Abstract:
A rigid modular connector operable to attach to any type of standard male surgical feature that is suitable for large axial loads in both rotational and translational directions while providing accurate tactile feedback. The rigid modular connector includes a handle, a connector rigidly affixed to a proximal end of the handle, and a collar that may slide longitudinally about the connector. The collar may further include one or more leaf springs that are operable to pivot slightly away from or closer to the collar. When the collar slides towards the handle on the connector, the one or more leaf springs may pivot inwardly, locking the collar with the handle in an open position. When the collar slides or the collar slides towards a proximal end of the connector, the one or more leaf springs may pivot outwardly, locking the collar with the connector in a closed position.

Description:
FIELD OF THE INVENTION 
     The present disclosure relates to a modular connector operable to attach to any type of standard male surgical feature, and related methods of using a modular connector operable to attach and rotate and/or translate any type of standard male surgical feature. In an embodiment, the modular connector may allow for a rigid connection between a shaft and the connector while maintaining modularity. 
     BACKGROUND OF THE INVENTION 
     Surgeons frequently use instruments comprising a handle connected to an elongated shaft during a variety of surgical procedures. These instruments may be used, for example, to rotate a screw or to translate an instrument such as a rasp to prepare a surgical surface. 
     Often, a surgeon may need to insert one or more screws into the human body in order to stabilize or heal certain parts of the human body, especially the spinal region. These screws may include low-profile screws, pedicle screws, cervical screws, polyaxial screws, monoaxial screws, locking screws, self-drilling screws, self-locking screws, self-tapping screws, cannulated screws, hex-head screws, or screws with custom heads and/or threads. Each of these screws requires a driving tool to drive the screw into human bone. While each screw may require a unique driving tool, surgeons may prefer a modular handle that may be combined with multiple connectors and may be configured to drive a plurality of different driven elements. 
     Surgeons may also be required to prepare a surgical location for surgery. For example, in a spinal procedure, disc space may need to prepared so that an injured vertebrate disc may be repaired or removed or an artificial vertebrate disc may be inserted. In order to prepare this disc space, an handle attached to an instrument such as a curette or a rasp may be used in a translational and/or rotational motion to prepare the disc space for further surgical procedures. 
     However, conventional modular handles comprise either a connection and/or a fiddle that is not suitable for large axial loads in both rotational and translational direction, making them unsuitable for some applications where forceful action and tactile feedback are needed. These modular handles often give incorrect tactile feedback, which is critical to screw insertion and surgical surface preparation. 
     Therefore, a surgical tool operable to maintain a rigid connection between a shaft and a handle while maintaining modularity is desirable. 
     BRIEF SUMMARY 
     Disclosed herein is a rigid modular connector comprising a handle, a collar, and a connector. The handle may comprise a distal end, a proximal end, and an internal handle recess extending longitudinally within the handle from the proximal end and ending at a threaded recess. The collar may comprise a distal end, a proximal end, and an internal collar aperture extending from the distal end to the proximal end and is operable to longitudinally slide within the internal handle recess of the handle. The collar may further comprise one or more leaf springs, wherein the one or more leaf springs each may comprise one collar external capture extending from and proximal to an outer surface of the proximal end of the collar and separated by one slot on each side of the collar external capture. Each slot may extend from the proximal end of the collar substantially halfway to the distal end of the collar and extends from the outer surface of the collar to an inner surface of the collar. The connector may comprise a distal end and a proximal end and is operable to be received within the internal collar aperture of the collar and rigidly affixed within a distal end of the internal handle recess of the handle. The proximal end of the connector further may further comprise a female drive feature operable to receive a male drive feature. Advantageously, the one or more leaf springs may be operable to pivot slightly away from or closer to a center longitudinal axis defined through the internal collar aperture of the collar, thereby locking the collar with either the handle or the collar. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Embodiments are illustrated by way of example in the accompanying figures, in which like reference numbers indicate similar parts, and in which: 
         FIG. 1  illustrates a cross-sectional view of a rigid modular connector, in accordance with one embodiment of the present disclosure; 
         FIG. 2  illustrates a perspective view of a handle of the rigid modular connector of  FIG. 1 , in accordance with one embodiment of the present disclosure; 
         FIG. 3  illustrates a perspective view of a collar of the rigid modular connector of  FIG. 1 , in accordance with one embodiment of the present disclosure; 
         FIG. 4  illustrates a perspective view of a connector of the rigid modular connector of  FIG. 1 , in accordance with one embodiment of the present disclosure; 
         FIG. 5  illustrates a cross-sectional view of the internal workings of a collar and a connector of the rigid modular connector of  FIG. 1 , in accordance with one embodiment of the present disclosure; 
         FIG. 6  illustrates a profile view of the proximal end of the rigid modular connector of  FIG. 1 , in accordance with one embodiment of the present disclosure 
         FIG. 7  illustrates a profile view of the rigid modular connector of  FIG. 1  in a first, open position, in accordance with one embodiment of the present disclosure; and 
         FIG. 8  illustrates a profile view of the rigid modular connector of  FIG. 1  in a second, closed position, in accordance with one embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  illustrates a cross-sectional view of a rigid modular connector  100 , in accordance with one embodiment of the present disclosure. The rigid modular connector  100  comprises a handle  102 , a collar  104 , and a connector  106 .  FIG. 2  illustrates a perspective view of the handle  102  of the rigid modular connector  100  of  FIG. 1 , in accordance with one embodiment of the present disclosure.  FIG. 3  illustrates a perspective view of the collar  104  of the rigid modular connector  100  of  FIG. 1 , in accordance with one embodiment of the present disclosure.  FIG. 4  illustrates a perspective view of the connector  106  of the rigid modular connector  100  of  FIG. 1 , in accordance with one embodiment of the present disclosure.  FIG. 5  illustrates a cross-sectional view of the internal workings of the collar  104  and the connector  106  of the rigid modular connector  100  of  FIG. 1 , in accordance with one embodiment of the present disclosure.  FIG. 6  illustrates a profile view of the proximal end of the rigid modular connector  100  of  FIG. 1 , in accordance with one embodiment of the present disclosure. 
     As shown in  FIGS. 1 and 2 , the handle  102  may comprise a distal end  108  and a proximal end  110 . The distal end  108  of the handle  102  may be shaped to allow a physician to rotate or translate the rigid modular connector  100  in order to drive or remove a fastener (not shown) or prepare a surgical surface, respectively, coupled with the rigid modular connector  100 . In an embodiment, the distal end  108  may be longitudinally shaped with a substantially cylindrical profile and may comprise an internal recess  112  extending to one or more openings in an outer surface of the distal end  108 . In an embodiment, the internal recess  112  may extend to four longitudinal openings in the outer surface of the distal end  108  spaced approximately 90° from each other about the outer surface. The internal recess  112  may be operable to reduce the overall weight of the rigid modular connector  100  and to provide gripping locations at the one or more openings. The internal recess  112  may be shaped for aesthetic purposes. The handle  102  may also be shaped in any size and/or shape, for example, an elongated, t-shaped, ball-shaped, small, medium, large, short, long, or flat handle. 
     The proximal end  110  of the handle  102  may comprise an internal handle recess  114  operable to receive the collar  104  and the connector  106 . The size and shape of the internal handle recess  114  may be approximately the same size and shape of the collar  104 , as shown in  FIG. 3 . The internal handle recess  114  may comprise at least two inner diameters—a first, proximal diameter and a second, distal diameter, wherein the first diameter is greater than the second diameter. 
     The internal handle recess  114  may further comprise a threaded recess  116  located at a distal end of the internal handle recess  114  and operable to receive and fixedly connect with the connector  106 , wherein a diameter of the threaded recess  116  is smaller than both the first, proximal diameter and the second, distal diameter of the internal handle recess  114 . The threaded recess  116  may comprise female threads operable to mate with male threads of the connector  106 , as shown in  FIG. 4 . 
     The proximal end  110  of the handle  102  may further comprise one or more opposing slots  118  extending from an outer surface of the handle  102  through to the internal handle recess  114  substantially the entire longitudinal length of the internal handle recess  114 , starting at the proximal end  110 . The opposing slots  118  may be operable to receive one or more finger scallop tabs on the collar  104  (not shown). In an embodiment, two opposing slots  118  may be spaced approximately 180° apart from each other about the proximal end  110  of the handle  102 , although in other embodiments any number of slots  118  may be used that correspond with the number of finger scallop tabs on the collar  104 . 
     As shown in  FIGS. 1 and 3 , the collar  104  may comprise a substantially cylindrical profile shaped to be received within the internal handle recess  114  at the proximal end of the handle  102 . The collar  104  may comprise a distal end  120  and a proximal end  122 . The distal end  120  of the collar  104  may comprise one or more finger scallop tabs  124  extending from an outer surface of the distal end  120 . The one or more finger scallop tabs  124  may be operable to be received within the one or more slots  118  in the handle  102 . In an embodiment, the collar  104  may comprise two finger scallop tabs  124  spaced approximately 180° apart from each other about the distal end  120  of the collar  104 , although in other embodiments any number of finger scallop tabs  124  may be used that correspond with the number of slots  118  in the handle  102 . 
     The collar  104  may further comprise one or more leaf springs  132 , each comprising an external capture  126  and defined by two slots  127 . The slots  127  may extend from the proximal end of the collar  104  from the outer surface of the collar  104  to an inner surface of the collar  104  and extending distally substantially halfway towards the distal end of the collar  104 . The slots  127  may be located on each side and proximate to the one or more external captures  126  and may define each leaf spring  132 . Each leaf spring  132  may be operable to pivot slightly away from or closer to a center longitudinal axis defined through the internal collar aperture  114  of the collar  104 . The one or more leaf springs  132  are each operable to engage both with the handle  102  in the first, open position and engage with the connector  106  in the second, closed position. The collar  104  may be locked in both the first and second positions. In the first, open position, the leaf springs  132  may be operable to collapse inwardly, and in the second, closed position, the leaf springs  132  may be operable to expand outwardly. 
     The one or more collar external captures  126  may extend outwardly from the outer surface of the proximal end  122  of the collar  104  and may be operable to be received within the first, proximal diameter of the internal handle recess  114  of the handle  102 , while the remainder of the collar  104  may be operable to be received within the second, distal diameter of the internal handle recess  114  of the handle  102 . The one or more collar external captures  126  may each comprise a female receiving recess  131  in an inner surface of the collar external captures  126  and operable to mate with a male circumferential connector external capture lip (not shown) of the connector  106 . The one or more collar external captures  126  may each further comprise a male dome  129  extending outwardly from an outer surface of the collar external captures  126  and opposite to the female receiving recess  131 . The male domes  129  may be operable to lock with the first, proximal diameter of the internal handle recess  114  of the handle  102 . In an embodiment, the collar  104  may comprise two collar external captures  126  spaced approximately 180° apart from each other about the proximal end  122  of the collar  104 , although in other embodiments any number of collar external captures  126  may be used. 
     The collar  104  may further comprise a collar aperture  128  extending from the distal end  120  to the proximal end  122  and operable to receive the connector  106  therethrough. The collar aperture  128  may be substantially cylindrical in shape and may comprise a collar aperture diameter slightly larger than a connector  106  diameter so that the collar  104  may slide from a first, open position to a second, closed position about the connector  106 , and as discussed in more detail in relation to  FIGS. 7 and 8 . The collar aperture  128  may comprise internal female threads  130  operable to mate with male threads (not shown) of the connector  106 . The connector  106  may be operable to be received within both the collar aperture  128  and the leaf spring  132 . 
     As shown in  FIGS. 1 and 4 , the connector  106  may comprise a cannulated cylinder  134  with a distal end  136  and a proximal end  138 . At the proximal end  138 , the connector  106  may comprise a female drive feature  140  operable to receive a male drive feature (not shown) at a internal connector recess  142 . The internal connector recess  142  may be sized and shaped to receive any desirable male drive feature. An outer circumference of the female drive feature  140  may comprise a male circumferential connector external capture lip operable to be received within the female receiving recess of the one or more collar external captures  126  of the collar  104  in the second, closed position. 
     The connector  106  may comprise male threads  144  proximate to and distal of the female drive feature  140 , wherein the male threads  144  are operable to mate with the internal female threads  130  of the collar  104 . The male threads  144  may be single, double, or triple threads (leads), requiring the collar  104  to rotate various number of degrees about the connector  106  to lock or unlock the collar  104  from the connector  106 . The connector  106  may also comprise a twist-to-lock mechanism in lieu of male threads, wherein, for example, a ¼, ⅓, or ½ twist locks the collar  104  relative to the connector  106 . 
     The connector  106  may further comprise a threaded extension  146  extending from the distal end  136 . The male threads of the threaded extension  146  are operable to mate with the female threads within the threaded recess  116  of the handle  102  and fixedly connect the connector  106  to the handle  102 . 
     As shown in  FIG. 6 , the connector  106  may further comprise one or more captures  148  located within the female drive feature  140 . Each capture  148  may comprise a domed surface and a matching recess. The geometry of the domed surface may match a recess of the female drive feature  140 , thereby allowing a male drive feature (not shown) to be received therewithin. The geometry of the domed surface may further be operable to allow the leaf spring  132  to pivot outwardly during assembly and disassembly. The capture  148  and the leaf spring  132  may be shaped to receive any standard male drive feature, i.e., round, square, hex-shaped, star-shaped, etc. 
       FIG. 7  illustrates a profile view of the rigid modular connector  100  of  FIG. 1  in the first, open position, while  FIG. 8  illustrates a profile view of the rigid modular connector of  FIG. 1  in the second, closed position, in accordance with one embodiment of the present disclosure. In operation, the collar  104  is operable to longitudinally move between the first, open position proximate to the handle  102  to the second, closed position proximate to the female drive feature  140  at the proximal end of the connector  106 . To move the collar  104  from the second, closed position to the first, open position, a surgeon may use two fingers to distally pull the collar  104  at the one or more finger scallop tabs  124  so that the one or more finger scallop tabs  124  distally slide within the one or more slots  118  in the handle  102  and the collar  104  becomes assembled with the handle  102 . To move the collar  104  from the first, open position to the second, closed position, a surgeon may use two fingers to proximally push the collar  104  at the one or more finger scallop tabs  124  so that the one or more finger scallop tabs  124  proximally slide within the one or more slots  118  in the handle  102  and the collar  104  becomes assembled with the connector  106 . The amount of resistance required to assemble the collar  104  with the handle  102  in the first, open position is consistent with the amount of force used to distally pull the one or more finger scallop tabs  124 . The amount of resistance required to assemble the collar  104  with the connector  106  in the second, closed position is greater than the amount of resistance required to assemble the collar  104  with the handle  102  in the first, open position. The amount of resistance is determined by the size and engagement of the dome  129  and the female receiving recess  131  of the external captures  126 . 
     In the first, open position, the collar  104  may be substantially entirely received within the handle  102  and the collar  104  may lock to the handle  102 . When the collar  104  is locked to the handle  102 , the leaf spring  132  may be collapsed inwardly relative to the center longitudinal axis defined through the cylindrical profile of the collar  104 . When the collar  104  is unlocked, the collar  104  may be free to slide longitudinally along the connector  106 . When the collar  104  is slid proximally to the second, closed position, the collar  104  is operable to be rotated in a clockwise direction, wherein the male threads  144  of the connector  106  are operable to mate with the internal female threads  130  of the collar  104 , locking the collar  104  with the connector  106 . When the collar  104  is locked to the connector  106 , the leaf spring  132  may be advanced proximally and extended outwardly relative to the center longitudinal axis defined through the cylindrical profile of the collar  104 . In the locked position, the one or more collar external captures  126  may engage with the outer circumference of the male circumferential connector external capture lip of the connector  106 . From the locked position, the collar  104  is operable to be rotated in a counterclockwise direction, unlocking the collar  104  from the connector  106  so that the collar is free once again to slide longitudinally along the connector  106 . 
     In operation, when a male drive feature is received within the capture  148 , the capture  148  bottoms out within the within the collar aperture  128  and the collar  104  is rotated clockwise and locked with the connector  106 , the male drive feature may be locked relative to the capture  148 , thereby allowing the rigid modular connector  100  to rotate the male drive feature clockwise or counterclockwise or translate the male drive feature relative to the surgical site. 
     The dimensions of the rigid modular handle  100  may depend on the surgical procedure and the surgeon&#39;s personal preferences. The connector  106  may be sized to receive any type of standard male drive feature that can be contained within an approximately 0.2″ to 0.4″ shaft at the capture. For example, the connector  106  may be sized to receive any type of standard male drive feature that can be contained within an approximately 0.315″ (8 mm) shaft at the capture  148 . In an embodiment, the handle  102  may be approximately 5″ long from proximal end to distal end and approximately 1.125″ wide it its widest point. In an embodiment, the collar  104  may be approximately 0.875″ long from proximal end to distal end and approximately 0.625″ wide (1.5″ including finger scallop tabs  124 ). In an embodiment, the connector  106  may be approximately 2.75″ long from proximal end to distal end and approximately 0.5″ wide at the female drive feature  140  and approximately 0.375″ wide at the cannulated cylinder  134 . 
     One or more components of the rigid modular connector  100  disclosed herein may be made from any of the following materials: (a) a metal (e.g., a pure metal such as titanium and/or an alloy such as Ti—Al—Nb, TI-6Al-4V, stainless steel); (b) a plastic; (c) a fiber; (d) a polymer; or (e) any combination thereof. In an embodiment, the handle  102 , the collar  104 , and the connector  106  may each be made from stainless steel. In another embodiment, the connector  106  may be made from stainless steel while the handle  102  and the collar  104  may be made from stainless steel, silicone, titanium, or a combination thereof. The components of the rigid modular connector  100  may be sterilized after surgery and may be reused one or more times in order to save on surgical costs and/or to prevent raw material waste. 
     While various embodiments in accordance with the principles disclosed herein have been described above, it should be understood that they have been presented by way of example only, and are not limiting. Thus, the breadth and scope of the invention(s) should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the claims and their equivalents issuing from this disclosure. Furthermore, the above advantages and features are provided in described embodiments, but shall not limit the application of such issued claims to processes and structures accomplishing any or all of the above advantages. 
     It will be understood that the principal features of this disclosure can be employed in various embodiments without departing from the scope of the disclosure. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, numerous equivalents to the specific procedures described herein. Such equivalents are considered to be within the scope of this disclosure and are covered by the claims. 
     Additionally, the section headings herein are provided for consistency with the suggestions under 37 CFR 1.77 or otherwise to provide organizational cues. These headings shall not limit or characterize the invention(s) set out in any claims that may issue from this disclosure. Specifically and by way of example, although the headings refer to a “Field of Invention,” such claims should not be limited by the language under this heading to describe the so-called technical field. Further, a description of technology in the “Background of the Invention” section is not to be construed as an admission that technology is prior art to any invention(s) in this disclosure. Neither is the “Summary” to be considered a characterization of the invention(s) set forth in issued claims. Furthermore, any reference in this disclosure to “invention” in the singular should not be used to argue that there is only a single point of novelty in this disclosure. Multiple inventions may be set forth according to the limitations of the multiple claims issuing from this disclosure, and such claims accordingly define the invention(s), and their equivalents, that are protected thereby. In all instances, the scope of such claims shall be considered on their own merits in light of this disclosure, but should not be constrained by the headings set forth herein.