled surface 74. The radius of the peak 66 may be determined based on optimal sliding parameters of the projection 52 within the channel 54. Thus, the radius of the peak 66 may be formed to fit within the channel 54 defined in the hub 14. Other shapes of the projection 52 are also contemplated.

[0029] As previously mentioned, the projection 52 is disposed adjacent the recess 48. Specifically, in certain configurations, the first angled surface 72 is formed near the chamfered edge 50 of the recess 48. Both the retention (shown as recess) and radial alignment features (shown as projections) 48, 52 of the nose tube assembly 16 can be disposed adjacent to one another. The projection 52 is disposed adjacent the recess 48 so that when the nose tube assembly 16 is coupled to the hub 14, the biasing member 46 is adjacent to the projection 52 on the nose tube 17. To maintain alignment during insertion, the projection 52 defines a height of the peak 66 relative to the horizontal axis 20, and the recess 48 defines a distance to the horizontal axis 20 that is less than the height of the peak 66. The height of the peak 66 is greater than the distance from the biasing member 46 to the horizontal axis 20 so that the projection 52 can properly engage and slide into the channel 54 formed in the hub 14.

[0030] In another configuration, if recess 48 defines a distance from horizontal axis 20 greater than the height of peak 66, peak 66 will not engage channel 54 and rotational misalignment between nose tube 17 and hub 14 may be introduced during use of surgical handpiece system 10. Thus, by having a distance from recess 48 to horizontal axis 20 less than the height of peak 66, protrusion 52 may maintain rotational alignment between nose tube 17 and hub 14 during use of surgical handpiece system 10 while allowing retention feature 48 to maintain axial alignment of hub 14 with nose tube assembly 16 and, therefore, drive shaft 24.

[0031] It may be useful to understand the nose tube 17 in terms of a first region 84 and a second region 86 (see FIGS. 2 and 3). The first region 84 may represent the majority of the length of the nose tube 17, while the second region 86 may be the portion of the nose tube 17 that interacts with the hub 14. In certain configurations, the first region 84 and the second region 86 may both be formed from a metallic material, such as stainless steel. The second region 86 may extend monolithically from the first region 84 from a single piece of metal stock. In other words, the nose tube 17, including both the first region 84 and the second region 86, may be formed from a single piece of metal stock. The second region 86 may include a radial alignment feature 52 and an axial retention feature 48 for axially retaining the nose tube assembly 16 in the surgical handpiece system 10. The alignment and retention features 52, 48 may be formed from the metal material that forms the first and second regions 84, 86, and thus the alignment feature 52 and the retention feature 48 may be machined from the same piece of metal stock used to machine the first region 84 of the nose tube 17.

[0032] 7 and 8, the proximal portion of the drive shaft 24 is shown. FIG. 7 shows a perspective view of the alignment portion 28, including the leading edge 36, the retention portion 27, and the drive portion 30. FIG. 8 shows a front view of the proximal portion of the drive shaft 24. Specifically, FIG. 8 shows a front view of the alignment portion 28 of the drive shaft 24.

[0033] In one exemplary configuration of the assembly, a user grasps the nose tube 17 of the nose tube assembly 16. The user partially inserts the nose tube assembly 16 into the bore 58 of the hub 14. The user then aligns the protrusion 52 of the nose tube 17 with the channel 54 of the hub 14 and continues to press the nose tube assembly 16 towards the hub 14. The engagement between the protrusion 52 and the channel 54 radially aligns the nose tube 17 to the hub 14. When the proximal end of the nose tube 17 is adjacent the biasing member 46, the biasing member 46 expands to accommodate the nose tube 17. As the nose tube assembly 16 continues to be pressed towards the hub 14, the biasing member 46 is received by the recess 48 of the nose tube 17. As the recess 48 receives the biasing member 46, the nose tube 17 and the remainder of the nose tube assembly 16 are axially held relative to the hub 14.

[0034] Before the recess 48 receives the biasing member 46, the leading edge 36 of the alignment portion 28 of the drive shaft 24 abuts the inclined surface 38 of the rotatable drive chuck 34 to cam the drive portion 30 of the drive shaft 24 toward engagement of the drive shaft 24, and thus the drive portion 30 of the drive shaft 24, with the rotatable drive chuck 34. When the recess 48 receives the biasing member 46, the drive shaft 24 is cammed in an orientation in which the drive portion 30 is received in the drive chamber 42 of the rotatable drive chuck 34 and the drive portion 30 is abutting the flat surface 40 of the rotatable drive chuck 34 to receive torque from and rotate therewith. Depending on the initial radial orientation of the drive shaft 24 when the nose tube assembly 16 is initially introduced into the hub 14 (i.e., prior to camming), the leading edge 36 of the alignment portion 28 may initially contact the inclined surface 38 of the rotatable drive chuck 34 at different axial positions of the nose tube 17 relative to the hub 14. If the initial radial direction of drive shaft 24 is already in the orientation required for drive portion 30 of drive shaft 24 to be received in drive chamber 42 and engage with rotatable drive chuck 34, leading edge 36 of alignment portion 28 will not contact inclined surface 38 of rotatable drive chuck 34.

[0035] The axial position of drive shaft 24 relative to rotatable drive chuck 34 is maintained by the axial retention of nose tube 17 to hub 14 via biasing member 46 and recess 48. In other words, because drive shaft 24 is axially retained relative to nose tube 17, the axial position of drive shaft 24 relative to hub 14 and rotatable drive chuck 34 is tied to the axial position of nose tube 17 relative to hub 14 and rotatable drive chuck 34. Nose tube 17 is retained by biasing member 46 until a user pulls nose tube assembly 16 against hub 14 with sufficient force to overcome biasing member 46 by expanding biasing member 46.

[0036] As previously mentioned, the alignment portion 28 of the drive shaft 24 defines a leading edge 36 that assists in aligning the drive portion 30 of the drive shaft 24 within the drive chamber 42 of the rotatable drive chuck 34. When the nose tube assembly 16 is inserted into the bore 58 of the hub 14, the leading edge 36 engages an angled surface 38 of the drive chamber 42 in the rotatable drive chuck 34 to align the drive portion 30 of the drive shaft 24 within the drive chamber 42 of the rotatable drive chuck 34. The leading edge 36 engages the angled surface 38 to convert an insertion force into a rotational force and provide alignment between the drive portion 30 of the drive shaft 24 and the rotatable drive chuck 34. Although described as a single leading edge 36, the alignment portion 28 of the drive shaft 24 may include one or more leading edges 36.

[0037] FIG. 6 illustrates a leading edge 36 defined between at least two curved surfaces 80 defined on the alignment portion 28 of the drive shaft 24. The curved surfaces 80 interconnect to define the leading edge 36. The leading edge may be asymmetric across the horizontal axis 20. The curved surfaces 80 connect to form a tip 82 of the alignment portion 28. As shown in FIGS. 7 and 8, the tip 82 resembles a parallelogram. As previously discussed, the rotatable drive chuck 34 rotates independently of the hub 14. Upon insertion of the projection 52 into the channel 54, the alignment portion 28 engages the angled surface 38 of the rotatable drive chuck 34 to align the drive portion 30 within the drive chamber 42. Specifically, the leading edge 36 contacts the angled surface 38 to cause a cam rotation of the drive shaft 24 and ensure proper alignment of the drive portion 30 within the drive chamber 42. Thus, leading edge 36 further aids in aligning drive portion 30 of drive shaft 24 with flat surface 40 within drive chamber 42 to accurately transfer torque from motor 12 to cutting tool 18 disposed at distal end 21 of nose tube assembly 16.

[0038] 9-25, there is shown another configuration of surgical handpiece system 100. It should be understood that the configuration of surgical handpiece system 10 described above may include similar elements as surgical handpiece system 100 described below, and vice versa.

[0039] As shown in Figure 9, surgical handpiece system 100 includes a high speed surgical burr assembly 102 (Figure 10) and a surgical handpiece assembly 104 (Figure 14). Similar to the configuration of surgical handpiece system 10 shown in Figures 1-8, surgical handpiece system 100 may also include a motor (not shown) configured to be coupled to surgical handpiece assembly 104 to provide torque to surgical handpiece system 100.

[0040] With reference to FIG. 11, a cross-section of one configuration of a high speed surgical burr assembly 102 is shown. The high speed surgical burr assembly 102 includes a nose tube 106. The nose tube 106 defines a lumen extending between a proximal end and a distal end of the nose tube 106. At least a proximal portion 108 of the nose tube 106 extends along an axis AX. Rather than extending axially along the entire length of the nose tube 106, the nose tube 106 may include a bend, such as the distal bend of the nose tube 106 shown in FIG. 11. The bend can assist a user in positioning the distal end of the nose tube 106 in a particular advantageous position during surgery.

[0041] The high speed surgical burr assembly 102 further includes a drive shaft 110 disposed at least partially within a lumen of the nose tube 106. The drive shaft 110 is configured to rotate relative to the nose tube 106. A proximal region 112 of the drive shaft 110 is configured to engage with the surgical handpiece assembly 104, as described in further detail below. The high speed surgical burr assembly 102 further includes a cutting tool 114 coupled to a distal region of the drive shaft 110. The cutting tool 114 is configured to rotate with the drive shaft 110 relative to the nose tube 106. In one configuration, the cutting tool 114 is a bur. In other configurations, the cutting tool 114 includes another rotating tool configured to abrade tissue.

[0042] The high speed surgical burr assembly 102 may include bushings 116, 118, 120 to facilitate relative rotation between the drive shaft 110 and the nose tube 106. The proximal bushing 116 may be coupled to the nose tube 106 and disposed at least partially within the lumen of the nose tube 106 and about the drive shaft 110. The distal bushing 118 may be coupled to the nose tube 106 and disposed at least partially within the lumen of the nose tube 106 and about the drive shaft 110. The central bushing 120 may be disposed within the lumen between the proximal bushings 116, 120 and the distal bushings 116, 120 to prevent contact between the drive shaft 110 and the nose tube 106 within the lumen of the nose tube 106. In one configuration, the central bushing 120 is fixed to the nose tube 106. In another configuration, the proximal and distal bushings 116, 118 retain the central bushing 120 within the lumen of the nose tube 106. In other configurations, the central bushing 120 is retained within the lumen of the nose tube 106 by a bend in the nose tube 106 and a corresponding bend in the central bushing 120. The proximal and distal bushings 116, 118 may also function as retention features to couple the drive shaft 110 to the nose tube 106. In one configuration, the proximal region 112 of the drive shaft 110 includes a retention portion 122 proximal to the proximal bushing 116. The retention portion 122 of the proximal region 112 of the drive shaft 110 has an outer diameter larger than the inner diameter of the proximal bushing 116 to prevent movement of the drive shaft 110 in a distal direction relative to the nose tube 106. The cutting tool 114 can have an outer diameter larger than the inner diameter of the distal bushing 118 to prevent movement of the drive shaft 110 in a proximal direction relative to the nose tube 106. In other configurations, the drive shaft 110 is otherwise coupled to the nose tube 106 to allow relative rotation between the drive shaft 110 and the nose tube 106 and prevent axial movement between the drive shaft 110 and the nose tube 106.

[0043] 12, the proximal portion 108 of the nose tube 106 has an outer surface. The outer surface can define a recess 124 for engaging the surgical handpiece assembly 104 to constrain the depth of the nose tube 106 relative to the surgical handpiece assembly 104. The outer surface of the proximal portion 108 of the nose tube 106 can have a proximal shoulder 126 that defines a proximal end of the recess 124 and a distal shoulder 128 that defines a distal end of the recess 124. Either or both of the proximal and distal shoulders 126, 128 can be tapered. The nose tube 106 can include a protrusion 130 disposed proximally of the recess 124. The protrusion 130 is configured to constrain the radial orientation of the nose tube 106 relative to the surgical handpiece assembly 104. The protrusion 130 can extend proximally and generally parallel to the axis AX. The proximal end of the projection 130 may include a rounded surface 132. The projection 130 of the proximal portion 108 of the nose tube 106 may include a flat surface 344 that is parallel to the axis AX of the proximal portion 108 of the nose tube 106. The rounded flat surfaces 132, 134 of the projection 130 may aid in the engagement between the nose tube 106 and the surgical handpiece assembly 104. The engagement between the nose tube 106 and the surgical handpiece assembly 104 is described in further detail below. In the configuration shown in FIG. 12, the nose tube 106 includes two projections 130 to constrain the radial orientation of the nose tube 106 relative to the surgical handpiece assembly 104. It is contemplated that a single projection 130 may instead be used to constrain the radial orientation of the nose tube 106 relative to the surgical handpiece assembly 104. It is also contemplated that more than two protrusions 130 may be used to constrain the radial orientation of the nose tube 106 relative to the surgical handpiece assembly 104 .

[0044] 13, proximal region 112 of drive shaft 110 is rotatable about axis AX at proximal portion 108 of nose tube 106. Proximal region 112 of drive shaft 110 includes a drive portion 136 proximal to retaining portion 122 for engaging surgical handpiece assembly 104 in a driving direction. Drive portion 136 may include two or more drive faces 138 for engaging surgical handpiece assembly 104. Drive faces 138 may be flat and parallel to axis AX.

[0045] The proximal region 112 of the drive shaft 110 may also include an alignment portion 140 proximal to the drive portion 136 of the drive shaft 110. The alignment portion 140 has an outer surface that tapers toward the axis AX as the alignment portion 140 extends from the drive portion 136 of the drive shaft 110 to the proximal end. The alignment portion 140 is configured to engage with the surgical handpiece assembly 104 to align the drive portion 136 in the drive direction. In the configuration shown in FIG. 13, the alignment portion 140 includes a proximal edge 142 adjacent the proximal end of the proximal region 112 of the drive shaft 110 for engaging with the surgical handpiece assembly 104. In other configurations, the alignment portion 140 may include a flat or rounded surface in place of the proximal edge 142. The alignment portion 140 may define a notch 144 extending distally from the proximal end of the drive shaft 110 to reduce contact between the alignment portion 140 of the drive shaft 110 and the surgical handpiece assembly 104 during engagement. Reducing the amount of contact during engagement may reduce potential jamming during engagement due to multiple contact points. In other configurations, the alignment portion 140 may not define a notch 144.

[0046] 13, the proximal region 112 of the drive shaft 110 is disposed outside the lumen of the nose tube 106 and proximal to the proximal portion 108 of the nose tube 106. In other configurations, the proximal region 112 of the drive shaft 110 may be disposed at least partially within the lumen of the nose tube 106 or distal to the proximal portion 108 of the nose tube 106. The engagement between the proximal region 112 of the drive shaft 110 and the surgical handpiece assembly 104 is described in further detail below.

[0047] 27-28, alignment portion 140 of drive shaft 110 may include a proximal face 194 disposed proximally of proximal edge 142 to prevent proximal edge 142 from engaging rotatable drive chuck 172 of surgical handpiece assembly 104 after drive portion 136 is aligned in the drive direction. Proximal face 194 may include a plane perpendicular to axis AX. In other configurations, proximal face 194 may include a rounded surface.

[0048] 15 and 16, surgical handpiece assembly 104 includes a hub 146. Hub 146 has a bore 148 that defines a cavity 150 for receiving at least a portion of high speed surgical burr assembly 102. Specifically, cavity 150 is configured to receive at least a proximal portion 108 of nose tube 106 and a proximal region 112 of drive shaft 110 of high speed surgical burr assembly 102. The proximal portion of hub 146 may be configured to be coupled to a motor housing (not shown) that contains a motor, similar to motor 12 that couples to hub 14 in the configuration shown in FIG.

[0049] The surgical handpiece assembly 104 further includes a biasing member 152 disposed within the cavity 150 of the hub 146. The biasing member 152 may be a C-clip. The bore 148 of the hub 146 may define a recess 154 in communication with the cavity 150. The recess 154 defined by the bore 148 of the hub 146 is configured to receive the biasing member 152. The bore 148 of the hub 146 may have a distal shoulder 156 defining a distal end of the recess 154 of the hub 146. The distal shoulder 156 prevents the biasing member 152 from exiting distally from the recess 154 of the hub 146. When the high speed surgical burr assembly 102 is received by the cavity 150 of the hub 146 of the surgical handpiece assembly 104, the biasing member 152 is received by the recess 124 of the nose tube 106. Biasing member 152 may be configured to engage one or both of proximal and distal shoulders 126, 128 of recess 124 of nose tube 106 to constrain the depth of nose tube 106 of high speed surgical burr assembly 102 within cavity 150 of hub 146 relative to hub 146. Biasing member 152 may have tapered surfaces 158, 160 at the proximal or distal end to aid in the engagement between biasing member 152 and nose tube 106.

[0050] 18-20. The surgical handpiece assembly 104 may also include a radial alignment member 162 disposed within the cavity 150 of the hub 146 proximal to the biasing member 152. The radial alignment member 162 may be press fit into the cavity 150 of the hub 146 such that no relative movement occurs between the hub 146 and the radial alignment member 162. It is contemplated that the radial alignment member 162 and the hub 146 may be coupled to one another in other manners, so long as no relative movement is permitted between the radial alignment member 162 and the hub 146.

[0051] The radial alignment member 162 defines notches 164 for receiving the projections 130 of the nose tube 106 to constrain the radial orientation of the nose tube 106 relative to the hub 146. In the configuration shown in FIGS. 18-20, the radial alignment member 162 defines four notches 164 that are circumferentially spaced apart at equal angles from one another such that each notch 164 is 90 degrees away from an adjacent notch 164. It is contemplated that three or fewer notches 164 may be used to receive the projections 130 of the nose tube 106 to constrain the radial orientation of the nose tube 106 relative to the hub 146. It is also contemplated that five or more notches 164 may be used to receive the projections 130 of the nose tube 106 to constrain the radial orientation of the nose tube 106 relative to the hub 146. It is further contemplated that the spacing between the notches 164 may be unequal and located at any circumferentially spaced location. It will be appreciated that the number of notches 164 can determine the number of possible radial orientations of the nose tube 106 relative to the hub 146. Additionally, the spacing of the notches 164 can determine how far apart the radial orientations are. Allowing for multiple orientations can be particularly advantageous when the nose tube 106 uses bends. The bends can be oriented differently relative to the surgical handpiece assembly 104 based on the notches 164 of the radial alignment member 162 receiving the protrusions 130 of the nose tube 106.

[0052] The radial alignment member 162 can have an alignment wall 166 extending distally from the notch 164 for engaging the protrusion 130 of the nose tube 106. The alignment wall 166 can radially position the nose tube 106 during engagement to allow the notch 164 to receive the protrusion 130 of the nose tube 106 if the protrusion 130 is not already radially aligned with the notch 164 of the radial alignment member 162. Two alignment walls 166 can be used for each notch 164 of the radial alignment member 162, one on each side. Each of the two alignment walls 166 may taper inwardly toward the notch 164 such that when the nose tube 106 is axially pressed into the hub 146, contact between the alignment wall 166 of the radial alignment member 162 and the projection 130 of the nose tube 106 orients the projection 130 into the notch 164 due to relative rotation between the nose tube 106 and the hub 146. In a configuration in which the radial alignment member 162 includes multiple alignment walls 166, successive alignment walls 166 between the notches 164 may taper in opposite directions. The successive alignment walls 166 may also collectively form an edge 168 to mitigate the possibility of the projection 130 jamming the radial alignment member 162 instead of radially locating the projection 130 of the nose tube 106 into the notch 164 of the radial alignment member 162. A configuration in which the projection 130 has a rounded surface 132 further aids in mitigating jamming with the radial alignment member 162.

[0053] 18 , radial alignment member 162 may also include one or more flat surfaces 170 to further define each notch 164. Flat surfaces 170 of radial alignment member 162 may engage flat surfaces 134 of projection 130 of nose tube 106 to prevent relative rotation between nose tube 106 and hub 146 when projection 130 is received in notch 164. With relative rotation between nose tube 106 and hub 146 prevented, axial movement between nose tube 106 and hub 146 due to relative rotation is also prevented.

[0054] 20, the radial alignment member 162 aids in a distal shoulder 156 of the recess 154 of the hub 146 retaining the biasing member 152 in the recess 154 of the hub 146. As noted above, the distal shoulder 156 prevents the biasing member 152 from exiting the recess in a distal direction. With the radial alignment member 162 disposed immediately proximal to the biasing member 152, the radial alignment member 162 forms a proximal shoulder of the recess 154 to prevent the biasing member 152 from exiting the recess 154 in a proximal direction. In other configurations, the bore 148 of the hub 146 may include a proximal shoulder (not shown) to define a proximal end of the recess 154, and the radial alignment member 162 may be disposed proximal of the proximal shoulder.

[0055] In some configurations, the biasing member 152 is configured to engage the distal shoulder 156 of the hub 146 and the proximal shoulder 126 of the nose tube 106 when the nose tube 106 is inserted into the cavity 150 of the hub 146 to urge the projection 130 of the nose tube 106 into the notch 164 of the radial alignment member 162. If the projection 130 is already partially received by the notch 164, the engagement between the biasing member 152 and the shoulders 126, 156 may urge the projection 130 deeper into the notch 164 until the engagement is stopped or until the projection 130 is adjacent the proximal face of the notch 164 and fully received by the notch 164.

[0056] As shown in FIG. 16 , the surgical handpiece assembly 104 also includes a rotatable drive chuck 172. The rotatable drive chuck 172 is configured to be rotated by the motor about the hub axis HX. A proximal portion 174 of the rotatable drive chuck 172 can be directly engaged to the motor, or the rotatable drive chuck 172 can be engaged to a gear assembly or another assembly configured to be driven by the motor and to transfer torque from the motor to the rotatable drive chuck 172. The rotatable drive chuck 172 is at least partially disposed within the cavity 150 of the hub 146 proximal to the radial alignment member 162 and configured to rotate relative to the hub 146. The rotatable drive chuck 172 defines an opening 176 for receiving the proximal region 112 of the drive shaft 110.

[0057] As shown in FIGS. 23-25, rotatable drive chuck 172 includes a drive portion 178 proximal to opening 176. Drive portion 178 has at least two drive faces 180 configured to engage drive portion 136 of proximal region 112 of drive shaft 110 to rotate drive shaft 110. Drive faces 180 of drive portion 178 of rotatable drive chuck 172 engage drive faces 138 of drive portion 136 of drive shaft 110 when drive shaft 110 is in a drive direction and high speed surgical burr assembly 102 is coupled to surgical handpiece assembly 104 (see FIG. 17 ). Drive shaft 110 is in a drive direction when drive faces 138 of drive shaft 110 are parallel to drive faces 180 of drive portion 178 of rotatable drive chuck 172. In the configuration shown in FIGS. 23-25, the drive portion 178 includes eight drive faces 180 to accommodate various orientations of the drive portion 136 of the drive shaft 110. If there are more than two drive faces 180, it is believed that there are multiple drive directions. For example, in the configuration shown in FIGS. 23-25, there are four different drive directions. Stated another way, the drive shaft 110 can be rotated by the rotatable drive chuck 172 in four different radial orientations relative to the rotatable drive chuck 172. It is contemplated that the drive portion 178 can alternatively include three to seven drive faces 180 to engage the drive portion 136 of the drive shaft 110. It is contemplated that the drive portion 178 can alternatively include nine or more drive faces 180 to engage the drive portion 136 of the drive shaft 110.

[0058] The rotatable drive chuck 172 may also include an alignment portion 182 disposed between the drive portion 178 of the rotatable drive chuck 172 and the opening 176. The alignment portion 182 may have an alignment edge 184 extending distally from the drive portion 178 of the rotatable drive chuck 172 toward the opening of the rotatable drive chuck 172. As the alignment edge 184 extends distally from the drive portion 178 of the rotatable drive chuck 172, the alignment edge 184 tapers away from the hub axis HX. The alignment edge 184 of the alignment portion 182 is configured to engage the alignment portion 140 of the drive shaft 110 to rotate the drive shaft 110 in the drive direction.

[0059] The alignment portion 182 of the rotatable drive chuck 172 may have a first angled surface 186 that extends distally from the drive portion 178 of the rotatable drive chuck 172 toward the opening 176 of the rotatable drive chuck 172. As the first angled surface 186 extends distally from the drive portion 178 of the rotatable drive chuck 172, the first angled surface 186 tapers away from the hub axis HX. The alignment portion 182 of the rotatable drive chuck 172 may have a second angled surface 188 that is separate from and adjacent the first angled surface 186. The second angled surface 188 extends distally from the drive portion 178 of the rotatable drive chuck 172 toward the opening 176 of the rotatable drive chuck 172. As the second angled surface 188 extends distally from the drive portion 178 of the rotatable drive chuck 172, the second angled surface 188 tapers away from the hub axis HX. The first and second angled surfaces 186, 188 collectively define the alignment edge 184 of the rotatable drive chuck 172. In the configuration shown in FIGS. 23-25, the alignment portion 182 includes four alignment edges 184. Each alignment edge 184 is formed by a first angled surface 186 and a second angled surface 188. In other configurations, the alignment portion 182 of the rotatable drive chuck 172 includes three or fewer alignment edges 184. In still other configurations, the alignment portion 182 includes five or more alignment edges 184. In some configurations, the first and second angled surfaces 186, 188 are symmetrical about the alignment edge 184. In other configurations, the first and second angled surfaces 186 , 188 are not symmetrical about the alignment edge 184 .

[0060] In one exemplary configuration, the coupling between high speed surgical burr assembly 102 and surgical handpiece assembly 104 is described below. A user can grasp nose tube 106 of high speed surgical burr assembly 102 or another portion of high speed surgical burr assembly 102 and axially load (i.e., insert) proximal portion 108 of nose tube 106 and proximal region 112 of drive shaft 110 into cavity 150 of hub 146 of surgical handpiece assembly 104. After nose tube 106 and drive shaft 110 enter cavity 150 to a certain depth, nose tube 106 is radially and axially constrained relative to hub 146 of surgical handpiece assembly 104, and drive shaft 110 is radially and axially constrained relative to rotatable drive chuck 172 of surgical handpiece assembly 104. The constraining is described in more detail below. As noted above, drive shaft 110 is axially restrained to nose tube 106 by proximal and distal bushings 116, 118 of high speed surgical burr assembly 102. Additionally, rotatable drive chuck 172 is axially restrained within cavity 150 of hub 146 by bushing 190 (see FIG. 15 ) coupled to hub 146. Thus, when nose tube 106 is axially restrained relative to hub 146, drive shaft 110 is axially restrained relative to rotatable drive chuck 172. With regard to radially restraining nose tube 106 and drive shaft 110, drive shaft 110 is radially restrained relative to rotatable drive chuck 172 before nose tube 106 is radially restrained relative to hub 146. In other configurations, drive shaft 110 and nose tube 106 may be radially restrained simultaneously. In yet other configurations, nose tube 106 may be radially restrained before drive shaft 110. After both the drive shaft 110 and the nose tube 106 are radially constrained, the nose tube 106 is axially constrained. One exemplary configuration for constraining the nose tube 106 and drive shaft 110 is described below.

[0061] As drive shaft 110 of high speed surgical burr assembly 102 enters cavity 150 of hub 146 of surgical handpiece assembly 104, drive shaft 110 enters through aperture 176 of rotatable drive chuck 172. After entering through aperture 176 of rotatable drive chuck 172, an outer surface of alignment portion 140 of drive shaft 110 abuts one of alignment edges 184 of alignment portion 182 of rotatable drive chuck 172. As drive shaft 110 continues to be axially loaded into cavity 150 of hub 146, the engagement between alignment portion 140 of drive shaft 110 and alignment edge 184 of rotatable drive chuck 172 orients drive portion 136 of drive shaft 110 in the drive direction. In the drive direction, drive surface 138 of drive shaft 110 may engage drive surface 180 of rotatable drive chuck 172 to radially restrain drive shaft 110 to rotatable drive chuck 172. When drive surface 138 engages drive surface 180, torque may be transferred from rotatable drive chuck 172 to drive shaft 110 and ultimately to cutting tool 114.

[0062] In one configuration shown in FIG. 26 , rotatable drive chuck 172 may define a cutout 192 to provide additional clearance between rotatable drive chuck 172 and the proximal end of drive shaft 110 when high speed surgical burr assembly 102 is coupled to surgical handpiece assembly 104. The additional clearance provided by cutout 192 may mitigate the clearance that occurs upon engagement between the proximal end of drive shaft 110 and a surface of rotatable drive chuck 172 before nose tube 106 is axially restrained to hub 146. In other words, the additional clearance provided by cutout 192 ensures that continued insertion of drive shaft 110 into rotatable drive chuck 172 does not interfere with the axial coupling of nose tube 106 to hub 146.

[0063] The engagement between alignment portion 140 of drive shaft 110 and alignment portion 182 of rotatable drive chuck 172 allows rotation of drive shaft 110 in the drive direction to be accomplished only by a user axially loading high speed surgical burr assembly 102 into cavity 150 of hub 146 of surgical handpiece assembly 104. In other words, drive shaft 110 can be oriented in the drive direction without a user grasping cutting tool 114 or another portion of drive shaft 110 to manipulate drive shaft 110 in the drive direction. In some cases, drive shaft 110 will enter cavity 150 of hub 146 in the drive direction. In such cases, alignment portion 140 of drive shaft 110 should not contact alignment portion 182 of rotatable drive chuck 172 and drive shaft 110 should not engage anything until drive portion 136 of drive shaft 110 engages drive portion 178 of rotatable drive chuck 172.

[0064] As shown in Figures 20-22, the nose tube 106 is shown axially and radially constrained. The drive shaft 110 in Figures 20-22 has been removed to better illustrate the engagement between the nose tube 106 and the surgical handpiece assembly 104. With reference to Figure 20, the surgical handpiece assembly 104 is shown with the hub 146, the radial alignment member 162, and the biasing member 152. The biasing member 152 is shown in an unbiased, compressed state. As the nose tube 106 enters the cavity 150 of the hub 146 of the surgical handpiece assembly 104, the nose tube 106 engages the biasing member 152 by abutting the distal tapered surface 160 of the biasing member 152. When a sufficient axial force is applied to the nose tube 106 to overcome the spring force of the biasing member 152, the biasing member 152 expands to the biased state shown in FIG. 21 to accommodate the proximal portion 108 of the nose tube 106. Often, the projection 130 of the nose tube 106 may be misaligned and may engage the alignment wall 166 of the radial alignment member 162 such that continued axial force applied to the nose tube 106 can result in relative rotation between the nose tube 106 and the hub 146 until the projection 130 aligns with the notch 164. In other words, the nose tube 106 can be oriented such that the projection 130 of the nose tube 106 can be received by the notch 164 of the radial alignment member 162 without the user having to grasp the nose tube 106 and manipulate the nose tube 106 radially.

[0065] 22 , the biasing member 152 may be received in the recess 124 of the nose tube 106 when the nose tube 106 is at a particular depth within the cavity 150 of the hub 146, and the proximal tapered surface 158 of the biasing member 152 may abut the proximal shoulder 126 of the recess of the nose tube 106. When the proximal tapered surface 158 of the biasing member 152 is abutted against the proximal shoulder 126 of the recess 124 of the nose tube 106 and the distal end of the biasing member 152 is abutted against the distal shoulder 156 of the recess 154 of the hub 146, the spring force of the biasing member 152 may be sufficient to engage the nose tube 106 and urge the protrusion 130 of the nose tube 106 deeper into the notch 164 of the radial alignment member 162. If the biasing member 152 has not returned to its unbiased compressed state and the projection 130 of the nose tube 106 is fully received by the notch 164 of the radial alignment member 162, thereby preventing axial movement of the nose tube 106 in a proximal direction relative to the hub 146, the biasing member 152 may continue to engage the nose tube 106, axially restraining the nose tube 106 relative to the hub 146 and maintaining a tight axial fit between the hub 146, the biasing member 152, the radial alignment member 162, and the nose tube 106. The tight axial fit may eliminate gaps that may otherwise be present. Such gaps may form from wear, tolerance stack-up, etc. In other configurations, the recess 124 of the nose tube 106 receives the biasing member 152, and the biasing member 152 restrains the depth of the nose tube 106 relative to the hub 146. In such a configuration, the biasing member 152 does not remain engaged with the nose tube 106 to maintain a tight axial fit between the hub 146, the biasing member 152, the radial alignment member 162, and the nose tube 106.

[0066] In some cases, the nose tube 106 enters the cavity 150 of the hub 146 radially so that the projection 130 of the nose tube 106 can be received by the notch 164 of the radial alignment member 162 without rotating the nose tube 106. In such a case, the projection 130 of the nose tube 106 may not contact the alignment wall 166 of the radial alignment member 162 and the projection 130 of the nose tube 106 may not engage anything until the projection 130 of the nose tube 106 is received by the notch 164 of the radial alignment member 162.

[0067] Additionally, it will be understood that the terms "include," "includes," and "including" have the same meaning as the terms "comprise," "comprises," and "comprising." It will be further understood that terms such as "first," "second," "third," etc. are used herein to distinguish certain structural features and components for non-limiting, illustrative purposes of clarity and consistency.

[0068] Several configurations have been described in the foregoing description. However, the configurations described herein are not intended to be exhaustive or to limit the invention to the particular forms. The terminology used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations are possible in light of the above teachings, and the invention may be practiced otherwise than as specifically described.

[0069] The present disclosure is intended to be defined in the independent claims with particular features placed in the dependent claims, and subject matter of a dependent claim can also be implemented in conjunction with another independent claim.

[0070] The present disclosure also includes the following sections with specific features arranged in the subsections that may be specifically implemented as described in more detail with reference to the above configurations and drawings. section

[0071] I. A high speed surgical burr assembly for connection to a surgical handpiece, comprising: a nose tube defining a lumen, the lumen having a proximal portion having a longitudinal axis, the nose tube having an outer surface defining a recess for receiving a biasing member to constrain a depth of the nose tube relative to the surgical handpiece, the nose tube including at least one protrusion distal to the recess, the protrusion configured to radially align the high speed surgical burr assembly with the surgical handpiece; a drive shaft disposed at least partially within the lumen and having an alignment portion at a proximal region of the drive shaft configured to align a drive portion of the drive shaft for engagement with a rotatable drive chuck, the drive shaft having a retaining portion distal to the alignment portion and the drive portion, the retaining portion having a diameter greater than a diameter of the lumen such that the drive shaft is retained within the lumen of the nose tube; and a cutting tool coupled to a distal region of the drive shaft opposite the alignment portion. II. The high speed surgical burr assembly of clause I, wherein the projection extends radially relative to a longitudinal axis of the proximal portion of the lumen to a peak, and a distance between an outer surface of the nose tube defining the recess and the longitudinal axis is less than a distance between a surface of the peak and the longitudinal axis. III. The high speed surgical burr assembly of any of paragraphs I-II, wherein at least one protrusion includes an inclined surface, the peak of the protrusion enabling the high speed surgical burr assembly to be radially aligned with the surgical handpiece. IV. The high speed surgical burr assembly of any of clauses I-III, wherein the peak defines a distal radius of the beveled surface. V. The high speed surgical burr assembly of any of clauses I-IV, wherein the alignment portion of the drive shaft defines a leading edge that aligns with the rotatable drive chuck in a direction to engage the drive portion of the drive shaft with the rotatable drive chuck. VI. The high speed surgical burr assembly of claim V, wherein the leading edge is defined between at least two curved surfaces to enable the drive portion to be cammed into engagement with the rotatable drive chuck. VII. The high speed surgical burr assembly of clause VI, wherein at least two of the curved surfaces are asymmetric across the longitudinal axis. VIII. A high speed surgical handpiece assembly comprising: a hub having a proximal end and a distal end opposite the proximal end, the hub having an inner surface defining a bore extending from the distal end to the proximal end, the inner surface defining an alignment channel in communication with the bore extending from the distal end toward the proximal end; a retaining element disposed within the proximal bore of the alignment channel; a rotatable drive chuck disposed within the proximal bore of the retaining element, the rotatable drive chuck having a drive chamber; a nose tube defining a lumen extending between a proximal end and a distal end, the nose tube having an outer surface defining a recess surrounding the nose tube and constraining a depth of the nose tube relative to the hub when the recess is engaged by the retention element, the nose tube including at least one protrusion, the protrusion configured to be received by the alignment channel to align the nose tube to the hub; a drive shaft having an alignment portion disposed at least partially within the lumen of the nose tube and configured to align the drive portion of the drive shaft for engagement with a drive chamber of a rotatable drive chuck; a cutting tool coupled to a drive shaft. IX. The high speed surgical handpiece assembly of clause VIII, wherein the alignment portion of the drive shaft defines a leading edge that engages the inclined surface of the rotatable drive chuck to align the drive portion of the drive shaft in an orientation for engaging the drive chamber of the rotatable drive chuck. X. The high speed surgical handpiece assembly of any of clauses VIII-IX, wherein the retention feature includes a biasing member. XI. The high speed surgical handpiece assembly of any of paragraphs VIII-X, wherein the nose tube comprises a monolithic structure. XII. The high speed surgical handpiece assembly of paragraph XI, wherein the recesses and protrusions are formed from a metallic material. XIII. The high speed surgical handpiece assembly of paragraph XII, wherein the monolithic nose tube is formed of a metallic material with projections and recesses. Other technical ideas that can be understood from the above-described embodiments will be described below. (1) 1. A surgical handpiece system comprising: 1. A high speed surgical burr assembly comprising: a nose tube defining a lumen extending between a proximal end and a distal end, the nose tube having a proximal portion extending along an axis, the proximal portion having an outer surface defining a nose tube recess, the protrusion including a projection disposed proximal to the nose tube recess; a drive shaft disposed at least partially within the lumen of the nose tube and configured to rotate relative to the nose tube; a cutting tool coupled to a distal region of the drive shaft, the cutting tool configured to rotate with the drive shaft relative to the nose tube; a high speed surgical burr assembly including: 1. A surgical handpiece assembly comprising: a hub having a bore defining a cavity for receiving a proximal portion of a nose tube of a high speed surgical burr assembly; a biasing member disposed within the cavity of the hub, the biasing member configured to be received by a nose tube recess of the nose tube to constrain a depth of a nose tube of the high speed surgical burr assembly within the cavity of the hub relative to the hub; a radial alignment member disposed within a cavity of the hub proximal to the biasing member, the radial alignment member defining a notch for receiving the protrusion to constrain radial orientation of the nose tube relative to the hub; a surgical handpiece assembly including: 1. A surgical handpiece system comprising: (2) The surgical handpiece system of claim 1, wherein the protrusion on the proximal portion of the nose tube extends proximally and generally parallel to the axis. (3) The surgical handpiece system of claim 1 or 2, wherein the proximal end of the protrusion on the proximal portion of the nose tube includes a rounded surface. (4) A surgical handpiece system as described in any one of (1) to (3) above, wherein the protrusion on the proximal portion of the nose tube includes a flat surface parallel to an axis of the proximal portion of the nose tube, the flat surface being configured to abut a surface of the radial alignment member defining a notch for constraining radial orientation of the nose tube relative to the hub. (5) A surgical handpiece system as described in any one of (1) to (4) above, wherein the outer surface of the proximal portion of the nose tube has a proximal shoulder defining a proximal end of the recess, the proximal shoulder being tapered. (6) The surgical handpiece system of (5) above, wherein the bore of the hub defines a hub recess communicating with the cavity, the bore including a distal shoulder for defining a distal end of the hub recess, and the biasing member is configured to engage with the distal shoulder of the hub and the proximal shoulder of the nose tube to urge the protrusion of the nose tube toward the notch of the radial alignment member. (7) The surgical handpiece system of any one of (1) to (6) above, further comprising a proximal bushing disposed at least partially within the lumen of the nose tube, the proximal bushing surrounding a portion of the drive shaft. (8) The surgical handpiece system of (7) above, wherein the drive shaft further includes a proximal region, the proximal region of the drive shaft including a retaining portion proximal to the proximal bushing, the retaining portion having an outer diameter larger than an inner diameter of the proximal bushing, preventing movement of the drive shaft in a distal direction relative to the nose tube. (9) The surgical handpiece system of any one of (1) to (8) above, further comprising a distal bushing coupled to a distal region of the nose tube, the distal bushing surrounding a portion of the drive shaft. (10) The surgical handpiece system of claim 9, wherein the cutting tool has an outer diameter larger than an inner diameter of the distal bushing to prevent the drive shaft from moving proximally relative to the nose tube. (11) The surgical handpiece system of any one of (1) to (10) above, wherein the cutting tool includes a bur. (12) The surgical handpiece system of any one of (8) to (11) above, wherein a proximal region of the drive shaft is disposed outside the lumen of the nose tube. (13) 1. A high speed surgical burr assembly configured to cut tissue and to couple to a surgical handpiece assembly, comprising: a nose tube defining a lumen extending between a proximal end and a distal end, the nose tube having a proximal portion extending along an axis, the proximal portion having an outer surface defining a recess for receiving a biasing member of a surgical handpiece assembly, the proximal portion constraining a depth of the nose tube relative to the surgical handpiece assembly and including a protrusion disposed proximal of the recess, the protrusion configured to constrain a radial orientation of the nose tube relative to the surgical handpiece assembly; a drive shaft disposed at least partially within a lumen of the nose tube and configured to rotate relative to the nose tube, the drive shaft having a drive portion at a proximal region thereof for engaging a rotatable drive chuck of the surgical handpiece assembly; a cutting tool coupled to a distal region of the drive shaft opposite the drive portion, the cutting tool configured to rotate with the drive shaft relative to the nose tube in response to rotation of a rotatable drive chuck of the surgical handpiece assembly; 1. A high speed surgical burr assembly comprising: (14) 14. The high speed surgical burr assembly of claim 13, wherein the projection on the proximal portion of the nose tube extends proximally and generally parallel to the axis. (15) The high speed surgical burr assembly of any one of claims 13 to 14, wherein the proximal end of the protrusion on the proximal portion of the nose tube includes a rounded surface. (16) 16. The high speed surgical burr assembly of any one of claims 13 to 15, wherein the protrusion on the proximal portion of the nose tube includes a flat surface parallel to an axis of the proximal portion of the nose tube, the flat surface configured to abut a surface of the surgical handpiece assembly to prevent relative rotation between the nose tube and the surgical handpiece assembly. (17) The high speed surgical burr assembly of any one of claims 13 to 16, wherein the drive shaft further includes an alignment portion proximal to the drive portion of the drive shaft, the alignment portion configured to align the drive portion of the drive shaft with a rotatable drive chuck of the surgical handpiece assembly to enable engagement between the drive portion of the drive shaft and the rotatable drive chuck. (18) 18. The high speed surgical burr assembly of claim 17, wherein the alignment portion has an outer surface that tapers toward the axis as the alignment portion extends from the drive portion to a proximal end of the drive shaft, and the alignment portion is configured to engage a rotatable drive chuck of the surgical handpiece assembly to align the drive portion in a drive direction for engagement of the drive portion of the drive shaft with the rotatable drive chuck. (19) 19. The high speed surgical burr assembly of claim 17 or 18, wherein the alignment portion defines a notch extending distally from a proximal end of the drive shaft to reduce contact between the alignment portion of the drive shaft and the rotatable drive chuck during engagement of the alignment portion with the rotatable drive chuck. (20) 20. The high speed surgical burr assembly of any one of claims 17 to 19, wherein the alignment portion includes a proximal edge for engaging a rotatable drive chuck of a surgical handpiece assembly to align the drive portion of the drive shaft in a drive direction so that the drive portion engages the rotatable drive chuck. (21) 21. The high speed surgical burr assembly of claim 20, wherein the alignment portion includes a proximal face disposed proximally of the proximal edge to prevent the proximal edge from further engaging a rotatable drive chuck of the surgical handpiece assembly after the drive portion is aligned in the drive direction. (22) The high speed surgical burr assembly of claim 21, wherein the proximal surface includes a plane perpendicular to the axis. (23) 23. The high speed surgical burr assembly of claim 13, wherein an outer surface of a proximal portion of the nose tube has a proximal shoulder defining a proximal end of the recess, the proximal shoulder being tapered, the proximal shoulder being configured to engage a biasing member of the surgical handpiece assembly to urge the nose tube into the surgical handpiece assembly. (24) The high speed surgical burr assembly of any one of (13) to (23), further comprising a proximal bushing disposed at least partially within the lumen of the nose tube, the proximal bushing surrounding a portion of the drive shaft. (25) The high speed surgical burr assembly of claim 24, wherein the drive shaft further includes a retaining portion distal to the drive portion and proximal to the proximal bushing, the retaining portion having an outer diameter greater than an inner diameter of the proximal bushing and preventing movement of the drive shaft in a distal direction relative to the nose tube. (26) 26. The high speed surgical burr assembly of any one of claims 13 to 25, further comprising a distal bushing coupled to a distal region of the nose tube, the distal bushing surrounding a portion of the drive shaft. (27) The high speed surgical burr assembly of claim 26, wherein the cutting tool has an outer diameter larger than an inner diameter of the distal bushing to prevent the drive shaft from moving proximally relative to the nose tube. (28) The high speed surgical burr assembly of any one of claims 13 to 27, wherein the cutting tool comprises a burr. (29) The high speed surgical burr assembly of any one of claims 13 to 28, wherein the proximal region of the drive shaft is disposed outside the lumen of the nose tube. (30) 1. A high speed surgical burr assembly configured to cut tissue and to couple to a surgical handpiece assembly, comprising: a nose tube defining a lumen extending between a proximal end and a distal end, the nose tube having a proximal portion configured to be coupled to a surgical handpiece assembly, the proximal portion including a protrusion configured to constrain a radial orientation of the nose tube relative to the surgical handpiece assembly; a drive shaft disposed at least partially within a lumen of the nose tube and configured to rotate relative to the nose tube, the drive shaft having a proximal region extending along an axis, the proximal region comprising: a drive portion for engaging a rotatable drive chuck of a surgical handpiece assembly in a driving direction; an alignment portion proximal to the drive portion of the drive shaft, the alignment portion having an outer surface that tapers toward the axis as the alignment portion extends from the drive portion to the proximal end of the drive shaft, the alignment portion configured to engage the rotatable drive chuck to align the drive portion of the drive shaft in a driving direction for engagement with the rotatable drive chuck, and defining a notch extending distally from the proximal end of the drive shaft to reduce contact between the alignment portion of the drive shaft and the rotatable drive chuck during engagement of the alignment portion with the rotatable drive chuck; a drive shaft including a cutting tool coupled to a distal region of the drive shaft opposite the proximal region of the drive shaft, the cutting tool configured to rotate with the drive shaft relative to the nose tube in response to rotation of a rotatable drive chuck of the surgical handpiece assembly; 1. A high speed surgical burr assembly comprising: (31) 31. The high speed surgical burr assembly of claim 30, wherein the alignment portion includes a proximal edge for engaging a rotatable drive chuck of a surgical handpiece assembly to align the drive portion of the drive shaft in a drive direction so as to engage the rotatable drive chuck. (32) 32. The high speed surgical burr assembly of claim 31, wherein the alignment portion includes a proximal face disposed proximally of the proximal edge to prevent the proximal edge from further engaging a rotatable drive chuck of the surgical handpiece assembly after the drive portion is aligned in the drive direction. (33) The high speed surgical burr assembly of claim 32, wherein the proximal surface includes a plane perpendicular to the axis. (34) 34. The high speed surgical burr assembly of any one of claims 30 to 33, wherein the projection on the proximal portion of the nose tube extends proximally and generally parallel to the axis. (35) The high speed surgical burr assembly of any one of claims 30 to 34, wherein the proximal end of the protrusion on the proximal portion of the nose tube includes a rounded surface. (36) 36. The high speed surgical burr assembly of any one of claims 30 to 35, wherein the protrusion on the proximal portion of the nose tube includes a flat surface parallel to an axis of the proximal portion of the nose tube, the flat surface configured to abut a surface of the surgical handpiece assembly to prevent relative rotation between the nose tube and the surgical handpiece assembly. (37) 37. The high speed surgical burr assembly of any one of claims 30 to 36, wherein a proximal portion of the nose tube has an outer surface defining a recess for receiving a biasing member of the surgical handpiece assembly to constrain a depth of the nose tube relative to the surgical handpiece assembly. (38) 38. The high speed surgical burr assembly of claim 37, wherein an outer surface of a proximal portion of the nose tube has a proximal shoulder defining a proximal end of the recess, the proximal shoulder being tapered, the proximal shoulder being configured to engage a biasing member of the surgical handpiece assembly to urge the nose tube into the surgical handpiece assembly. (39) The high speed surgical burr assembly of any one of (30) to (38), further comprising a proximal bushing disposed at least partially within the lumen of the nose tube, the proximal bushing surrounding a portion of the drive shaft. (40) The high speed surgical burr assembly of claim 39, wherein the drive shaft further includes a retaining portion distal to the drive portion and proximal to the proximal bushing, the retaining portion having an outer diameter greater than an inner diameter of the proximal bushing to prevent movement of the drive shaft in a distal direction relative to the nose tube. (41) The high speed surgical burr assembly of any one of (30) to (40), further comprising a distal bushing coupled to a distal region of the nose tube, the distal bushing surrounding a portion of the drive shaft. (42) The high speed surgical burr assembly of claim 41, wherein the cutting tool has an outer diameter larger than an inner diameter of the distal bushing to prevent the drive shaft from moving in a proximal direction relative to the nose tube. (43) The high speed surgical burr assembly of any one of claims 30 to 42, wherein the cutting tool comprises a burr. (44) The high speed surgical burr assembly of any one of claims 30 to 43, wherein a proximal region of the drive shaft is disposed outside the lumen of the nose tube. (45) 1. A surgical handpiece assembly configured to be coupled to a high speed surgical burr assembly having a nose tube and a drive shaft rotatably coupled to the nose tube, a hub having a bore defining a cavity for receiving a proximal portion of the nose tube; a biasing member disposed within the cavity of the hub, the biasing member configured to engage the nose tube to constrain a depth of the nose tube within the cavity of the hub relative to the hub; a radial alignment member disposed within the cavity of the hub proximal to the biasing member, the radial alignment member defining a notch for receiving a protrusion of the nose tube to constrain radial orientation of the nose tube relative to the hub, the radial alignment member having an alignment wall extending distally from the notch, the radial alignment member engaging the protrusion of the nose tube such that the notch can receive the protrusion of the nose tube to radially position the nose tube; 1. A surgical handpiece assembly comprising: (46) The surgical handpiece assembly of (45) above, further comprising a rotatable drive chuck configured to be rotated by the motor about an axis, the rotatable drive chuck being configured to be disposed within the cavity of the hub and engage the drive shaft for rotation relative to the hub, the rotatable drive chuck defining an opening for at least partially receiving the drive shaft. (47) A surgical handpiece assembly as described in (46) above, wherein the rotatable drive chuck includes a drive portion disposed proximal to the opening, the drive portion having at least two drive surfaces configured to engage the drive shaft in a driving direction to rotate the drive shaft. (48) A surgical handpiece assembly as described in (47) above, wherein the rotatable drive chuck includes an alignment portion disposed between the drive portion and the opening of the rotatable drive chuck, the alignment portion having an alignment edge extending distally from the drive portion of the rotatable drive chuck toward the opening of the rotatable drive chuck, the alignment edge tapering away from the axis as it extends distally from the drive portion of the rotatable drive chuck. (49) A surgical handpiece assembly as described in (48) above, wherein the alignment edges of the alignment portion of the rotatable drive chuck are configured to engage with the drive shaft and orient the drive shaft in a drive direction to engage the drive shaft with at least two drive surfaces of the drive portion of the rotatable drive chuck. (50) 49. A surgical handpiece assembly as described in claim 48, wherein the alignment portion of the rotatable drive chuck has a first sloping surface extending distally from the drive portion of the rotatable drive chuck toward the opening of the rotatable drive chuck, the first sloping surface tapering away from the axis as it extends distally from the drive portion of the rotatable drive chuck, and the alignment portion of the rotatable drive chuck has a second sloping surface separate from and adjacent to the first sloping surface extending distally from the drive portion of the rotatable drive chuck toward the opening of the rotatable drive chuck, the second sloping surface tapering away from the axis as it extends distally from the drive portion of the rotatable drive chuck, and the first and second sloping surfaces collectively define an alignment edge of the rotatable drive chuck. (51) A surgical handpiece assembly as described in any one of (45) to (50) above, wherein the bore defines a recess communicating with the cavity, the bore including a distal shoulder for defining a distal end of the recess, the distal shoulder configured to engage a biasing member of the surgical handpiece assembly to urge the nose tube toward the radial alignment member. (52) 1. A surgical handpiece system comprising: 1. A high speed surgical burr assembly comprising: a nose tube defining a lumen extending between a proximal end and a distal end; a drive shaft disposed at least partially within a lumen of the nose tube and configured to rotate relative to the nose tube, the drive shaft having a proximal region extending along a drive shaft axis; a cutting tool coupled to a distal region of the drive shaft, the cutting tool configured to rotate with the drive shaft relative to the nose tube; a high speed surgical burr assembly including: 1. A surgical handpiece assembly comprising: a hub having a bore defining a cavity for receiving a proximal end of a nose tube and a proximal region of a drive shaft of a high speed surgical burr assembly; a rotatable drive chuck configured to be rotated by the motor about the hub axis, the drive chuck being configured to be disposed within the cavity of the hub and to rotate relative to the hub, the drive chuck defining an opening for receiving a proximal region of the drive shaft; a drive portion disposed proximal to the opening, the drive portion having at least two drive surfaces configured to engage the drive shaft in a drive direction to rotate the drive shaft; an alignment portion disposed between the drive portion and the opening of the rotatable drive chuck, the alignment portion having an alignment edge extending distally from the drive portion of the rotatable drive chuck toward the opening of the rotatable drive chuck, the alignment edge tapering away from the hub axle as it extends distally from the drive portion of the rotatable drive chuck; a rotatable drive chuck including: a surgical handpiece assembly including: Including, A surgical handpiece system, wherein the drive shaft is configured to engage alignment edges of an alignment portion of a rotatable drive chuck to orient the drive shaft in a drive direction for engaging the drive shaft with at least two drive surfaces of a drive portion of the rotatable drive chuck. (53) The surgical handpiece system of claim 52, wherein the drive shaft includes a drive portion and an alignment portion proximal to the drive portion, the alignment portion of the drive shaft configured to engage with an alignment edge of the alignment portion of the rotatable drive chuck to orient the drive shaft in a drive direction to engage the drive portion of the drive shaft with at least two drive surfaces of the drive portion of the rotatable drive chuck. (54) The surgical handpiece system of claim 53, wherein the alignment portion of the drive shaft has an outer surface that tapers toward the drive shaft axis as the alignment portion extends from the drive portion to the proximal end of the drive shaft, and the outer surface of the alignment portion is configured to engage with alignment edges of the alignment portion of the rotatable drive chuck to orient the drive shaft in a drive direction so as to engage the drive portion of the drive shaft with at least two drive surfaces of the drive portion of the rotatable drive chuck. (55) 5. The surgical handpiece system of claim 4, wherein the alignment portion of the drive shaft defines a notch extending distally from a proximal end of the drive shaft to reduce contact between the alignment portion of the drive shaft and the alignment portion of the rotatable drive chuck during engagement with the alignment portion of the rotatable drive chuck. (56) The high speed surgical burr assembly of any one of (53) to (55), wherein the alignment portion of the drive shaft includes a proximal edge for engaging an alignment edge of the alignment portion of the rotatable drive chuck of the surgical handpiece assembly and aligning the drive portion in a drive direction such that the drive portion of the drive shaft engages with the drive portion of the rotatable drive chuck. (57) The high speed surgical burr assembly of claim 56, wherein the alignment portion of the drive shaft includes a proximal face disposed proximally of the proximal edge to prevent the proximal edge from further engaging a rotatable drive chuck of the surgical handpiece assembly after the drive portion is aligned in the drive direction. (58) The high speed surgical burr assembly of claim 57, wherein the proximal surface of the alignment portion of the drive shaft comprises a plane perpendicular to the drive shaft axis. (59) The surgical handpiece system of any one of (52) to (58) above, further comprising a proximal bushing disposed at least partially within the lumen of the nose tube, the proximal bushing surrounding a portion of the drive shaft. (60) The surgical handpiece system of claim 59, wherein the drive shaft further includes a retaining portion distal to the drive portion and proximal to the proximal bushing, the retaining portion having an outer diameter larger than an inner diameter of the proximal bushing and preventing movement of the drive shaft in a distal direction relative to the nose tube. (61) The surgical handpiece system of any one of (52) to (60) above, further comprising a distal bushing coupled to a distal region of the nose tube, the distal bushing surrounding a portion of the drive shaft. (62) The surgical handpiece system of claim 61, wherein the cutting tool has an outer diameter larger than an inner diameter of the distal bushing to prevent the drive shaft from moving proximally relative to the nose tube. (63) The surgical handpiece system of any one of claims 52 to 62, wherein the cutting tool includes a bur. (64) 64. The surgical handpiece system of claim 62, wherein the alignment portion of the rotatable drive chuck has a first sloped surface extending distally from the drive portion of the rotatable drive chuck toward the opening of the rotatable drive chuck, the first sloped surface tapering from the hub axle as it extends distally from the drive portion of the rotatable drive chuck, the alignment portion of the rotatable drive chuck has a second sloped surface separate from and adjacent to the first sloped surface extending distally from the drive portion of the rotatable drive chuck toward the opening of the rotatable drive chuck, the second sloped surface tapering from the hub axle as it extends distally from the drive portion of the rotatable drive chuck, and the first and second sloped surfaces collectively define an alignment edge of the rotatable drive chuck. (65) The surgical handpiece system of any one of (52) to (64), wherein the proximal region of the drive shaft is disposed outside the lumen of the nose tube. (66) 1. A high speed surgical burr assembly for connection to a surgical handpiece assembly, comprising: a drive shaft having a proximal end and a distal end; a nose tube having a first region defining a lumen for at least partially receiving a drive shaft between a proximal end and a distal end and a second region extending monolithically from the first region for coupling the drive shaft to a surgical handpiece at the proximal end, the second region including an alignment feature configured to radially align the nose tube to the surgical handpiece assembly and the second region including a retention feature configured to axially retain the nose tube to the surgical handpiece assembly; a cutting tool coupled to the drive shaft at a distal end of the drive shaft; 1. A high speed surgical burr assembly comprising: (67) The high speed surgical burr assembly of claim 8, wherein the alignment feature includes a protrusion for engaging a hub of the surgical handpiece assembly to align the nose tube to the surgical handpiece assembly. (68) The high speed surgical burr assembly of claim 66 or 67, wherein the first and second regions are formed from a metallic material. (69) The high speed surgical burr assembly as described above in (68), wherein the alignment and retention features are formed from the metallic material forming the first and second regions. (70) The high speed surgical burr assembly of any one of claims 66 to 69, wherein the drive shaft includes an alignment portion at a proximal end of the drive shaft and a drive portion adjacent to the alignment portion, the alignment portion defining a leading edge that engages an inclined surface of a rotatable drive chuck of the surgical handpiece to align the drive portion of the drive shaft in a direction for engaging the rotatable drive chuck.

Claims

1. 1. A surgical handpiece system comprising:

1. A high speed surgical burr assembly comprising: a nose tube defining a lumen extending between a proximal end and a distal end, the nose tube having a proximal portion extending along an axis, the proximal portion having an outer surface defining a nose tube recess, the proximal portion including a proximal extending projection proximal to the nose tube recess; a drive shaft disposed at least partially within the lumen of the nose tube and configured to rotate relative to the nose tube; a cutting tool coupled to a distal region of the drive shaft, the cutting tool configured to rotate with the drive shaft relative to the nose tube; a high speed surgical burr assembly including:

1. A surgical handpiece assembly comprising: a hub having a bore defining a cavity for receiving the proximal portion of the nose tube of the high speed surgical burr assembly; a biasing member configured to be held in a predetermined position within the cavity of the hub in a receiving orientation of the proximal portion of the nose tube to allow insertion of the proximal portion of the nose tube in the receiving orientation, the biasing member configured to radially expand and biasingly seat in the nose tube recess of the nose tube upon insertion of the proximal portion of the nose tube in the receiving orientation to constrain a depth of the nose tube of the high speed surgical burr assembly within the cavity of the hub relative to the hub; a radial alignment member disposed in the cavity of the hub proximal to the biasing member, the radial alignment member defining a distally opening notch for receiving the protrusion, the protrusion being configured to be forced distally into the notch upon receipt of the proximal portion of the nose tube in the hub cavity to constrain a radial orientation of the nose tube relative to the hub; a surgical handpiece assembly including:

1. A surgical handpiece system comprising:

2. The surgical handpiece system of claim 1 , wherein the outer surface of the proximal portion of the nose tube has a proximal shoulder defining a proximal end of the recess, the proximal shoulder being tapered.

3. 3. The surgical handpiece system of claim 2, wherein the bore in the hub defines a radially recessed portion on an inner surface facing the cavity, the bore including a distal shoulder to define a distal end of the portion, and the biasing member configured to engage the distal shoulder of the hub and the proximal shoulder of the nose tube to urge the projection of the nose tube toward the notch of the radial alignment member.

4. The surgical handpiece system of claim 1 , wherein the projection of the proximal portion of the nose tube extends proximally and generally parallel to the axis.

5. The surgical handpiece system of claim 1 , wherein a proximal end of the protrusion of the proximal portion of the nose tube includes a rounded surface.

6. 6. The surgical handpiece system of claim 1, wherein the protrusion of the proximal portion of the nose tube includes a flat surface parallel to the axis of the proximal portion of the nose tube, the flat surface configured to abut a surface of the radial alignment member that defines the notch to constrain the radial orientation of the nose tube relative to the hub.

7. 7. The surgical handpiece system of claim 1, further comprising a proximal bushing disposed at least partially within the lumen of the nose tube, the proximal bushing surrounding a portion of the drive shaft.

8. 8. The surgical handpiece system of claim 7, wherein the drive shaft further includes a proximal region, the proximal region of the drive shaft including a retaining portion proximal to the proximal bushing, the retaining portion having an outer diameter greater than an inner diameter of the proximal bushing, preventing movement of the drive shaft in a distal direction relative to the nose tube.

9. 9. The surgical handpiece system of claim 1, further comprising a distal bushing coupled to a distal region of the nose tube, the distal bushing surrounding a portion of the drive shaft.

10. The surgical handpiece system of claim 9 , wherein the cutting tool has an outer diameter larger than an inner diameter of the distal bushing to prevent proximal movement of the drive shaft relative to the nose tube.

11. The surgical handpiece system of claim 1 , wherein the cutting tool comprises a burr.

12. The surgical handpiece system of claim 8 , wherein the proximal region of the drive shaft is disposed outside the lumen of the nose tube.

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