Surgical cutting system and related accessories

Abstract

A surgical cutting system having a motor assembly including a housing, a motor, and a drive shaft driven by the motor. A surgical cutting tool having a hub is coupled to the housing. The hub has a protrusion extending away from an outer surface of the hub. A nose tube is coupled to the hub and defines a lumen. A cutting accessory is disposed within the lumen. The cutting accessory is rotated by the drive shaft of the motor assembly. A surgical driving assembly is connected to the surgical cutting tool. The assembly has a shroud defining a bore for receiving the nose tube. A handle is coupled to the shroud. A lever is pivotably coupled to the handle or the shroud. The lever engages with the protrusion to translate the cutting accessory within the bore of the shroud in response to pivoting of the lever.

Description

SURGICAL CUTTING SYSTEM AND RELATED ACCESSORIESCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The subject application claims priority to and all the benefits of U.S. Provisional Patent Application No. 63 / 645,192, filed May 10, 2024, the disclosure of which is incorporated by reference in its entirety herein.BACKGROUND

[0002] Conventional medical and surgical procedures routinely involve the use of surgical tools and instruments which allow surgeons to approach and manipulate surgical sites. Some of these medical procedures may involve surgical techniques such as drilling, shaping, or decortication of bone using a rotary instrument, where a cutting accessory, such as a high-speed bur, rotates at speeds in excess of 75k rpm to remove tissue. During use, contact between noncutting portions of the bur (e.g., a shank) and soft tissue can result in tissue wrap, in which friction between the rotating bur shank and the soft tissue causes the soft tissue to be pulled around the shank. Surgeons must be mindful to avoid unexpected tissue wrap.

[0003] While surgical cutting systems for removing tissue are routinely utilized to assist in the performance of a variety of different types of medical and / or surgical procedures, there is a need in the art to continuously improve such surgical cutting systems.SUMMARY

[0004] In a first aspect, a surgical cutting tool for a surgical system having a motor, a motor housing, a handle, and a lever pivotably coupled to the handle is provided. The surgical cutting tool includes a hub configured to be coupled to the motor housing of the surgical system. The hub has an outer surface including a planar portion. The surgical cutting tool also includes a nose tube coupled to and extending along an axis distally from the hub. The nose tube defines a lumen. The surgical cutting tool also includes a cutting accessory at least partially disposed within the lumen of the nose tube and coupled to the hub to rotate about the axis. The cutting accessory has a distal portion and a proximal portion. The distal portion has a cutting tip. The proximalportion is configured to receive torque from the motor of the surgical system. The hub includes a protrusion extending outwardly away from the planar portion of the outer surface of the hub. The protrusion is configured to be operably connected to the lever of the surgical system for permitting the hub, the nose tube, and the cutting accessory to be translated along the axis by the surgical system.

[0005] In a second aspect, a surgical cutting system is provided. The surgical cutting system includes a motor assembly having a housing, a motor disposed within the housing, and a drive shaft rotatably coupled to and driven by the motor. The surgical cutting system also includes a surgical cutting tool that includes a hub removably coupled to the motor housing, the hub has an outer surface and a protrusion extending outwardly away from the outer surface. The surgical cutting tool also includes a nose tube coupled to and extending distally from the hub. The nose tube defines a lumen. The surgical cutting tool also includes a cutting accessory at least partially disposed within the lumen of the nose tube and rotatably coupled to the hub. The cutting accessory is configured to be coupled to and receive torque from the drive shaft of the motor assembly. The surgical cutting system also includes a surgical driving assembly operably connected to the surgical cutting tool. The surgical driving assembly includes a shroud defining a bore extending along an axis for receiving the nose tube of the surgical cutting tool. The surgical driving assembly also includes a handle coupled to the shroud. The surgical driving assembly also includes a lever pivotably coupled to at least one of the handle and the shroud. The lever is releasably engageable with the protrusion of the hub of the surgical cutting tool to translate the cutting accessory along the axis within the bore of the shroud in response to the lever pivoting relative the handle.

[0006] In a third aspect, a surgical cutting system is provided. The surgical cutting system includes a surgical driving assembly. The surgical driving assembly includes a shroud extending from a proximal end to a distal end and defining a bore. The surgical driving assembly also includes a footplate extending distally from the distal end of the shroud. The footplate has a plurality of teeth. The surgical driving assembly also includes a handle coupled to the shroud. The surgical cutting system also includes a surgical cutting tool operably connected to the surgical driving assembly. The surgical cutting tool includes a hub configured to be releasably engageable with the surgical driving assembly. The surgical cutting tool also includes a nose tube shaped to be received within the bore of the shroud. The nose tube is coupled to and extends distally fromthe hub. The nose tube defines a lumen. The surgical cutting tool also includes a cutting accessory at least partially disposed within the lumen of the nose tube and rotatably coupled to the hub.

[0007] In a fourth aspect, a method of using a surgical cutting system including a surgical driving assembly having a shroud, a handle, a lever, a surgical cutting tool having a hub, a nose tube, and a cutting accessory, and a motor assembly having a motor housing and a motor is provided. The method includes introducing at least a portion of the cutting accessory and the nose tube of the surgical cutting tool into a bore of the shroud of the surgical driving assembly. The method also includes releasably engaging the lever of the surgical driving assembly with the hub of the surgical cutting tool. The method further includes energizing the motor to rotate the cutting accessory. The method also includes pivoting the lever relative to the handle of the surgical driving assembly. The method further includes translating the cutting accessory and the nose tube along an axis within the bore of the shroud.

[0008] In a fifth aspect, a surgical cutting system including a motor assembly having a motor housing, a motor, and a drive shaft driven by the motor is provided. The surgical cutting system includes a surgical driving assembly having a shroud extending along an axis from a proximal end to a distal end and defining a bore therebetween. The surgical driving assembly also includes a handle coupled to the shroud. The surgical driving assembly further includes a first lever portion pivotably coupled to the handle. The surgical driving assembly also includes a link pivotably coupled to the first lever portion. The surgical driving assembly further includes a second lever portion pivotably coupled to the link and one of the handle and the shroud. The surgical cutting system also includes a surgical cutting tool operably connected to the surgical driving assembly. The surgical cutting tool includes a hub configured to be coupled to the motor housing. The hub is releasably engageable with the first lever portion of the surgical driving assembly. The surgical cutting tool also includes a nose tube coupled to and extending distally from the hub. The nose tube defines a lumen. The surgical cutting tool also includes a cutting accessory at least partially disposed within the lumen of the nose tube and rotatably coupled to the hub. The cutting accessory has a distal portion and a proximal portion. The distal portion has a cutting tip. The proximal portion is configured to receive torque from the drive shaft of the motor assembly. The cutting accessory is moveable with the nose tube within the bore of the shroud and along the axis in response to pivoting of the first and second lever portions relative to the handle.A mechanical advantage of the lever portions, the link, and the handle acting on the surgical cutting tool is less than a factor of 1.5.

[0009] In a sixth aspect, a surgical cutting system is provided. The surgical cutting system includes a motor assembly having a housing, a motor disposed within the housing, and a drive shaft rotatably coupled to and driven by the motor. The surgical cutting system also includes an oscillatory converter coupled to the motor assembly. The oscillatory converter may include an input shaft rotatable about an axis and configured to be coupled to and receive torque from the drive shaft of the motor assembly. The oscillatory converter also includes an output shaft coaxial with the input shaft, and an oscillatory motion linkage operably coupled between the input shaft and the output shaft. The oscillatory motion linkage is configured to convert rotational motion of the input shaft to oscillating motion of the output shaft. The surgical cutting system also includes a surgical cutting tool. The surgical cutting tool includes a cutting accessory couplable to and configured to oscillate with the output shaft of the oscillatory converter. The surgical cutting system also includes a surgical driving assembly operably connected to the surgical cutting tool and the oscillatory converter. The surgical driving assembly includes a shroud defining a bore extending along an axis for receiving the surgical cutting tool. The surgical driving assembly further includes a handle coupled to the shroud. The surgical driving assembly also includes a lever pivotably coupled to at least one of the handle and the shroud. The lever is engageable with the surgical cutting tool to translate the cutting accessory along the axis within the bore of the shroud in response to the lever pivoting relative the handle.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 is a perspective view of a surgical cutting system comprising a motor assembly, an oscillatory converter, a surgical cutting tool, and a surgical driving assembly.

[0011] Figure 2 is an exploded perspective view of the surgical cutting system of Figure 1.

[0012] Figure 3 is an elevation view of the surgical cutting tool.

[0013] Figure 4 is a sectional view taken along line 4-4 of Figure 3.

[0014] Figure 5 is a perspective view of the surgical driving assembly.

[0015] Figure 6 is an elevation view of a portion of the surgical cutting tool and the surgical driving assembly in a first configuration.

[0016] Figure 7 is an elevation view of a portion of the surgical cutting tool and the surgical driving assembly in a second configuration.

[0017] Figure 8 is a sectional view of the surgical cutting tool and the surgical driving assembly in the second configuration.

[0018] Figure 9 is a sectional view of the surgical cutting tool and the surgical driving assembly in a third configuration.

[0019] Figure 10 is a sectional view of the surgical driving assembly taken along lines 10-10 of Figure 7 with a lever of the surgical driving assembly in a first configuration.

[0020] Figure 11 is a sectional view of the surgical driving assembly with the lever of the surgical driving assembly in a second configuration.

[0021] Figure 12 is an exploded view of the oscillatory converter.

[0022] Figure 13 is another exploded view of the oscillatory converter.

[0023] Figure 14 is a perspective view of a footplate of the surgical cutting tool.

[0024] Figure 15 is an elevation view of the footplate of the surgical cutting tool.DETAILED DESCRIPTION

[0025] With reference to the drawings, where like numerals are used to designate like structure throughout the several views, a surgical system, or surgical cutting system, is shown at 30 in Figures land 2 for performing an operational function associated with medical and / or surgical procedures. In the representative configuration illustrated herein, the surgical cutting system 30 is employed to facilitate cutting of a workpiece, such as tissue or a bone of a patient. To this end, the illustrated configuration of the surgical cutting system 30 comprises a motor assembly 32 including a housing 34 and a motor 36 (shown schematically) disposed within the housing 34. The surgical cutting system 30 also includes a surgical cutting tool 38. The surgical cutting tool 38 includes a hub 40 that may be removably coupled to the motor housing 34. In other configurations, the hub 40 is fixed to the motor housing 34. The surgical cutting tool 38 also includes a nose tube 42 coupled to and extending distally from the hub 40. The surgical cutting tool 38 also includes a cutting accessory 44 disposed at least partially within a lumen of the nosetube 42. The cutting accessory 44 is rotatably coupled to the hub 40. The cutting accessory 44 is configured to be coupled to and receive torque from the motor assembly 32 when the hub 40 is coupled to the motor assembly 32. In some configurations, the cutting accessory 44 is coupled to the motor assembly 32 via the coupling of the hub 40 to the motor assembly 32.

[0026] The surgical cutting system 30 further includes a surgical driving assembly 46 operably connected to the surgical cutting tool 38. More specifically, the surgical driving assembly 46 is configured to translate the surgical cutting tool 38 along an axis AX. The surgical driving assembly 46 includes a shroud 48 defining a bore 50 extending along the axis AX. The bore 50 receives the nose tube 42 of the surgical cutting tool 38. The surgical driving assembly 46 also includes a handle 52 coupled to the shroud 48. The handle 52 extends from the shroud 48 for the user to grasp. The surgical driving assembly 46 further includes a lever 54 pivotably coupled to at least one of the handle 52 and the shroud 48 and configured to pivot or otherwise move relative to the lever 54. In later configurations, where the lever 54 includes a linkage, the lever 54 refers to first lever portion 54. The lever 54 is releasably engageable with the hub 40 of the surgical cutting tool 38. Movement of the lever 54 relative to the handle 52 causes the surgical cutting tool 38, and the motor assembly 32 when the motor assembly 32 is coupled to the hub 40 of the surgical cutting tool 38, to translate along the axis AX while the nose tube 42 and the cutting accessory 44 translate within the bore 50 of the shroud 48 in response to the lever 54 pivoting relative to the handle 52. In this manner, movement of the lever 54 relative to the handle 52 moves a cutting tip 56 of the cutting accessory 44 from a first position (shown in Figure 8) with the cutting tip 56 disposed within the bore 50 to a second position (shown in Figure 9) with the cutting tip 56 disposed outside and distal relative to the bore 50. In some configurations, the surgical driving assembly 46 includes a footplate 58 extending from a distal portion of the shroud 48. The footplate 58 and the distal portion of the shroud 48 may collectively define an opening 60. In the first position, the cutting tip 56 is not disposed in the opening 60. In the second position, the cutting tip 56 is disposed within the opening 60.

[0027] The motor assembly 32 includes a drive shaft rotatably coupled to and driven by the motor 36. The motor assembly 32 is illustrated employing a tethered connection to a power source. The power source may be an external console, power supply, or the like to be coupled to the motor 36. In other configurations, it will be appreciated that a battery which could bereleasably attachable to the motor assembly 32 may operate as a power source for the motor 36. Alternatively, it will be appreciated that the motor assembly 32 may be configured in other ways, such as with an internal (e.g., non-removable) battery.

[0028] In the illustrated configuration, the power source provides power to a controller (not shown). The controller is generally configured to facilitate operation of the motor 36 in response to actuation of an input by the user, such as via electrical signals produced by magnets and Hall effect sensors. Thus, when the user actuates an input to operate the motor 36, the controller directs power from the power source to the motor 36 which, in turn, generates rotational torque employed to rotate the cutting accessory 44 of the surgical cutting tool 38, as described in greater detail below. The motor assembly 32, the power source, and the controller could each be configured in a number of different ways to facilitate generating rotational torque without departing from the scope of the present disclosure.

[0029] As shown in Figures 3 and 4, the hub 40 has an outer surface 62 and a protrusion 64 extending outwardly away from the outer or planar surface 62. The protrusion 64 may comprise a pin. The cutting accessory 44 is at least partially disposed within the lumen of the nose tube 42 and coupled to the hub 40 to rotate about the axis AX. In other words, the cutting accessory 44 translates with the hub 40 and the nose tube 42 as the cutting accessory 44 and the nose tube 42 translate within the bore 50 of the shroud 48. The cutting accessory 44 has a distal portion including the cutting tip 56 and a proximal portion configured to receive torque from the drive shaft of the motor 36 of the motor assembly 32 when the hub 40 is coupled to the motor assembly 32. In some configurations, the cutting tip 56 may comprise a bur. In other configurations, the cutting tip 56 may comprise another rotatable or oscillatory cutting implement used to cut tissue. The protrusion 64 is configured to be operably connected to the lever 54 of the surgical driving assembly 46 to permit the hub 40, the nose tube 42, and the cutting accessory 44 to be translated along the axis AX by the lever 54.

[0030] In some configurations, the protrusion 64 extends from a planar portion of the hub 40. It is contemplated that the surgical cutting tool 38 may include a single protrusion 64 extending from the hub 40. However, in the configuration illustrated in Figures 3 and 4, the surgical cutting tool 38 includes two planar surfaces 62a, 62b with protrusions 64a, 64b extending outwardly away from each of them. In other words, the planar portion 62 may be further definedas a first planar portion 62a and the protrusion 64 may be further defined as a first protrusion 64a. The outer surface of the hub 40 may further include a second planar portion 62b spaced from the first planar portion 62a and a second protrusion 64b extending outwardly away from the second planar portion 62b of the outer surface of the hub 40. In some configurations, the first and second planar portions 62a, 62b may be parallel to each other. The planar portions 62a, 62b cooperate with complementary planar portions of the lever 54 to prevent rotation of the hub 40 about the axis AX relative to the surgical driving assembly 46.

[0031] The hub 40 may define a channel 66 extending transversely through the axis AX. The cutting accessory 44 may be disposed within the channel 66. In some configurations, the proximal and distal portions of the cutting accessory 44 are coupled to and meet within the channel 66. In some configurations, the protrusions 64a, 64b are disposed proximal the channel 66.

[0032] As shown in Figures 5-9, the handle 52 extends from the shroud 48 at an oblique angle relative to the axis AX. It is contemplated that the handle 52 may extend from the shroud 48 transversely relative to the axis AX in other configurations. A thickness of the shroud 48 defined between an outer surface 68 of the shroud 48 and the bore 50 may comprise a non- uniform thickness along the length of the bore 50. The bore 50 of the shroud 48 may be sized to mitigate transverse movement of the nose tube 42 relative to the axis AX. Said differently, the inner diameter of the bore 50 may approximate the outer diameter of the nose tube 42 such that the surgical cutting tool 38 is prevented from moving in directions other than along the axis AX. Alternatively, the surgical driving assembly 46 may include bushings, bearings, ribs or another centering feature disposed within the bore 50 to mitigate transverse movement.

[0033] The lever 54 of the surgical driving assembly 46 may comprise a fork having a first tine 70a, 70b and a second tine 72a, 72b. The first and second tines 70a, 70b, 72a, 72b may define a slot 74a, 74b therebetween. The first tine 70a, 70b is distal to the second tine 72a, 72b. The first tine 70a, 70b may be longer than the second tine 72a, 72b to allow the protrusion 64 to enter into the slot 74a, 74b. The protrusion 64 of the hub 40 is rotatable and translatable within the slot 74a, 74b relative to the tines 70a, 70b, 72a, 72b as the surgical cutting tool 38 translates along the axis AX with the nose tube 42 and the cutting accessory 44 disposed within the bore 50 of the shroud 48.

[0034] As shown in Figures 6-1 1 , the surgical driving assembly 46 may include a tool release pin 76. The tool release pin 76 is moveable relative to the handle 52 to a released position in which the surgical cutting tool 38 is permitted to be decoupled from the surgical driving assembly 46. The tool release pin 76 is moveable relative to the handle 52 to an engaged position (see Figure 11) in which the surgical cutting tool 38 is prevented from being decoupled from the surgical driving assembly 46. The tool release pin 76 may be biased to the engaged position by a biasing member 78. A user may selectively move the tool release pin 76 in opposition to the biasing member 78 to the released position. The lever 54 is pivotable relative to the handle 52 to a first position in which the bore 50 of the shroud 48 receives the nose tube 42 of the surgical cutting tool 38 and the protrusion 64 is permitted to freely enter and exit the slot 74a, 74b between the tines 70a, 70b, 72a, 72b without moving the lever 54 and the tool release pin 76 is in the released position. In the first position of the lever 54, the lever 54 is blocking the tool release pin 76 from returning to the engaged position.

[0035] The lever 54 is pivotable relative to the handle 52 to a second position in which the bore 50 of the shroud 48 receives the nose tube 42 of the surgical cutting tool 38 and the protrusion 64 is received in the slot 74a, 74b between the tines 70a, 70b, 72a, 72b and the tool release pin 76 is in the engaged position. In the second position of the lever 54, the lever 54 is spaced from the tool release pin 76 so that the tool release pin 76 returns to the engaged position via the biasing member 78. The lever 54 is prevented from returning to the first position absent movement of the tool release pin 76 to the released position by the user.

[0036] In some configurations, the lever 54 may comprise a linkage to adjust the mechanical advantage of the surgical driving assembly 46 and maintaining surface area for the user to grasp. In such a configuration, the surgical driving assembly 46 further comprises a first lever portion 54 (lever 54 above) pivotably coupled to the handle 52 and a second lever portion 80 pivotably coupled to the shroud 48. In some configurations, the first lever portion 54 could also be pivotably coupled to the shroud 48 at a different location than the second lever portion 80. The surgical driving assembly 46 further comprises a link 82 pivotably coupled to the first and second lever portions 54, 80. The mechanical advantage between the first and second lever portions 54, 80, the link 82, and the handle 52 is less than a factor of 1.5. The first lever portion 54 extends from a first end to a second end and defines a length therebetween. In configurations where thefirst lever portion 54 is coupled to the handle 52, the central region of the first lever portion 54 is coupled to the handle 52 to reduce the mechanical advantage of the first lever portion 54 acting on the surgical cutting tool 38. More specifically, the first lever portion 54 is coupled to the handle 52 at a pivot point 84 disposed in a central twenty percent of the length of the first lever portion 54 between the first and second ends of the first lever portion 54.

[0037] In some configurations, an oscillatory converter 86, sometimes referred to as a converter, is coupled to and disposed between the motor assembly 32 and the hub 40 as shown in Figures 1, 12, and 13. The converter 86 converts rotational motion from the drive shaft of the motor 36 to oscillatory motion at the cutting tip 56 of the cutting accessory 44. Oscillating the cutting tip 56 of the cutting accessory 44 can mitigate instances of tissue wrap on the cutting tip 56 that may otherwise occur when the cutting tip 56 is operated conventionally to make full rotations. One exemplary converter can be found in International Publication No. WO 2024 / 239013 entitled “MOTION CONVERTING ATTACHMENT FOR A SURGICAL TOOL” published on November 21, 2024, the contents of which are incorporated by reference in their entirety herein.

[0038] Returning to Figures 12 and 13, the converter 86 comprises an input shaft 88 that is rotatable about the axis AX. The input shaft 88 is configured to be coupled to and receive torque from the drive shaft of the motor assembly 32. The converter 86 also comprises an output shaft 90 that is configured to be coupled to the proximal portion of the cutting accessory 44. In some configurations, the input and output shafts 88, 90 are coaxial. An oscillatory motion linkage 92 may be operably coupled between the input shaft 88 and the output shaft 90. The oscillatory motion linkage 92 is configured to convert the rotational motion of the input shaft 88 to oscillating motion of the output shaft 90. The oscillatory linkage 92 comprises a crank shaft 94 supported for rotation about a crank axis CX. The crank shaft 94 is rotationally coupled to the input shaft 88. The crank axis CX may be perpendicular to the axis AX. The oscillatory motion linkage 92 may also include a rocker shaft 96 supported for rotation about a rocker axis RX. The rocker shaft 96 is rotationally coupled to the output shaft 90. The oscillatory motion linkage 92 may also comprise an intermediate link 98 coupled between the crank shaft 94 and the rocker shaft 96. The oscillatory motion linkage 92 may also include an input gear 100 coupled to a distal end of the input shaft 88 and a crank gear 102 coupled to the crank shaft 94. The input and crank gears 100, 102 are engagedin meshing relationship to transfer rotational movement therebetween. The oscillatory motion linkage 92 may also include an output gear 104 coupled to a proximal end of the output shaft 90 and a rocker gear 106 coupled to the rocker shaft 96. The output gear 104 and rocker gear 106 are engaged in meshing relationship to transfer limited rotational movement therebetween. Unlike the input and crank gears 100, 102, the output and rocker gears 104, 106 do not make full rotations. In some configurations, a ratio between the input gear 100 and the crank gear 102, and between the output gear 104 and the rocker gear 106, may be approximately 2:1. While the input gear 100, the output gear 102, the crank gear 104, and the rocker gear 106 are all configured as bevel gears, other types of gears are contemplated. It is also contemplated that the surgical cutting system 30 could employ an alternative version of the converter 86 without departing from the scope of the present disclosure.

[0039] As shown in Figures 14 and 15 and described briefly above, the surgical driving assembly 46 may comprise a footplate 58 extending distally from the distal end of the shroud 48. The footplate 58 and the end of the bore 50 of the shroud 48 collectively define the opening 60 into which the cutting tip 56 is moveable to remove tissue during use. The footplate 58 is used to restrict the cutting radius of the cutting tip 56 and prevent inadvertent contact with tissue that the user does not wish to cut. The footplate 58 may have a plurality of teeth 108 for gripping tissue that is desired to be cut and preventing movement of the footplate 58 during cutting. The footplate 58 may also comprise a distal portion 110 that is smooth to present the user the ability to manipulate tissue while avoiding damaging or gripping the tissue with teeth 108.

[0040] An exemplary configuration of coupling the surgical cutting tool 38 to the surgical driving assembly 46 is described below with reference to Figures 6-11. The user may begin by introducing the cutting accessory 44 and the nose tube 42 into the bore 50 of the shroud 48 while the lever 54 is in the first position (Figure 6) with the tool release pin 76 in the released position (Figure 10). The user may then continue to axially translate the surgical cutting tool 38 without moving the lever 54 until the protrusions 64a, 64b abut the first tines 70a, 70b (Figures 7 and 8). After contact is made between the protrusion 64a, 64b and the first tines 70a, 70b, continued translation of the surgical cutting tool 38 will cause the protrusions 64a, 64b to be seated in the slots 74a, 74b between the tines 70a, 72b and rotate the lever 54 relative to the handle 52 to the second position of the lever 54 (Figure 9) with the tool release pin 76 in the engaged position(Figure 1 1 ). The second position may be referred to as a loaded position and the engaged position may be referred to as a locked position. In Figure 11, the rotation of the lever 54 back to the first position is prevented by the tool release pin 76. Owing to the bore 50 of the shroud 48 constraining transverse movement of the nose tube 42 away from the axis AX, and the tool release pin 76 preventing proximal movement of the lever 54, the protrusions 64a, 64b are prevented from exiting the slots 74a, 74b. The motor assembly 32 and / or the oscillatory converter 86 may be coupled to or detached from the hub 40 during the steps of coupling the hub 40 to the surgical driving assembly 46.

[0041] Several configurations have been discussed in the foregoing description. However, the configurations discussed herein are not intended to be exhaustive or limit the invention to any particular form. The terminology which has been 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.

[0042] It will be further appreciated that the terms “include,” “includes,” and “including” have the same meaning as the terms “comprise,” “comprises,” and “comprising.” Moreover, it will be appreciated that terms such as “first,” “second,” “third,” and the like are used herein to differentiate certain structural features and components for the non-limiting, illustrative purposes of clarity and consistency.

Claims

CLAIMSWhat is claimed is:

1. A surgical cutting tool for a surgical system having a motor, a motor housing, a handle, and a lever pivotably coupled to the handle, the surgical cutting tool comprising: a hub configured to be coupled to the motor housing of the surgical system, the hub having an outer surface including a planar portion; a nose tube coupled to and extending along an axis distally from the hub, the nose tube defining a lumen; and a cutting accessory at least partially disposed within the lumen of the nose tube and coupled to the hub to rotate about the axis, the cutting accessory having a distal portion and a proximal portion, the distal portion having a cutting tip, and the proximal portion being configured to receive torque from a motor of the surgical system; wherein the hub includes a protrusion extending outwardly away from the planar portion of the outer surface of the hub, the protrusion being configured to be operably connected to the lever of the surgical system for permitting the hub, the nose tube, and the cutting accessory to be translated along the axis by the surgical system.

2. The surgical cutting tool of claim 1, wherein the planar portion is further defined as a first planar portion and the protrusion is further defined as a first protrusion, and wherein the outer surface of the hub further includes a second planar portion spaced from the first planar portion and the hub includes a second protrusion extending outwardly away from the second planar portion of the outer surface of the hub.

3. The surgical cutting tool of claim 2, wherein the first and second planar portions are parallel to each other.

4. The surgical cutting tool of any one of claims 1-3, wherein the hub defines a channel extending transversely through the axis, and wherein the cutting accessory is disposed within the channel.

5. The surgical cutting tool of claim 4, wherein the proximal and distal portions of the cutting accessory are coupled to and meet within the channel.

6. The surgical cutting tool of claim 5, wherein the protrusion is disposed proximal the channel.

7. A surgical cutting system comprising: a motor assembly including a housing, a motor disposed within the housing, and a drive shaft rotatably coupled to and driven by the motor; a surgical cutting tool comprising, a hub removably coupled to the motor housing, the hub having an outer surface and a protrusion extending outwardly away from the outer surface, a nose tube coupled to and extending distally from the hub, the nose tube defining a lumen, and a cutting accessory at least partially disposed within the lumen of the nose tube and rotatably coupled to the hub, the cutting accessory being configured to be coupled to and receive torque from the drive shaft of the motor assembly; and a surgical driving assembly operably connected to the surgical cutting tool, the surgical driving assembly comprising, a shroud defining a bore extending along an axis for receiving the nose tube of the surgical cutting tool, a handle coupled to the shroud, and a lever pivotably coupled to at least one of the handle and the shroud, the lever releasably engageable with the protrusion of the hub of the surgical cutting tool to translate the cutting accessory along the axis within the bore of the shroud in response to the lever pivoting relative the handle.

8. The surgical cutting system of claim 7, wherein the lever comprises a fork having a first tine and a second tine, and wherein the first and second tines define a slot therebetween.

9. The surgical cutting system of claim 8, wherein the first tine is distal the second tine, and wherein the first tine is longer than the second tine.

10. The surgical cutting system of one of claims 8 and 9, wherein the protrusion is rotatable and translatable within the slot as the cutting accessory and the nose tube translate in the bore of the shroud.

11. The surgical cutting system of any one of claims 8-10, wherein the surgical driving assembly includes a tool release pin coupled to the handle and selectively moveable relative to the handle to a released position in which the surgical cutting tool is permitted to be decoupled from the surgical driving assembly and an engaged position in which the surgical cutting tool is prevented from being decoupled from the surgical driving assembly.

12. The surgical cutting system of claim 11, wherein the lever is pivotable relative to the handle to a first position in which the bore of the shroud receives the nose tube of the surgical cutting tool and the protrusion is permitted to freely enter and exit the slot between the tines without moving the lever and the tool release pin is in the released position.

13. The surgical cutting system of claim 12, wherein the lever is pivotable relative to the handle to a second position in which the bore of the shroud receives the nose tube of the surgical cutting tool and the protrusion is received in the slot between the tines and the tool release pin is in the engaged position, and wherein the lever is prevented from returning to the first position absent movement of the tool release pin to the released position.

14. The surgical cutting system of any one of claims 7-13, wherein the shroud includes an outer surface and wherein the shroud comprises a non-uniform thickness between the outer surface and the bore along the axis.

15. The surgical cutting system of any one of claims 7- 14, wherein the lever comprises a lever linkage comprising a first lever portion pivotably coupled to the handle and a second lever portion pivotably coupled to one of the handle or the shroud, and wherein the lever linkage comprises a link pivotably coupled to the first and second lever portions, and wherein a mechanical advantage of the lever portions, the link, and the handle acting on the surgical cutting tool is less than a factor of 1.5.

16. A surgical cutting system comprising: a surgical driving assembly comprising, a shroud extending from a proximal end to a distal end and defining a bore, a footplate extending distally from the distal end of the shroud, the footplate having a plurality of teeth, a handle coupled to the shroud; and a surgical cutting tool operably connected to the surgical driving assembly comprising, a hub configured to be releasably engageable with the surgical driving assembly, a nose tube shaped to be received within the bore of the shroud, the nose tube coupled to and extending distally from the hub, the nose tube defining a lumen, and a cutting accessory at least partially disposed within the lumen of the nose tube and rotatably coupled to the hub.

17. The surgical cutting system of claim 16, wherein the footplate comprises a first portion comprising a smooth surface to avoid damaging tissue.

18. The surgical cutting system of claim 17, wherein the footplate comprises a second portion comprising the plurality of teeth to grip tissue.

19. The surgical cutting system of claim 18, wherein the second portion is proximal the first portion.

20. A method of using a surgical cutting system including a surgical driving assembly having a shroud, a handle, and a lever, a surgical cutting tool having a hub, a nose tube, and a cutting accessory, and a motor assembly having a motor housing and a motor, the method comprising: introducing at least a portion of the cutting accessory and the nose tube of the surgical cutting tool into a bore of the shroud of the surgical driving assembly, releasably engaging the lever of the surgical driving assembly with the hub of the surgical cutting tool, energizing the motor to rotate the cutting accessory, pivoting the lever relative to the handle of the surgical driving assembly, and translating the cutting accessory and the nose tube along an axis within the bore of the shroud.

21. The method of claim 20, wherein the step of releasably engaging the lever further comprises abutting a protrusion extending from the hub with a first tine of a fork of the lever and receiving the protrusion in a slot defined between the first tine and a second tine of the fork of the lever.

22. The method of claim 21, wherein the step of releasably engaging the lever further comprises pivoting the lever to a loaded position such that a pin moveably coupled to the handle is permitted to return to a locked position in which removal of the protrusion from the slot in the fork is prevented.

23. A surgical cutting system including a motor assembly having a motor housing, a motor, and a drive shaft driven by the motor, the surgical cutting system comprising: a surgical driving assembly comprising, a shroud extending along an axis from a proximal end to a distal end and defining a bore therebetween, a handle coupled to the shroud, a first lever portion pivotably coupled to the handle,a link pivotably coupled to the first lever portion, and a second lever portion pivotably coupled to the link and one of the handle and the shroud; and a surgical cutting tool operably connected to the surgical driving assembly comprising, a hub configured to be coupled to the motor housing, the hub releasably engageable with the first lever portion of the surgical driving assembly, a nose tube coupled to and extending distally from the hub, the nose tube defining a lumen, a cutting accessory at least partially disposed within the lumen of the nose tube and rotatably coupled to the hub, the cutting accessory having a distal portion and a proximal portion, the distal portion having a cutting tip, and the proximal portion being configured to receive torque from the drive shaft of the motor assembly, the cutting accessory moveable with the nose tube within the bore of the shroud and along the axis in response to pivoting of the first and second lever portions relative to the handle; wherein a mechanical advantage of the lever portions, the link, and the handle acting on the surgical cutting tool is less than a factor of 1.5.

24. The surgical cutting system of claim 23, wherein the first lever portion extends from a first end to a second end and defines a length therebetween, and wherein the first lever portion is coupled to the handle at a pivot point disposed in a central twenty percent of the length of the first lever portion between the first and second ends.

25. A surgical cutting system comprising: a motor assembly including a housing, a motor disposed within the housing, and a drive shaft rotatably coupled to and driven by the motor; an oscillatory converter coupled to the motor assembly, the oscillatory converter comprising, an input shaft rotatable about an axis and configured to be coupled to and receive torque from the drive shaft of the motor assembly, an output shaft coaxial with the input shaft, andan oscillatory motion linkage operably coupled between the input shaft and the output shaft, the oscillatory motion linkage being configured to convert rotational motion of the input shaft to oscillating motion of the output shaft; a surgical cutting tool comprising a cutting accessory couplable to and configured to oscillate with the output shaft of the oscillatory converter; and a surgical driving assembly operably connected to the surgical cutting tool and the oscillatory converter, the surgical driving assembly comprising, a shroud defining a bore extending along an axis for receiving the surgical cutting tool, a handle coupled to the shroud, and a lever pivotably coupled to at least one of the handle and the shroud, the lever engageable with the surgical cutting tool to translate the cutting accessory along the axis within the bore of the shroud in response to the lever pivoting relative the handle.

26. The surgical cutting system of claim 25, wherein the oscillatory motion linkage comprises; a crank shaft supported for rotation about a crank axis and rotationally coupled to the input shaft, wherein the crank axis is perpendicular to the axis; a rocker shaft supported for rotation about a rocker axis and rotationally coupled to the output shaft; and an intermediate link coupled between the crank shaft and the rocker shaft.

27. The surgical cutting system of claim 26, wherein the oscillatory motion linkage further comprises: an input gear coupled to a distal end of the input shaft; and a crank gear coupled to the crank shaft and engaged with the input gear to transfer rotational movement therebetween.

28. The surgical cutting system of claim 27, wherein the oscillatory motion linkage further comprises:an output gear coupled to a proximal end of the output shaft; and a rocker gear coupled to the rocker shaft and engaged with the output gear- to transfer rotational movement therebetween.

29. The surgical cutting system of claim 28, wherein a ratio between the input gear’ and the crank gear is approximately 2:1, and wherein a ratio between the rocker gear and the output gear is approximately 2:1.

30. The surgical cutting system of one of claims 28 and 29, wherein the input gear, the output gear, the crank gear, and the rocker gear are bevel gears.

31. The surgical cutting system of any one of claims 25-30, wherein the surgical cutting tool further comprises: a hub removably coupled to the oscillatory converter; and a nose tube coupled to and extending distally from the hub, the nose tube defining a lumen, and wherein the cutting accessory is at least partially disposed within the lumen of the nose tube and rotatably coupled to the hub.

32. The surgical cutting system of claim 31, wherein the hub has an outer surface and a protrusion extending outwardly away from the outer surface, and wherein the lever is releasably engageable with the protrusion to translate the cutting accessory along the axis within the bore of the shroud.

33. The surgical cutting system of claim 32, wherein the lever comprises a fork having a first tine and a second tine, and wherein the first and second tines define a slot therebetween.

34. The surgical cutting system of claim 33, wherein the first tine is distal the second tine, and wherein the first tine is longer than the second tine.

35. The surgical cutting system of one of claims 33 and 34, wherein the protrusion is rotatable and translatable within the slot as the cutting accessory and the nose tube translate in the bore of the shroud.

36. The surgical cutting system of any one of claims 33-35, wherein the surgical driving assembly includes a tool release pin coupled to the handle and selectively moveable relative to the handle to a released position in which the surgical cutting tool is permitted to be decoupled from the surgical driving assembly and an engaged position in which the surgical cutting tool is prevented from being decoupled from the surgical driving assembly.

37. The surgical cutting system of claim 36, wherein the lever is pivotable relative to the handle to a first position in which the bore of the shroud receives the nose tube of the surgical cutting tool and the protrusion is permitted to freely enter and exit the slot between the tines without moving the lever and the tool release pin is in the released position.

38. The surgical cutting system of claim 37, wherein lever is pivotable relative to the handle to a second position in which the bore of the shroud receives the nose tube of the surgical cutting tool and the protrusion is received in the slot between the tines and the tool release pin is in the engaged position, and wherein the lever is prevented from returning to the first position absent movement of the tool release pin to the released position.

39. The surgical cutting system of any one of claims 25-38, wherein the shroud includes an outer surface and wherein the shroud comprises a non-uniform thickness between the outer surface and the bore along the axis.

40. The surgical cutting system of any one of claims 25-39, wherein the lever comprises a lever linkage comprising a first lever portion pivotably coupled to the handle and a second lever portion pivotably coupled to one of the handle or the shroud, and wherein the lever linkage comprises a link pivotably coupled to the first and second lever portions, and wherein a mechanicaladvantage of the lever portions, the link, and the handle acting on the surgical cutting tool is less than a factor of 1.5.

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