SURGICAL INSTRUMENT

Abstract: A surgical instrument apparatus (10) includes an elongated alignment rod (11) that can enable a surgeon to define alignment with a patient's long bone. An instrument block body (16) can slide upon the alignment rod (11) between its end portions (12, 13). A locking member forms a connection with the rod at a selected position along the rod. The locking member includes a cam locking arrangement (25) that rotates about a pivot (24) on the instrument body. The cam has a handle portion or arm (28) that enables a user to rotate the cam and its locking tab about its pivot. Part of the locking cam includes a locking tab having a slot (37) that extends circumferentially about ninety degrees around the pivot of the cam. The slot is positioned radially in between the pivot and the periphery of the locking member at a locking member bearing surface. The open end portion (40) of the slot communicates with the locking member periphery.

Description: SURGICAL INSTRUMENT The present invention relates to medical orthopaedic instrumentation and more particularly relates to an improved bone cutting instrument. Many orthopaedic surgical instruments require the use of an elongated rod, plate or bar for alignment purposes. During surgery, this rod can be supported in parallel relationship with a patient's long bone such as for example a patient's tibia or femur. Cutting instruments are often adjustably mounted upon such an alignment rod. It is common to attach tibial or femoral cutting blocks in a sliding manner upon an alignment rod. One of the most common methods of affixing a tibial cutting block, femoral cutting block or like orthopaedic instrumentation to an alignment rod is a threaded set screw or set bolt that is mounted at the opening in the block through which the rod is mounted. In order to tighten the instrument to a selected position on an alignment rod, the user simply tightens the bolt or set screw so that it engages the outer surface of the rod. In order to move the instrumentation with respect to the rod, the user simply loosens the bolt to disengage it from the rod. One of the problems of set screw type locking mechanisms is that they tend to loosen very easily. An improved locking mechanism would be desirable in providing a firm locking arrangement between an orthopaedic surgical instrument that is used for cutting patient's bone tissue and an elongated alignment rod. According to the invention, a surgical instrument system comprises a first surgical instrument and a second surgical instrument which is movable with respect to said first instrument; said second instrument comprising a locking member which forms a connection with said first instrument whereby to secure said second instrument in a selected position with respect to said first instrument; said locking member comprising a cam member pivotally mounted on said second instrument for rotation about said pivot; said cam member comprising a handle portion for enabling a user to rotate said cam, and a cam body portion having a bearing surface which is arranged to engage said first surgical instrument upon rotation of said cam member. The present invention provides an improved surgical instrument system comprising for example a cutting block body that slides upon an elongated linear alignment rod. A locking member carried by the block body can form a connection with the rod at a selected position along the rod. The locking member is in the form of a cam that rotates about a pivot pin on the second instrument body. The cam includes a handle portion that enables the user to rotate the cam about its pivot. The locking member also includes a bearing surface that engages the first instrument when the cam member is in a locked position. The user can apply force to the handle portion when locking the cam bearing surface to the first instrument. A portion of the cam preferably includes a slot that extends circumferentially about the pivot. The slot provides a cam locking arrangement which provides the advantage that the manufacturing tolerances of the cam arrangement are not critical to its performance . This is because the slot may allow a portion of the cam to deflect resiliently in the manner of a spring when force is applied to the bearing surface. The deflection creates a small opposing force in the cam which serves to urge the bearing surface into contact with the first instrument to provide a firm engagement between the first and second instruments to lock them into a desired position relative to each other. The slot is preferably positioned radially in between the pivot pin and the periphery of the locking member in the region of the bearing surface. The slot has a closed end portion and an open end portion. The open end portion communicates with the locking member periphery at a position which is preferably spaced away from the bearing surface. The slot preferably extends along a curved path circumferentially about the locking member so as to generally track the bearing surface in the region adjacent the bearing surface. In the preferred embodiment, the slot extends at least ninety degrees (90°) circumferentially about the pivot. The slot is preferably curved, but a portion of the slot adjacent the bearing surface can be "S" shaped. The locking member has a center of rotation defined by the pivot pin. The pivot pin extends between two flanges that are an integral portion of the second instrument. The slot is preferably very narrow (e.g. 0.014 inches thick), being between about 0.006 and 0.10 inches in thickness. The cam is preferably about one to three inches long. In the preferred embodiment, the slot is generally of a uniform thickness along its entire length. The first instrument may comprise an alignment rod which is preferably a cylindrically shaped rod having a portion that is flat. Thus, the rod provides a flat longitudinally extending linear surface thereon for receiving the bearing surface of the cam. The alignment rod can be a rectangular or square shaped plate like distal cutting block stylus. However, it should preferably have at least one flat surface. The bearing surface of the cam which engages the first instrument as the cam is rotated may be shaped to provide a peak force between the cam and the first surface which must be exceeded to move the cam to its engaged position in which the first and second instruments are locked together. This may conveniently be achieved by providing a pair of outwardly inclined surfaces, which may be generally flat, such that the peak force occurs when the intersection between the inclined surfaces bears against the first instrument. Thus, in moving from disengaged to engaged position the force required to move the cam peaks just before the fully engaged position is reached so that the locking member cannot be inadvertently moved out of the locked position without reapplying the peak force. The deflecting force on the part of the cam between the slot and the bearing surface reaches a maximum when the peak force is applied. Preferably the slot relaxes slightly from its peak deflection when the locking member is fully engaged so that the peak deflection force must again be applied to unlock the locking member. For a further understanding of the nature and objects of the present invention, reference should be had to the following detailed description of a preferred embodiment which is given as an example only, taken in conjunction with the accompanying drawings, in which like parts are given like reference numerals, and wherein: FIGURE 1 is a perspective view of the preferred embodiment of the apparatus of the present invention; FIGURE 2 is another perspective view of the preferred embodiment of the apparatus of the present invention; FIGURE 3 is a schematic view of the preferred embodiment of the apparatus of the present invention illustrating the cam locking member; FIGURE 4 is another schematic, perspective view of the preferred embodiment of the apparatus of the present invention illustrating the cam locking member; FIGURE 5 is a perspective view of the preferred embodiment of the apparatus of the present invention; FIGURE 6 is bottom schematic, partial cut away view of the preferred embodiment of the apparatus of the present invention illustrating the locking cam and its engagement with the alignment rod; FIGURE 7 is a bottom view of the preferred embodiment of the apparatus of the present invention showing the locking cam in a relaxed, unlocked position; and FIGURE 8 is a bottom plan view of the preferred embodiment of the apparatus of the present invention illustrating the locking cam in a locked, engaged position. Figures 1-2 and 5 show generally the preferred embodiment of the apparatus of the present invention designated generally by the numeral 10. Knee cutting instrumentation 10 includes an elongated linear rod 11 having end portions 12, 13, flat longitudinally extending surface 14, and instrument block body 16. Rod 11 has an elongated rod linear axis 15 that can be aligned by a surgeon with a desired bone that is to be cut as part of a surgical procedure. For example, the rod 11 and its linear axis 15 can be aligned with the central longitudinal axis of a patient's tibia or with a patient's femur. Such a rod 11 can be aligned with the mechanical axis or with the anatomical axis of a patient's bone if desired. Instrument body 16 can provide one or more cutting guide surfaces 17 thereon. These guide surfaces 17 aid a surgeon by holding a saw blade in a plane while making an appropriate cut on the patient's bone tissue such as for example a patient's proximal tibia, distal femur, or the like. Instrument block body 16 can also provide a number of openings 18 through which pins or screws can be inserted and then into underlying bone tissue. Such pins or screws are used for rigidifying the block body 16 relative to the patient's bone tissue once alignment is completed using rod 11. A plurality of bores 19, 20, 21 are provided through body 16 as shown in Figure 1. The central bore 20 is cylindrically shaped to receive and conform generally to the outer surface of rod 11. A cam locking member 25 is positioned at or near bore 20 for engaging rod 11. Instrument block body 16 provides a pair of square flanges 22, 23 that are integrally connected thereto as shown in Figures 1-2. Each flange 22, 23 has an opening that receives rod 11. Flange 23 has opening 45. Flanges 22, 23 are spanned by a pivot pin 24 that carries cam locking member 25. The flanges 22, 23 provide flat surfaces 26, 27 that are parallel positioned and accept corresponding flat surfaces 41 , 42 of cam locking member 25. During use, the surgeon slides the instrument block body 16 upon rod 11 to a desired location between the ends 12, 13 of rod 11. The surgeon then grabs a handle portion 28 of cam locking member 25 then rotates the handle 28 toward the instrument body 16 in the direction shown by curved arrow 43 in Figure 7. This causes a bearing surface 30 portion of cam locking mechanism 25 to engage the flat longitudinally extending surface 14 of rod 11 as shown in Figures 5- 6. Figures 3-4 show more particularly the construction of the cam locking member 25. Cam locking member 25 has flat parallel surfaces 41 , 42 and an elongated slot 37 that extends between surfaces 41 and 42. The slot 37 is preferably of a uniform thickness of between about 0.006 to 0.100 inches. It can be wire cut with a EDM machine. Cam locking member 25 includes a handle portion 28 with a pair of spaced apart flat surface 33, 34. A flat surface 32 is generally perpendicular to the surface 33. Flat surface 31 is angled with respect to surface 34, preferably forming an obtuse angle therewith in Figure 3. An arcuate surface defines bearing surface 30 as shown in Figure 3. The bearing surface 30 extends between edges 35, 36. The elongated slot 37 extends between closed end portion 38 and open end portion 40 as shown in Figures 3 and 4. An "S" shaped portion 39 is provided closest surface 32. Further, the "S" shaped portion 39 of slot 37 is positioned adjacent to bearing surface 30. When the surgeon rotates the handle 28 in the direction of arrow 43, the bearing surface 30 also rotates into engagement with the rod 11 and more particularly its flat surface 14. Continued rotation of the handle 28 in the direction of arrow 43 causes the bearing surface 30 to very tightly engage the surface 14 of rod 11. This action produces compression in locking member 25 between pivot pin 24, bearing surface 30 and flat surface 14. In order to minimize tolerances, the wire cut slot 37 allows a portion 44 of cam locking member 25 to flex. The portion 44 is that portion of cam locking member that is bounded by the slot 37, bearing surface 30, and surfaces 41 and 42. Bearing surface 30 is not smoothly curved. It is formed of two relatively flat surfaces 46, 47 which are outwardly inclined with respect to each other, forming an obtuse angle at their intersection point 48. As the cam handle is rotated from a disengaged position, shown in fig 7, in the direction of arrow 43 to an engaged position, sown in fig 8, surface 46 is brought into engagement with the flat surface 14 of the rod " ! 1. The force required to move the cam then increases, due to the angle of surface 46, until a peak force is reached when the cam has been rotated until intersection point 48 engages the rod. This is also the point at which maximum deflection of flex portion 44 occurs. Further rotation of the cam handle brings surface 47 into engagement with the rod which, due to its angle, allows a very small reduction of both the rotational force and deflection of flex portion 44. This ensures that the cam may not be rotated to its disengaged position without applying the peak rotational force again and therefore offers some security against unlocking the instrument inadvertantly. The present invention thus provides a simple yet reliable cam locking arrangement for locking an instrument block body 16 to an elongated alignment rod 11. The present invention solves this problem by providing a unique cam locking arrangement that allows flexibility when the surgeon desires a connection between the cam locking member 25 and the rod 11 at a particular location not withstanding imperfections in manufacture or in assembly. The following table lists the parts numbers and parts descriptions as used herein and in the drawings attached hereto. Part Number Description 10 knee cutting instrumentation 11 rod 12 end 13 end 14 flat longitudinal surface 15 rod linear axis 16 instrument body 17 cutting guide surface 18 opening 19 bore 20 bore 21 bore 22 flange 23 flange 24 pivot pin 25 cam locking member 26 flat surface 27 flat surface 28 handle 29 pivot opening 30 bearing surface 31 flat surface 32 flat surface 33 flat surface 34 flat surface 35 edge 36 edge 37 wire cut slot 38 end portion 39 S shaped portion 40 open end 41 flat surface 42 flat surface 43 arrow 44 flex portion 45 opening 46 bearing surface 47 bearing surface 48 intersection point

Claims: CLAIMS 1. A surgical instrument system comprising a first surgical instrument and a second surgical instrument which is movable with respect to said first instrument; said second instrument comprising a locking member which forms a connection with said first instrument whereby to secure said second instrument in a selected position with respect to said first instrument; said locking member comprising a cam member pivotally mounted on said second instrument for rotation about said pivot; said cam member comprising a handle portion, for enabling a user to rotate said cam, and a cam body portion having a bearing surface which is arranged to engage said first surgical instrument upon rotation of said cam member. 2. A surgical instrument as claimed in claim 1 , wherein said cam member includes a cam body portion defined by a first side and a second side and a peripheral side wall extending between said sides and further comprises a slot extending between and communicating with said first and second sides and communicating with said peripheral sidewall whereby said slot defines a portion of said cam member between said slot and the peripheral edge of said cam member which may be resiliently deflected upon application of force to the bearing surface of said cam member. 3. The surgical instrument system of claim 1 or claim 2 wherein the first and second sides of said cam body comprise opposed flat surfaces and the slot communicates with each of the flat opposed surfaces. 4. A surgical instrument system as claimed in any preceding claim wherein said slot extends about the pivot in between the pivot and the periphery of the locking member 5. A surgical instrument system as claimed in claim 4 wherein the slot extends at least ninety degrees about the pivot. 6. A surgical instrument system as claimed in any of claims 2-5 wherein the slot has a curved portion. 7. The surgical instrument system of claim 6 wherein the slot has an "S" - shaped portion. 8. The surgical instrument system of any of claims 2-7 wherein the slot is between about 0.006 and 0.100 inches in thickness. 9. A surgical instrument system as claimed in claim 8 wherein the slot is about 0.014 inches in thickness. 10. A surgical instrument as claimed in any of claims 1-9, wherein said bearing surface is located on said peripheral sidewall. 11. The surgical instrument system of any of claims 2-10 wherein said cam body portion has a bearing surface at the slot. 12. The surgical instrument system of claim 11 wherein the slot extends continuously along the bearing surface. 13. The surgical instrument system of any of claims 2-10 wherein the open end portion of the slot is spaced away from the bearing surface. 14. A surgical instrument system as claimed in any preceding claim wherein said cam member is rotatable between an engaged position, in which said bearing surface engages said first instrument and said locking member locks said second instrument in a fixed position relative to said first instrument, and a disengaged position in which said second instrument is movable with respect to said first instrument. 15. A surgical instrument system as claimed in claim 14 wherein said locking member includes indexing means to control 17 rotation of the cam member about the pivot such that the force required to rotate the cam member from said engaged position, to said disengaged position reaches a critical peak value at a selected point of rotation which must be exceeded to permit further travel of the locking member. 16. A surgical instrument system as claimed in claim 15 wherein said indexing means comprises a pair of inclined surfaces forming a part of the bearing surface of the cam and said selected point of rotation occurs when the part of the bearing surface which comprises the intersection between said inclined surfaces bears against the first instrument. 17. A surgical instrument system as claimed in either of claims 2-16 wherein said slot enables a portion of said cam member to be deflected upon rotation of the cam member towards said engaged position such that, at a selected point of rotation, the deflection of said cam member portion reaches a maximum when said cam member reaches said engaged position. 18. A surgical instrument system as claimed in claim 17, wherein said bearing surface comprises a pair of inclined surfaces and said maximum deflection occurs at the point of rotation at which the intersecting portion between said inclined surfaces bears against said first instrument. 19. A surgical instrument system as claimed in any preceding claim wherein said first instrument comprises a rod. 20. A surgical instrument system as claimed in claim 19 wherein said rod is an intramedullary alignment rod. 21. A surgical instrument system as claimed in claim 19 or 20 wherein said rod has a flat longitudinally extending rod surface thereon and said bearing surface of the cam member engages said flat surface of said rod. 22. A surgical instrument system as claimed in any preceding claim wherein said second instrument comprises a surgical cutting block.

Inventors: LACKEY JENNIFER J, MARIK GREGORY C, ROBERSON RAYMOND H, SALEHI ABRAHAM B, SCHUMACHER BRIAN, TOKISH LEONARD J, LACKEY, JENNIFER, J., MARIK, GREGORY, C., ROBERSON, RAYMOND, H., SALEHI, ABRAHAM, B., SCHUMACHER, BRIAN, TOKISH, LEONARD, J.
Applicants: SMITH & NEPHEW INC, SMITH & NEPHEW, INC.
Application year: 1997
Main classification: A61B17
IPC codes: A61B17