Surgical rasps and methods of use

Abstract

A surgical rasp including an elongate rod and a shank disposed at a first end of the rod. The shank is sized and shaped for removable engagement with a drive assembly of a reciprocating saw. The surgical rasp includes a rasp head coupled to a second end of the rod. The rasp head has a first side and an opposing second side. Each of the first and second sides includes a cutting surface configured for at least one of bone resurfacing and bone decortication.

Description

46182-2 SURGICAL RASPS AND METHODS OF USE CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 640,041, filed April 29, 2024, the entire disclosure of which is hereby incorporated by reference. FIELD

[0002] The field of the disclosure relates generally to surgical rasps and, more particularly, to surgical rasps connectable to a powered reciprocating tool. BACKGROUND

[0003] Surgical rasps are used during orthopedic surgeries to shave bone surfaces, e.g., to shape a bone surface to fit an orthopedic implant, remove osteophytes, and / or during endplate decortication to promote bone growth during spinal fusion surgery. Conventional surgical rasps are small hand-held tools having a single filing surface and a handle. A surgeon may grip the handle and manually move the filing surface against a bone surface in order to shave the bone surface.

[0004] The small size of conventional surgical rasps, having a shortened handle length and / or a small filing surface area, restricts the use of conventional rasps for certain orthopedic surgeries. For example, conventional surgical rasps do not have sufficient length to extend through a thoracic or46182-2 abdominal cavity of a patient to reach a vertebrae, as required for endplate decortication during an anterior approach spinal fusion surgery. Orthopedic surgeries may be physically demanding, and the use of conventional surgical rasps which require a surgeon to manually move the surgical rasp against bone surfaces contributes to surgeon fatigue. Moreover, manual movement of surgical rasps may not be suitable for the precision required during spinal endplate decortication in which cortical bone surfaces are in close proximity to the spinal cords, spinal nerves branching therefrom, and / or the dura.

[0005] Accordingly, a need exists for surgical rasps which overcome the current drawbacks associated with conventional handheld surgical rasps described above.

[0006] This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the disclosure, which are described and / or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art. SUMMARY

[0007] In one aspect, a surgical rasp includes an elongate rod having a first end and an opposing second end and a shank disposed at the first end of the rod. The shank is sized and shaped for removable engagement with a drive assembly of a reciprocating saw.46182-2 The surgical rasp includes a rasp head coupled to the second end of the rod. The rasp head has a first side and an opposing second side. Each of the first and second side includes a cutting surface configured for at least one of bone resurfacing and bone decortication.

[0008] In another aspect, a surgical rasp system includes a reciprocating saw including a drive assembly and a surgical rasp. The surgical rasp includes an elongate rod having a first end and an opposing second end, a shank disposed at the first end of the rod, wherein the shank is sized and shaped for removable engagement with the drive assembly of the reciprocating saw. The surgical rasp includes a rasp head coupled to the second end of the rod. The rasp head has a first side and an opposing second side. Each of the first and second side includes a cutting surface configured for at least one of bone resurfacing and bone decortication.

[0009] In another aspect, a method of using a surgical rasp includes drivingly engaging a shank of a surgical rasp to a drive assembly of a reciprocating saw and inserting a head and a rod of the surgical rasp at least partially through a thoracic cavity of a patient. The method further includes inserting the head into a disc space between adjacent vertebrae and positioning a plurality of cutting teeth disposed on the head against a bone surface. The method includes activating the reciprocating saw to cause the drive assembly to move the surgical rasp in a reciprocating motion causing the plurality of cutting teeth to shave the bone surface.46182-2

[0010] Various refinements exist of the features noted in relation to the above-mentioned aspects of the present disclosure. Further features may also be incorporated in the above-mentioned aspects of the present disclosure as well. These refinements and additional features may exist individually or in any combination. For instance, various features discussed below in relation to any of the illustrated embodiments of the present disclosure may be incorporated into any of the above-described aspects of the present disclosure, alone or in any combination. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 is a perspective view of an example surgical rasp.

[0012] Figure 2 is another perspective view of the surgical rasp shown in Figure 1.

[0013] Figure 3 is a side view of the surgical rasp shown in Figure 1.

[0014] Figure 4 is an enlarged side view of a head of the surgical rasp shown in Figure 1.

[0015] Figure 5 is an enlarged top view of the head of the surgical rasp shown in Figure 4.

[0016] Figure 6 is an enlarged side view of a shank of the surgical rasp shown in Figure 1.

[0017] Figure 7 is an enlarged top view of the shank of the surgical rasp shown in Figure 6.46182-2

[0018] Figure 8 is an enlarged perspective view of the shank of the surgical rasp shown in Figure 6.

[0019] Figure 9 is a perspective view of another example surgical rasp.

[0020] Figure 10 is another perspective view of the surgical rasp shown in Figure 9.

[0021] Figure 11 is an enlarged top view of the surgical rasp shown in Figure 9.

[0022] Figure 12 is a perspective view of another example surgical rasp.

[0023] Figure 13 is a side view of the surgical rasp shown in Figure 12.

[0024] Figure 14 is a top view of the surgical rasp shown in Figure 12.

[0025] Figure 15 is an end view of the surgical rasp shown in Figure 12.

[0026] Figure 16 is a perspective view of another example surgical rasp.

[0027] Figure 17 is a bottom view of the surgical rasp shown in Figure 16.

[0028] Figure 18 is a side view of the surgical rasp shown in Figure 16.

[0029] Figure 19 is another side view of the surgical rasp shown in Figure 16.46182-2

[0030] Figure 20 is a perspective view of another example surgical rasp.

[0031] Figure 21 is a top view of the surgical rasp shown in Figure 20.

[0032] Figure 22 is a side view of the surgical rasp shown in Figure 20.

[0033] Figure 23 is another side view of the surgical rasp shown in Figure 20.

[0034] Figure 24 is a perspective view of another example surgical rasp.

[0035] Figure 25 is a bottom view of the surgical rasp shown in Figure 24.

[0036] Figure 26 is a side view of the surgical rasp shown in Figure 24.

[0037] Figure 27 is an end view of the surgical rasp shown in Figure 24.

[0038] Figure 28 is an enlarged perspective view of an example shank suitable for use with any of the surgical rasps shown in Figures 1-27.

[0039] Figure 29 is an enlarged top view of the shank shown in Figure 28.

[0040] Figure 30 is an enlarged side view of the shank shown in Figure 28.

[0041] Figure 31 is a perspective view of an example powered reciprocating tool, such as a46182-2 reciprocating saw, suitable for use with the surgical rasps disclosed herein.

[0042] Figure 32 is a flow diagram of a method suitable for use with the surgical rasps disclosed herein.

[0043] Corresponding reference characters indicate corresponding parts throughout the drawings. DETAILED DESCRIPTION

[0044] Embodiments of surgical rasps described herein include a shank enabling the surgical rasps to be selectively drivingly engaged with a drive mechanism of a reciprocating tool, such as a powered reciprocating surgical saw. The surgical rasps include one or more cutting surfaces. The cutting surfaces may include a plurality of cutting teeth, positioned on, or extending from, the cutting surface. Movement of the cutting surface against a bone surface causes the cutting surface to remove, e.g., shave or cut, a surface of the bone. When the rasp is drivingly engaged with the powered reciprocating tool, the tool may apply a reciprocating motion to move the cutting surface against a bone surface, reducing operator (e.g., surgeon or practitioner) fatigue, as the operator is not required to manually move the surgical rasp during orthopedic surgeries. Moreover, the reciprocating motion driven by the tool can be precise and controlled, having a consistent range of reciprocating motion and / or a consistent speed and / or acceleration, which is particularly advantageous for intricate procedures requiring meticulous surgical techniques associated with46182-2 the vertebral bones in proximity to the spinal cord, nerves, and / or dura.

[0045] In some embodiments described herein, the surgical rasp has a sufficient size, e.g., a length and / or a cutting surface area, such that the surgical rasp may be utilized for multiple different orthopedic surgical procedures. For example, the surgical rasp may have a sufficient length, enabling the surgical rasp to extend through the abdominal cavity from an incision on a patient’s abdomen or chest, to the spine, such that the rasp may be used during an anterior approach spinal surgical procedure. In some embodiments, the surgical rasp has a sufficient cutting surface area to efficiently, and quickly, clear a disc space and / or to shave a bone surface, e.g., during a laminectomy and / or for decortication of an endplate.

[0046] In some embodiments described herein, the surgical rasp includes two opposing cutting surfaces configured for at least one of bone resurfacing and / or bone decortication. A practitioner may use either, or both, opposing cutting surfaces during a surgical procedure. For example, a practitioner may insert the head of the rasp within a disc space between adjacent vertebrae, and the practitioner may shave either a lower bone endplate of an upper vertebrae and an upper endplate of a lower vertebrae, without requiring the surgeon to remove the head from the disc space in order to rotate the head to reposition the cutting surface adjacent to a bone surface, as would be required for a rasp having only a single cutting surface.46182-2

[0047] Example embodiments of surgical rasps are described in detail. Aspects of the surgical rasps are not limited to the specific embodiments described herein, but rather, components of the surgical rasps may be used independently and separately from other components described herein. For example, in some embodiments, a rod of the surgical rasp may be straight or, alternatively, the rod may have a bend. In another example, in some embodiments, a head of the surgical rasp may have cutting teeth having a pyramidal shape or, alternatively, the cutting teeth may have an elongated triangle shape.

[0048] In reference to Figs. 1-8, an embodiment of a surgical rasp is indicated generally at 100. The surgical rasp 100 includes a rod 110 extending between a first end 112 and a second end 114. The surgical rasp 100 includes a head 116 coupled to, or formed integrally with, the first end 112 and a shank 118 positioned at, or formed integrally with, the second end 114. As described herein, the surgical rasp 100, including the head 116 and the rod 110, may be generally paddle shaped and the shank 118 is sized and shaped for removable engagement with a reciprocating tool 700, e.g., a reciprocating saw, described in reference to Fig. 28.

[0049] The head 116 includes a first side 120 and an opposing second side 122. The first side 120 includes a first cutting surface 124 and the opposing second side 122 includes a second cutting surface 126 used to resurface a bone and / or for bone decortication, when either of the cutting surfaces 124, 126 are moved across / against the bone surface.46182-2

[0050] In some embodiments, at least one of the first cutting surface 124 and the second cutting surface 126 includes one or more cutting teeth 128 that may be used to resurface a bone or for bone decortication, when the cutting teeth 128 are moved across / against the bone surface. The surgical rasp 100 includes a plurality of cutting teeth 128 on both the first cutting surface 124 and the second cutting surface 126 of the head 116. The cutting teeth 128 have a pyramidal shape including four sides meeting at a point. The cutting teeth 128 may have a tooth angle µ that is between 45° and 65°, for example. See FIG. 27, for example. The cutting teeth 128 may be any suitable shape and / or configuration, for example, in some alternative embodiments, the cutting teeth 128 may have a conical shape. Each of the cutting teeth 128 may extend generally perpendicularly from the first and / or second sides 120, 122. In some embodiments, the first side 120 and second side 122 may be substantially dome shaped. In some alternative embodiments, the first side 120 and second side 122 may be planar or have planar portions. The cutting teeth 128 or the cutting surface 124 may be any suitable shape or configuration or any other contoured surface texture enabled for resurfacing, retexturing, reshaping, and / or decorticating bone.

[0051] In the surgical rasp 100, both the first and the second cutting surfaces 124, 126 of the head 116 have the same shape of cutting teeth 128 arranged in the same pattern. The plurality of cutting teeth 128 generally have the same size, e.g., the same height h128 and / or base length L128. The plurality of cutting teeth 128 are arranged in a grid like pattern,46182-2 e.g., the cutting teeth 128 are arranged in rows and / or columns across the cutting surfaces 124, 126. In some alternative embodiments, the plurality of cutting teeth 128 are arranged in an offset grid pattern.

[0052] In some alternative embodiments, the first and second cutting surfaces 124, 126 of the head 116 may have different shapes or sizes of cutting teeth 128, a different number of cutting teeth 128, and / or different cutting teeth 128 patterns / arrangements.

[0053] In some alternative embodiments, the cutting surfaces 124, 126 can include an abrasive coating and / or be a textured surface, such that the cutting surface 124, 126 includes cutting particle elements covering the cutting surfaces 124, 126. In alternative embodiments, the cutting surface 124, 126 may include any suitable features and / or surface coatings configured for at least one of bone resurfacing and / or bone decortication.

[0054] In reference to Fig. 5, the surgical rasp 100 includes a neck 130 coupled between the rod 110 and the head 116. The neck 130 extends between a first end 132, coupled at the head 116, and a second end 134, coupled at the first end 112 of the rod 110. The neck 130 may taper between the head 116 and the rod 110 such that the first end 132 of the neck 130 has a width W132 that is greater than a width W134of the second end 134. The neck 130 may have an arched section and / or curved sides 136. In some embodiments, the sides 136 of neck 130 are straight and / or have straight sections.46182-2

[0055] In some embodiments, the head 116 is oriented at a neck angle α relative to the rod 110. The neck angle α may be an oblique angle between the rod 110 and the neck 130. In some embodiments, the neck angle α may be any suitable angle between 90° and 180°. In some embodiments, for example, the neck angle α is in the range of 140° to 150°, in the range of 130° to 160°, or in the range of 120° to 160° In one example, the neck angle α is approximately 145°, e.g., 145°± 5°.

[0056] The head 116 includes a head length L116, a head width W116, and a head thickness t116. The head 116 also includes a distal end 140 that is arched or rounded and is devoid of sharp edges thereby reducing the risk of puncturing or tearing soft tissue structures during use of the surgical rasp 100. In some embodiments, the distal end 140 may be straight or have a straight section. Sides 142 of the head 116 may be substantially straight. In one embodiment, the head length L116is approximately 2.54 cm (1 inch), the head width W116is approximately 2.54 cm (1 inch), and the head thickness t116is approximately .381 cm (0.15 inches). In other embodiments, the head length L116 may be greater than or less than the head width W116. In some embodiments, the head length L116and head width W116of the head 116 may be the same such that the head 116 is substantially square shaped. The cutting surfaces 124, 126 may substantially cover the entire first or second sides 120, 122 of the head 116, and as such, the head length L116and / or head width W116can also be a length and a width of the cutting surfaces 124, 126.46182-2

[0057] The cutting teeth 128 can have any suitable size and shape that enables the surgical rasp to function as described herein. In one example, the cutting teeth 128 are pyramidal shaped and have a height H128 of approximately .2032 cm (0.08 inches) extending from the first or second sides 120, 122, and have a rectangular base having a side length L128of approximately 0.254 cm (0.10 inches).

[0058] The neck 130 can have any suitable size and shape that enables the surgical rasp to function as described herein. In one example, the neck 130 has a length L130, extending between the first end 132 and the second end 134 of approximately 1.905 cm (0.75 inches), and has a neck width W134of .3048 (0.12 inches) at the second end 134, where the neck 130 is connected to the rod 110. The neck width W132,at the first end 132, connected to the head 116, may be the same as the head width W116 (e.g., approximately 2.54 cm (1 inch)). In some embodiments, the neck 130 has a neck length L130that is shorter than the head length L116. In some embodiments, the neck length L130and the head length L116may be substantially the same.

[0059] In further reference to Fig. 3, The rod 110 may be an elongate rod 110 having a rod length L110, extending between the first end 112 and second end 114, that is much greater than a width, or diameter D110, of the rod 110. In some embodiments, for example, the rod length L110is in the range of 25.4 cm to 63.5 cm (10 inches to 25 inches), in the range of 25.4 cm to 50.8 cm (10 inches to 20 inches), in the range of 30.48 cm to 63.5 cm (12 inches to 25 inches), in the range of 25.4 cm46182-2 to 45.72 cm (10 inches to 18 inches), in the range of 30.48 cm to 50.8 cm (12 inches to 20 inches), in the range of 38.1 cm to 63.5 cm (15 inches to 25 inches), in the range of 30.48 cm to 45.72 cm (12 inches to 18 inches), in the range of 35.56 cm to 50.8 cm (14 inches to 20 inches), or in the range of 35.56 cm to 45.72 cm (14 inches to 18 inches). In one example, the rod length L110is approximately 16.51 cm (6.5 inches). In another example, the rod length L110is approximately 17.145 cm (6.75 inches). In some embodiments, the rod length L110 may be greater than, or equal to, 15.24 cm (6 inches).

[0060] In the illustrated embodiment, the surgical rasp 100 includes a first rod section 150 having a first rod length L150and a second rod section 152 having a second rod length L152. The first rod section 150 is connected to and extends from the neck 130 to the second rod section 152, and the second rod section 152 is connected to and extends from the shank 118 to the first rod section 150. In some embodiments, for example, the first rod length L150is in the range of 2.54 cm to 7.62 cm (1 inch to 3 inches), in the range of 5.08 cm to 7.62 cm (2 inches to 3 inches), in the range of 5.08 cm to 10.16 cm (2 inches to 4 inches), or in the range of 2.54 cm to 12.7 cm (1 inch to 5 inches). In some embodiments, for example, the second rod length L152is in the range of 5.08 cm to 12.7 cm (2 inches to 5) inches, in the range of 7.62 cm to 15.24 cm (3 inches to 6 inches), in the range of 7.62 cm to 17.78 cm (3 inches to 7 inches), or in the range of 7.62 cm to 20.32 cm (3 inches to 8 inches). In one example, the first rod length L150is approximately 6.985 cm (2.75 inches) and the second rod length L152is approximately 10.16 cm (4 inches). In some embodiments,46182-2 the first rod length L150is shorter than the second rod length L152. In some alternative embodiments, the first rod length L150 and the second rod length L152may be approximately equal in length.

[0061] In the illustrated embodiment, the first rod section 150 is oriented at an oblique rod angle β relative to the second rod section 152. In some embodiments, for example, the rod angle β may be any suitable angle between 90° and 180°. In one embodiment, the rod angle β is approximately 160°, e.g., 160°± 5°. In some embodiments, for example, the rod angle β is in the range of 140° to 180°, in the range of 145° to 170°, or in the range of 145° to 165°. In some embodiments, the second rod section 152 includes a flat shank section 158, positioned in proximity to the shank 118.

[0062] In some embodiments, the neck angle α and the rod angle β may be arranged in the same plane, a first plane XY. The first and second cutting surfaces 124, 126 of the head 116 may be arranged in a different plane, e.g., a second plane ZY, perpendicular to the first plane XY, as shown in Fig. 3.

[0063] In some embodiments, the first and second rod sections 150, 152 are substantially cylindrical in shape having a diameter D150, D152, respectively. In some embodiments, for example, the diameter D152is in the range of 0.254 cm to 1.27 cm (0.1 inches to 0.5 inches), in the range of 0.254 cm to 1.016 cm (0.1 to 0.4 inches), in the range of 0.254 cm to 0.635 cm (0.1 to 0.25 inches), or in the range of 0.635 cm to1.016 cm (0.25 to 0.4 inches). In one example, the46182-2 diameter D152is approximately 0.635 cm (0.25 inches). In some embodiments, the first rod section 150 may taper from the second rod section 152 towards the neck 130. Insome embodiments, for example, the diameter D150, inproximity to the second rod section 152, is in the range of 0.254 cm to 1.27 cm (0.1 inches to 0.5 inches), in the range of 0.254 cm to 1.016 cm (0.1 to 0.4 inches), or in the range of 0.254 cm to 0.635 cm (0.1 to 0.25 inches).In some embodiments, for example, the diameter D150, inproximity to the neck 130, is in the range of 0.127 cm to 0.508 cm (0.05 inches to 0.2 inches), in the range of 0.0635 cm to 0.508 cm (0.025 to 0.2 inches), or in the range of 0.254 cm to 0.635 cm (0.1 to 0.25 inches). In one example, the diameter D150is approximately .635 cm (0.25 inches) in proximity to the second rod section 152, and the diameter D150tapers to approximately 0.3048 cm (0.12 inches) in proximity to the neck 130.

[0064] In some alternative embodiments, the first rod section 150 may have a cylindrical shape near the second rod section 152 and an oblong shape, having a major diameter D150and a minor diameter d150,near the neck 130. In some embodiments, for example, the major diameter D150 in proximity to the neck 130 is in the range of 0.254 cm to 1.27 cm (0.1 inches to 0.5 inches), in the range of 0.254 cm to 1.016 cm (0.1 inches to 0.4 inches), or in the range of 0.254 cm to 0.635 cm (0.1 to 0.25 inches). In some embodiments, for example, the minor diameter d150, in proximity to the neck 130, is in the range of 0.127 cm to 0.508 cm (0.05 inches to 0.2 inches), in the range of 0.254 cm to 0.508 cm (0.025 to 0.2 inches), or in the range of 0.254 cm to 0.635 cm (0.1 to 0.25 inches). In one example, the major diameter D15046182-2 is approximately 0.7874 cm (.31 inches) and the minor diameter d150is approximately 0.381 cm (0.15 inches) in proximity to the neck 130. In some embodiments, the first rod section 150 may transition or change shape from the second rod section 152 towards the neck 130, e.g., the major diameter D150may increase and the minor diameter d150may decrease.

[0065] In reference to Figs. 6-8, the shank 118 is sized and shaped to engage with a drive mechanism 708 of a reciprocating surgical tool 700, such as a reciprocating surgical saw, described in reference to Fig. 31. For example, the shank 118 may be configured (e.g., sized, and shaped) to be removably engaged with any suitable reciprocating drive mechanism 708. In the illustrated embodiments, the shank 118 includes a rod 160, which may be cylindrical in shape. In some embodiments, the shank 118 includes a key tab 162 disposed on a first side 164 of the rod 160, and a key channel 166 disposed on a second side 168 of the rod 160. See FIGS. 3, 12, 13, 16, 18-26, for example. In some embodiments, the key tab 162 and the key channel 166 are disposed on a same side of the rod 160, e.g., both the key tab 162 and the key channel 166 are disposed on the second side 168 of the rod 160. See FIGS. 1-2 and 6-10, for example. In the illustrated embodiment, the key channel 166 is defined by a recessed surface 174 and two opposing side surfaces 172 that extend from the recessed surface and a radial outer surface 170 of the rod 160.

[0066] In some embodiments, the reciprocating drive mechanism 708 of the reciprocating surgical tool 700 may apply a force in a first direction46182-2 on the side surface 172 located distally of the key channel 166, and subsequently apply a reciprocating force in a second opposing direction on the side surface 172 proximal to the key channel 166.

[0067] In alternative embodiments, the shank 118 may include any suitable key features that are sized and shaped complementary to corresponding mating key features on a drive mechanism 708 of a pre-existing powered reciprocating surgical tool.

[0068] The surgical rasp 100 may include a chamfer 180 disposed between the second rod section 152 and the shank 118. The chamfer 180 may be a conical frustrum tapering from the second rod section 152 to the shank 118. The chamfer 180 may contact a distal end of a chuck 714 of the reciprocating tool 700, e.g., when the surgical rasp 100 is engaged with the reciprocating drive mechanism 708.

[0069] Embodiments of the surgical rasps described herein may be formed of a single piece of metal, e.g., the head 116, the neck 130, the rod 110, and / or the shank 118 are formed from a single piece of metal. The surgical rasp 100 may be composed of a surgical grade stainless steel and / or stainless-steel alloy, or any suitable material, e.g., titanium, copper, cobalt chrome, and the like. In some alternative embodiments, the cutting surfaces 124, 126 and / or the cutting teeth 128 may be composed of a different material than the neck 130, the rod 110 and / or the shank 118.

[0070] In reference to Figs. 9-11, another embodiment of a surgical rasp is shown and indicated46182-2 generally at 200. The surgical rasp 200 includes one or more components similar to the surgical rasp 100, including, for example, the rod 110, the head 116 having the first and second cutting surface 124, 126 , the shank 118, and the neck 130. The surgical rasp 200 includes cutting teeth 128 that are elongated oblique triangular prism shaped and are arranged in rows extending perpendicular to the head length L116and / or perpendicular to the elongate rod 110. In some embodiments, the first and / or the second cutting surface 124, 126 of the head 116 both include the plurality of elongated oblique triangular prism shaped cutting teeth 128 arranged inrows. The surgical rasp 200 includes a neck angle αand / or a rod angle β of 180° such that the surgical rasp 200 is substantially straight and, in one example the rod length L110is approximately 17.145 cm (6.75 inches). In some embodiments, for example, the straight rod length L110 is in the range of 25.4 cm to 63.5 cm (10 inches to 25 inches), in the range of 25.4 cm to 50.8 cm (10 inches to 20 inches), in the range of 30.48 cm to 63.5 cm (12 inches to 25 inches), in the range of 25.4 cm to 45.72 cm (10 inches to 18 inches), in the range of 30.48 cm to 50.8 cm (12 inches to 20 inches), in the range of 38.1 cm to 63.5 cm(15 inches to 25 inches), in the range of 30.48 cm to 45.72 cm (12 inches to 18 inches), in the range of 35.56 cm to 50.8 cm (14 inches to 20 inches), or in the range of 35.56 cm to 45.72 cm (14 inches to 18 inches).

[0071] In reference to Figs. 12-15, another embodiment of a surgical rasp is shown and indicated generally by 300. The surgical rasp 300 includes one or more components similar to the surgical rasp 100 and / or surgical rasp 200, including, for example, the rod 110,46182-2 the head 116 including the first and second cutting surfaces 124, 126, the shank 118, and the neck 130.

[0072] The surgical rasp 300 has a neck angle α and / or a rod angle β of 180° such that the surgical rasp 300 has a substantially straight rod 110, neck 130, and / or head 116. The surgical rasp 300 includes a plurality of pyramidal-shaped cutting teeth 128 arranged in rows and columns on each of the first and second cutting surfaces 124, 126 of the head 116. The surgical rasp 300 has a relatively narrower head width Was compared to surgical rasp 100. In some embodiments, for example, the head width W of surgical rasp is about 1.016 cm (.4 inches). The first rod section 150 has a major diameter D150which increases from the second rod section 152 to the neck 130 and the minor diameter d150decreases from the second rod section 152 to the neck 130. In one example, the major diameter D150 may be approximately 0.7874 cm (0.31 inches) or 0.635 cm (0.25 inches) in proximity to the neck 130. In some embodiments, for example, the minor diameter d150is in the range of 0.254 cm to 0.508 cm (0.1 inches to 0.2 inches), in the range of 0.127 cm to 0.762 cm (0.05 inches to 0.3 inches), or in the range of 0.254 cm to 1.016 cm (0.1 inches to 0.4 inches). In one embodiment, the minor diameter d150is approximately 0.381 cm (0.15 inches) or isapproximately the same as the head thickness t116. In someembodiments, for example, the neck length L130 is in the range of 0.254 cm to 0.508 cm (0.1 inches to 0.2 inches), in the range of 0.127 cm to 0.762 cm (0.05 inches to 0.3 inches), or in the range of 0.127 cm to 1.016 cm (0.05inches to 0.4 inches). In one example, the surgical rasp46182-2 300 has a relatively shortened neck length L130of 0.381 cm (0.15 inches).

[0073] In reference to Figs. 15-19, another embodiment of a surgical rasp is shown and indicated generally by 400. The surgical rasp 400 includes one or more components similar to the surgical rasps 100, 200 and / or 300, including, for example, the rod 110, the head 116 having a plurality of cutting teeth 128, the shank 118, and the neck 130. The surgical rasp 400 has a neck angle α arranged in the first plane XY. The first and second cutting surfaces 124, 126 of the head 116 are also arranged in the same first plane XY. The neck angle α may be approximately 45°, e.g., 45° ± 5°. In some alternative embodiments, the neck angle α may be any suitable angle between 0° and 90°.

[0074] In reference to Figs. 20-23, another example surgical rasp 500 is shown. The surgical rasp 500 includes one or more components similar to the surgical rasp 100, 200, 300 and / or 400, including, for example, the rod 110, the head 116 having a plurality of cutting teeth 128, the shank 118, and the neck 130. The surgical rasp 500 includes the neck angle α of approximately 145°, e.g., 145° ± 5°. The neck angle α is arranged in the first plane XY and the first and second cutting surfaces 124, 126 of the head 116 are arranged in the third plane XZ, perpendicular to the first plate XY. In some embodiments, the neck angle α may be any suitable angle between 90° and 180°. The rod 110 of surgical rasp 500 is substantially straight having a rod angle β of 180°.46182-2

[0075] In reference to Figs. 24-27, another surgical rasp 600 is shown. The surgical rasp 600 includes one or more components similar to the surgical rasps 100, 200, 300, 400, and / or 500, including, for example, the rod 110, the head 116 having a plurality of cutting teeth 128, the shank 118, and the neck 130. The surgical rasp 600 includes a neck angle α and a rod angle β of 180° and the rod 110 and neck 130 of the of surgical rasp 600 is substantially straight.

[0076] Figures 28-30 show enlarged views of another embodiment of an example shank 650 suitable for use with any of the surgical rasps shown in Figures 1-27. The shank 650 may include one or more features similar to shank 118, such as rod 160, key tab 162 and / or the key channel 166. The shank 650 further includes a second key channel 652. The second key channel 652 may be formed on a side of the rod 160 opposite (e.g., diametrically opposite to) the key channel 166. The second key channel 652 and the key channel 166 may be generally the same shape, e.g., having the same depth and / or width. As mentioned above, in alternative embodiments, the shank 118 or shank 650 may include any suitable key features that are sized and shaped complementary to corresponding mating key features on a drive mechanism 708 of a pre- existing powered reciprocating surgical tool.

[0077] In reference to Fig. 32, an example surgical saw, indicated by 700, may be used with any surgical rasp described herein, e.g., surgical rasps 100, 200, 300, 400, 500, and / or 600, shown and described in reference to Figs. 1-27. The saw includes a body 702 having a handle 704 and a head 706, and a reciprocating46182-2 drive mechanism 708 engaged with a motor 710 disposed within the body 702. The saw includes one or more user inputs 712, e.g., buttons, triggers, switches, etc., which may be selected by a practitioner to turn on / off the motor 710, adjust a reciprocating speed of the motor 710, adjust the reciprocating motion of the motor 710, e.g., translation or rotation, and the like. The drive mechanism 708 includes one or more key features, not shown, sized and shaped complementary too, and engageable with, the one or more key features of the shank 118 or shank 650, e.g., the key tab 162, the key channel 166, and / or the second key channel 652. The saw further includes a chuck 714, defining an adjustable aperture 716.

[0078] The surgical rasps described herein, e.g., surgical rasps 100, 200, 300, 400, 500, and / or 600 are selectively removably engaged with the drive mechanism 708 by inserting at least a section of the shank 118 or shank 650 through the aperture 716 and engaging the key features of the shank 118 or shank 650 with the complementary key features of the drive mechanism 708.

[0079] In alternative embodiments, the surgical rasps described herein may be selectively connectable to any suitable surgical saw enabled to provide reciprocating motion to the surgical rasps causing the cutting surfaces 124, 126 of the surgical rasp to shave a bone surface during an orthopedic surgery. As mentioned above, the key features of the shank 118 may have any suitable shape, placement, and / or46182-2 configuration to be complementary to the key features of a suitable surgical saw.

[0080] Figure 33 is an example method 800 for using any of the surgical rasps described above, e.g., surgical rasps 100, 200, 300, 400, 500, and / or 600. The surgical rasps may be used to shave and / or shape a bone surface during any suitable orthopedic surgery. In some embodiments, the surgical rasps may be used during a spinal fusion surgery, in which the surgical rasp may be used to clear a disc space between adjacent vertebrae and / or the surgical rasp may be used for decortication of an end plate of a vertebrae.

[0081] The method 800 includes engaging 802 key features of the shank 118 of the surgical rasp with complementary key features on the drive mechanism 708 of the reciprocating tool 700. The method may include inserting the shank 118 through the aperture 716 and adjusting the chuck 714 to engage a distal end of the surgical rasp, e.g., the rod 160 and / or chamfer 180.

[0082] In some embodiments, the method 800 includes creating 804 an incision on an anterior side of a patient, e.g., on an abdomen or chest of the patient.

[0083] The method includes inserting 805 the head 116 and at least a portion of the rod 110 into the insertion site and through the thoracic or abdominal cavity into proximity to a vertebral bone surface and / or within a disc space. The method includes positioning 808 a cutting surface in contact with a vertebral bone surface. The surgical rasp may have a sufficient overall length, e.g., the length of the rod 110 and / or length of46182-2 head 116, to extend through a depth of a thoracic or abdominal cavity to reach the vertebrae bone surface from the incision site. In some embodiments, the surgical rasp has a sufficient length such that no section of the tool 700, e.g., the chuck 714 of the tool 700, will need to be passed through the insertion site.

[0084] The method includes selecting 810 the user input 712 of the reciprocating tool 700, causing the motor 710 to apply a reciprocating motion to the surgical rasp, thereby moving either of the cutting surfaces 124, 126 against the bone surface to decorticate the bone.

[0085] In some embodiments, a plurality of surgical rasps, having various sized and shaped heads 116, lengths of the rod 110, various shapes / arrangements of the cutting teeth 128, may be provided in a surgical equipment kit for an orthopedic procedure, such as an anterior approach endplate decortication during spinal fusion surgery. The surgical equipment kit may include at least one of the surgical rasps 100, 200, 300, 400, 500 and / or 600. In some embodiments, the surgical equipment kit may further include the reciprocating tool 700. The surgical equipment kit, including at least one surgical rasp described herein, enables a practitioner to select a suitable surgical rasp for a particular surgical step(s) during an orthopedic procedure, e.g., different areas / regions on the endplate may require different sized head surgical rasps. For example, a practitioner may select a surgical rasp having a large cutting area to shave a larger bone surface and, likewise, the practitioner may select a surgical rasp having a smaller cutting area to shave a smaller bone surface.46182-2 Furthermore, a practitioner may select a surgical rasp having a suitable neck angle α or rod angle β to reach a bone surface and / or to circumvent soft tissue structures which should be avoided by the cutting surfaces 124, 126.

[0086] Embodiments of the surgical rasps described herein have advantages over conventional handheld surgical rasps. For example, the surgical rasp may have a sufficient size, i.e., extended rod length and / or head length and / or cutting area, suitable for orthopedic surgical procedures, such as an anterior approach spinal fusion surgery, wherein the surgical rasp may need to extend all the way through the thoracic cavity or abdominal cavity of a patient. The surgical rasps are selectively connectable to a reciprocating saw enabling controlled and precise cutting motions while reducing or preventing practitioner fatigue.

[0087] As used herein, the terms “about,” “substantially,” “essentially” and “approximately” when used in conjunction with ranges of dimensions, concentrations, temperatures or other physical or chemical properties or characteristics is meant to cover variations that may exist in the upper and / or lower limits of the ranges of the properties or characteristics, including, for example, variations resulting from rounding, measurement methodology or other statistical variation.

[0088] When introducing elements of the present disclosure or the embodiment(s) thereof, the articles “a,” “an,” “the,” and "said" are intended to mean that there are one or more of the elements. The46182-2 terms “comprising,” “including,” “containing” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. The use of terms indicating a particular orientation (e.g., “top,” “bottom,” "side," etc.) is for convenience of description and does not require any particular orientation of the item described.

[0089] As various changes could be made in the above constructions and methods without departing from the scope of the disclosure, it is intended that all matter contained in the above description and shown in the accompanying drawing[s] shall be interpreted as illustrative and not in a limiting sense.

Claims

46182-2 WHAT IS CLAIMED IS:

1. A surgical rasp comprising: an elongate rod having a first end and an opposing second end; a shank disposed at the first end of the rod, wherein the shank is sized and shaped for removable engagement with a drive assembly of a reciprocating saw; and a rasp head coupled to the second end of the rod, the rasp head having a first side and an opposing second side, wherein each of the first and second side includes a cutting surface configured for at least one of bone resurfacing and bone decortication.

2. The surgical rasp of claim 1, wherein the cutting surface includes a plurality of cutting teeth.

3. The surgical rasp of claim 1, wherein the cutting surface of the first side includes a plurality of first cutting teeth arranged in a first pattern and the cutting surface of the second side includes plurality of second cutting teeth arranged in a second pattern that is the same as the first pattern.

4. The surgical rasp of claim 3, wherein each tooth of the first and second cutting teeth is pyramidal- shaped, conical-shaped, or oblique triangular prism shaped.

5. The surgical rasp of claim 1, wherein the rasp head is oriented at an oblique angle relative to the rod.46182-2 6. The surgical rasp of claim 1, wherein the rod includes a first section and a second section, wherein the second section is oriented at an oblique angle relative to the first section.

7. The surgical rasp of claim 1, wherein the surgical rasp further comprises a neck disposed between the rod and the head, wherein a cross-sectional area of the neck tapers from the second end of the rod to the head.

8. The surgical rasp of claim 1, wherein the shank includes a shaft and at least one key feature that is sized and shaped complementary to a key feature of a saw drive mechanism.

9. The surgical rasp of claim 1, wherein the head has a length in a range of 2.413 cm and 2.667 cm (0.95 and 1.05 inches) and a width in a range of 24.13 cm and 26.67 cm (0.95 and 1.05 inches).

10. The surgical rasp of claim 1, wherein the rod has a length greater than 152.4 cm (6 inches).

11. The surgical rasp of claim 1, wherein the head includes a curved front edge.

12. A surgical rasp system comprising: a reciprocating saw including a drive assembly; a surgical rasp comprising: an elongate rod having a first end and an opposing second end;46182-2 a shank disposed at the first end of the rod, wherein the shank is sized and shaped for removable engagement with the drive assembly of the reciprocating saw; and a rasp head coupled to the second end of the rod, the rasp head having a first side and an opposing second side, wherein each of the first and second side includes a cutting surface configured for at least one of bone resurfacing and bone decortication.

13. The surgical rasp system of claim 12, wherein the cutting surface includes a plurality of cutting teeth.

14. The surgical rasp system of claim 12, wherein the cutting surface of the first side includes a plurality of first cutting teeth arranged in a first pattern and the cutting surface of the second side includes plurality of second cutting teeth arranged in a second pattern that is the same as the first pattern.

15. The surgical rasp system of claim 14, wherein each tooth of the first and second cutting teeth is pyramidal-shaped, conical-shaped, or oblique triangular prism shaped.

16. The surgical rasp system of claim 12, wherein the rasp head is oriented at an oblique angle relative to the rod.

17. The surgical rasp system of claim 12, wherein the rod includes a first section and a second section, wherein the second section is oriented at an oblique angle relative to the first section.46182-2 18. The surgical rasp system of claim 12, wherein the surgical rasp further comprises a neck disposed between the rod and the head, wherein a cross- sectional area of the neck tapers from the second end of the rod to the head.

19. The surgical rasp system of claim 12, wherein the shank includes a shaft and at least one key feature that is sized and shaped complementary to a key feature of a saw drive mechanism.

20. A method of using a surgical rasp comprising: drivingly engaging a shank of a surgical rasp to a drive assembly of a reciprocating saw; inserting a head and a rod of the surgical rasp at least partially through a thoracic cavity of a patient; inserting the head into a disc space between adjacent vertebrae; positioning a plurality of cutting teeth disposed on the head against a bone surface; and activating the reciprocating saw to cause the drive assembly to move the surgical rasp in a reciprocating motion causing the plurality of cutting teeth to shave the bone surface.

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