Patent Publication Number: US-11389176-B2

Title: Reciprocating surgical saw blade

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     The present application is a continuation of and claims priority to U.S. application Ser. No. 15/202,167, filed on Jul. 5, 2016, which claims priority to U.S. Provisional patent application 62/188,245, filed on Jul. 2, 2015, and entitled “Wear Reducing Cutting System,” both of which are herein incorporated by reference as if fully set forth in this description. 
    
    
     FIELD OF THE PRESENT DISCLOSURE 
     This present disclosure relates to surgical cutting system and components. More specifically, the present disclosure relates to a reciprocating surgical saw blade that prevents abrasions that may occur between a reciprocating surgical saw blade and a cutting guide slot, thereby helping to ensure bone cutting precision while also reducing undesired surgical debris. 
     BACKGROUND 
     Orthopedic related surgeries often require repositioning/partial removal of bone. One of the commonly used tools to cut or prepare the bone is a reciprocating surgical saw blade. This practice is more common in a joint replacement surgery. A joint replacement surgery is a procedure in which the arthritic or dysfunctional joint surface is replaced with an orthopedic prosthesis. Joint replacement is considered as a treatment when there is severe joint pain or dysfunction is not alleviated by less-invasive therapies. 
     In a joint replacement surgery, a reciprocating saw blade is one of the various instruments which are used for cutting the bone. The saw blades have teeth on their cutting edge so as to facilitate cutting through the bone. During such a surgery, the reciprocating a saw blade is fitted in a motor driven power tool to cut the measured section of the bone. The saw blade when connected to a motor driven power tool may oscillate in a back and forth and sideways oscillating motion. To enhance precision in cutting the measured section of the bone, the saw blade is used in conjunction with a cutting guide that is fixed or pinned around the target anatomy so that the bone is precisely cut along the lines of the slot. 
     The surgeon performs the surgical procedure by sequentially inserting the saw blade in the slot. Once the blade is inserted in the slot, the saw is actuated by the power tool. In this manner the surgeon is able to cut the bone along the precisely defined lines along which the bone is to be separated. The blade cuts the bone where its motion range is constrained by the walls of metal cutting guide slot. Such an interface of the blade and walls of the cutting guide slot gives rise to friction which can increase the heat and debris, thereby affecting the outcome of the surgery. Debris generated increases the potential of osteolysis and eventually bone loss around the affected region. Friction may also unnecessarily consume the power supplied to the saw blade. The wearing of the blade can also widen the slot thereby affecting the accuracy of the cut. This means that the slot and/or blade must be repaired or replaced with a new one which in turn may again affect the accuracy and also increase the overall cost. In the long run, excessive wear may affect the accuracy of the cutting guide, in which case life of the cutting guide is compromised. 
     In certain orthopedic procedures, the instruments used to resect bone can produce instances where particulate metal debris can be formed by the action of passing a reciprocating or oscillating surgical saw blade through a cutting guide. Even though steps are taken to ensure that dissimilar metals and coatings are used, there is still a propensity for both microscopic and macroscopic metal debris to form. This debris can find its way into the joint cavity/capsule of the patient. This debris will then be present in the patient post-surgery, where it may have a possibility of becoming lodged in either bone tissue or soft tissue in the knee joint, or where the saw was utilized. The local effect of metal debris that remains in the patient can eventually lead to osteolysis and implant loosening or bone resorption. 
     There is, therefore, a general need to reduce undesired debris that can be generated during a surgical procedure while also maintaining accuracy and precision in the cutting of the measured section of the bone during an orthopedic surgery. There is also a general need to reduce friction at the interface between the blade and the walls of cutting guide slot used during an orthopedic surgery, thereby reducing undesired metal particles so as to prevent osteolysis. 
     SUMMARY 
     In one arrangement, a reciprocating surgical saw blade is provided. The reciprocating surgical saw blade comprises, a distal portion, a proximal portion, and a main body extending from the distal portion to the proximal portion. The main body comprising an upper surface and a lower surface, and a first outer edge extending from the upper surface to the lower surface of the main body, and a second outer edge extending from the upper surface to the lower surface of the main body. A biocompatible polymer disposed along at least one of the upper surface, the lower surface, the first outer edge, or the second outer edge of the main body of the reciprocating surgical saw blade. 
     In one reciprocating surgical saw blade arrangement, the biocompatible polymer comprises a sheath that is disposed along the upper surface, the lower surface, the first outer edge, and the second outer edge of the main body of the reciprocating surgical saw blade. In one arrangement, the sheath extends from the distal portion to the proximal portion of the reciprocating surgical saw blade. As just one example, the sheath may comprise a solid sheath that extends from the distal portion to the proximal portion of the reciprocating surgical saw blade. 
     In one reciprocating surgical saw blade arrangement, either the upper surface or the lower surface of the main body of the reciprocating surgical saw blade comprises at least one recessed surface, wherein the biocompatible polymer resides within the at least one recessed surface. In one example, the biocompatible polymer residing within the at least one recessed surface may be flush or may not be flush with an upper surface of the distal portion of the reciprocating surgical saw blade. In addition, the at least one recessed surface defines a plurality of cavities. 
     In one reciprocating surgical saw blade arrangement, the reciprocating surgical saw blade may comprise a cutting geometry provided along a distal end face of the distal portion of the reciprocating surgical saw blade. 
     In one reciprocating surgical saw blade arrangement, the reciprocating surgical saw blade may comprise at least one elastic barrier running along either the first outer edge or the second outer edge of the main body of the reciprocating surgical saw blade. The at least one elastic barrier may be configured to dampen a force received from the reciprocating surgical saw blade when the blade comes into contact with a cutting guide. For example, the at least one elastic barrier may extend from the distal portion to the proximal portion of the reciprocating saw blade. 
     In one reciprocating surgical saw blade arrangement, the main body of the reciprocating surgical saw blade defines a plurality of cavities, wherein each cavity extends between the upper surface and the lower surface of the main body. 
     In one reciprocating surgical saw blade arrangement, the reciprocating surgical saw blade may comprise at least one elongated cavity provided either along the upper surface or the lower surface of the main body of the reciprocating surgical saw blade, wherein the biocompatible polymer is disposed within the at least one elongated cavity. For example, the at least one elongated cavity extends between the upper surface and the lower surface of the main body. 
     In one reciprocating surgical saw blade arrangement, the biocompatible polymer provided along at least one surface of the main body of the reciprocating surgical saw blade is flush with an upper surface of the distal portion of the reciprocating surgical saw blade. 
     In one reciprocating surgical saw blade arrangement, the distal portion comprises a distal portion height H DP  that is different than a main body portion height H MB  of the main body of the reciprocating surgical saw blade. 
     In one reciprocating surgical saw blade arrangement, the reciprocating surgical saw blade may comprise a distal portion, a proximal portion, and a main body extending between the distal portion and the proximal portion. The main body may comprise an upper surface and a lower surface, and a first outer edge extending from the upper surface to the lower surface, and a second outer a second outer edge extending from the upper surface to the lower surface. The reciprocating surgical saw blade may further comprise at least one elastic barrier running along either the first outer edge or the second outer edge of the main body of the reciprocating surgical saw blade. The at least one elastic barrier is configured to dampen a force received from the reciprocating surgical saw blade when the reciprocating surgical saw blade comes into contact with a cutting guide. For example, the at least one elastic barrier may comprise an elongated slot, the elongated slot extending between the upper surface and the lower surface of the main body of the reciprocating surgical saw blade. 
     In one reciprocating surgical saw blade arrangement, the reciprocating surgical saw blade may comprise a biocompatible polymer provided along at least one of the upper surface, the lower surface, the first outer edge or the second outer edge of the main body of the reciprocating surgical saw blade. 
     In one reciprocating surgical saw blade arrangement, the reciprocating surgical saw blade may comprise, either the upper surface or the lower surface of the main body of the reciprocating surgical saw blade comprises at least one recessed surface, wherein the biocompatible polymer resides within the at least one recessed surface. As just one example, the biocompatible polymer residing within the at least one recessed surface may or may not be flush with an upper surface of the distal portion of the reciprocating surgical saw blade. 
     In one reciprocating surgical saw blade arrangement, at least one recessed surface defines a plurality of cavities. 
     The disclosed reciprocating surgical saw blade arrangements provide numerous additions and enhancements. For example, disclosed surgical blade arrangements enable a reciprocating surgical blade to have less contact with another metal surfaces, such as a metal surface provided by cut guides. In addition, disclosed surgical blade arrangements also help to mitigate impact related damage or metal debris, from orthopedic cut guides. Typically, the use of oscillating surgical saw blades results in certain friction wear of the broad contact surfaces. This broad contact can develop microscopic metal debris that can be seen by the naked eye in the form of black smudges on the patient&#39;s resected bone tissue. Also, there is a tendency for the rigid metal edges of the saw blade to impact upon the interior edges of cut guide. This can potentially develop a buildup of burrs that can detach from the cut guides and end up in the patient. 
     The disclosed reciprocating surgical blade saw arrangements limits this with a twofold approach. First, in one reciprocating surgical blade saw arrangement, there is a thin layer of a biocompatible polymer or other friction and wear reducing coating, but not limited to, that acts as an intermediate friction reducing layer. When contact between the surgical blade saw and guide occurs, and wear of one or both also will typically occur, it is on behalf of the biocompatible polymer layer instead of the metal material that the saw blade is comprised of. In one arrangement, the biocompatible polymer layer may also wrap around to the edges of the saw blade, where the biocompatible polymer can act as a buffer to the impact forces created by the oscillation of the blade in the cut guide. 
     In an alternative arrangement, this impact buffering could also be achieved with a narrow slot or a plurality of slots running down the outboard edges of the reciprocating saw blade main body. These slots would create a thin area on the edge of the reciprocating saw blade that could compress and rebound to limit the impact force of the blade edge within the cut guide. 
     The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the figures and the following detailed description. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Exemplary embodiments are described herein with reference to the drawings, in which: 
         FIG. 1  illustrates a surgical cutting system that includes a reciprocating saw blade in combination with a cutting guide. 
         FIG. 2  shows a top down view of a reciprocating saw blade arrangement. 
         FIG. 3  illustrates a side view of the reciprocating saw blade arrangement illustrated in  FIG. 1 . 
         FIG. 4  illustrates a close up view of a portion of the reciprocating saw blade illustrated in  FIGS. 1 and 2 . 
         FIG. 5  shows a detail view of the recess that allows for the polymer material to be flush, or even to the surface of the metal blade. Detail  1   a  is the polymer material, and detail  2   a  is the distal end portion of the reciprocating saw blade. 
         FIG. 6  illustrates a perspective view of another reciprocating saw blade arrangement. 
         FIG. 7  illustrates a perspective view of another reciprocating saw blade arrangement. 
         FIG. 8  illustrates a perspective view of yet another reciprocating saw blade arrangement. 
     
    
    
     DETAILED DESCRIPTION 
     In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are explicitly contemplated herein. 
     Generally, the present disclosure relates to a bone cutting surgical device, such as a reciprocating saw blade. The device is able to engage with powered surgical instruments via proximal connection points on the proximal end of the cutting device. Once connected, the cutting device may oscillate side to side or back and forth. In one arrangement, the device will have a sleeve comprised of a biocompatible polymer material. This friction reducing coating will act as an intermediate wear reduction surface that will mitigate the broad surface metal on metal contact that typically occurs when in use in conjunction with a cutting guide. 
     In one arrangement, the reciprocating saw blade comprises a recessed surface so that the friction reducing coating surface geometry will sit flush with the broad metal surface of the blade body. Also, the reciprocating saw blade can have a series of slots running along the outer edge of the metal body to act as an elastic barrier to dampen the force received from the metal on metal contract the cutting device receives from the metal cutting guide. This can also be enhanced, or replaced, by a side relief where the friction reducing material comprises the outer perimeter of the blade that is most likely to contact the cut guide walls with an oscillating motion. The features that reduce the blade vibration also improves accuracy of the resection. 
     For example,  FIG. 1  illustrates a surgical cutting system  100  that includes a reciprocating surgical saw blade  110  in combination with a surgical cutting guide  120 . As illustrated, the saw blade  110  has a first or distal portion or end  104 . The saw blade  110  further comprises a second end or proximal end or portion  108 . Preferably, the first end or distal end/portion  104  comprises a plurality of teeth  105 . As will be described in greater detail herein, in one preferred arrangement, the saw blade  110  comprises a biocompatible polymer  140  that is provided along at least one surface of the saw blade  110 . 
     As illustrated, prior to a cutting surgical procedure, the saw blade  110  is inserted into a cutting guide slot  150  defined by the surgical cutting guide  120 . The cutting guide slot  120  defines a top surface  122 A, a bottom surface  122 B, and two side walls  122 C,D. During a cutting procedure, a motorized tool will oscillate the saw with the cutting guide slot  120  so as to guide the saw along a targeted cut path. The oscillating motion of the saw will drive the reciprocating saw blade, and allow it to make cuts in bone tissue with the cutting geometry provided along a distal end face of the saw. This cutting geometry can vary as needed based upon the desired cutting action and force. Materials and certain procedures may dictate other changes to blade cutting geometry or thickness. 
     The proximal portion  108  of the reciprocating saw blade  110  is configured to be connected to a motor driven power tool which can be of any shape compatible with the motor driven power tool to derive the power to cut the bone. During this bone cutting procedure, interferences can occur between the inner surfaces of the cutting guide and the various surfaces of the reciprocating saw. The biocompatible polymer  140  of the blade helps to minimize friction that may be generated by the interfaces occurring between the oscillating saw blade surfaces and the inner surfaces of the cutting guide slot. 
       FIG. 2  shows a top down view of a reciprocating saw blade arrangement  200  for use with a surgical cutting system  100 , such as the surgical cutting system  100  illustrated in  FIG. 1 .  FIG. 3  illustrates a side view of the reciprocating saw blade arrangement  200  illustrated in  FIG. 1 . Referring now to  FIGS. 2 and 3 , the reciprocating saw blade arrangement  200  comprises a distal portion or a first portion  204  and a proximal portion or a second portion  208 . The reciprocating saw blade arrangement  200  further comprises a main body  210  that extends from the distal portion  204  to the proximal portion  208 . A cutting geometry  214  is provided along a distal end face  212  of the distal portion  204  of the reciprocating saw blade arrangement  200 . Such a cutting geometry  214  may comprise a plurality of cutting teeth. 
     The main body  210  comprises an upper or a top surface  220  and a lower or a bottom surface  224 . The main body  210  further also comprises a first outer edge  230  that extends from the upper surface of the main body  210  to the lower surface  224  of the main body  210 . Similarly, the main body  210  further comprises a second outer edge  236  extending from the upper surface  220  to the lower surface  224  of the main body  210 . The illustrated blade saw arrangement  200  also comprises a biocompatible polymer  240  that disposed along at least one surface of the blade saw. That is, the illustrated blade saw arrangement  200  comprises a biocompatible polymer  240  that is disposed along at least one of the upper surface  220 , the lower surface  224 , the first outer edge  230 , or the second outer edge  236  of the main body  210  of the reciprocating surgical saw blade  200 . 
     As just one example, the biocompatible polymer  240  may comprise a sheath or a prophylactic coating  246  that surrounds the main body  210  or at least a portion of the main body  210 . Such a sheath may be disposed along the both the upper surface  220 , the lower surface  224 , the first outer edge  230 , and the second outer edge  236  of the main body  210  of the reciprocating surgical saw blade  200 . Such a sheath  246  may extend along the entire length L MB    250  of the main body  210  of the surgical saw blade  200 . In one exemplary arrangement, the sheath  246  may extend from the distal portion  204  to the proximal portion  208  of the reciprocating surgical saw blade  210 . Alternative sheath arrangements may also be used. As just one example, the sheath  246  may extend only along a portion of the length L MB    250  of the main body  210 . Alternatively, one or more sheaths may be utilized along the length L MB    250  of the main body  210  of the surgical saw  200 . 
     In one exemplary arrangement, the sheath  246  comprises a solid sheath that extends from the distal portion  204  to the proximal portion  208  of the reciprocating surgical saw blade  200 . In one exemplary arrangement, the sheath  246  is flush with a top surface of the distal portion  204  of the reciprocating saw  200 . For example,  FIG. 4  illustrates a close up view of the main body  210  and the distal portion  204  of the reciprocating saw  200  illustrated in  FIGS. 2 and 3 . As illustrated, a the distal portion  204  comprises a distal portion height H DP  that is different than a main body portion height H MB  of the main body  210  of the reciprocating surgical saw blade  200 . Specifically, in one arrangement, the distal portion  204  comprises a distal portion height H DP  that is larger than a main body portion height H MB  of the main body  210  of the reciprocating surgical saw blade. As such, in this arrangement, a polymer provided along the outer surfaces of the main body  210  would then be flush with the outer surfaces of the distal portion  204 . For example,  FIG. 5  shows a detail view of the recess that allows for the polymer material to be flush, or even to the surface of the saw blade. Detail  1   a  is the polymer material  240 , and detail  2   a  is the distal end portion  204  of the reciprocating saw blade  200 . 
     In one exemplary arrangement, the main body  210  of surgical saw arrangement  200  may define a plurality of cavities. For example,  FIG. 6  illustrates an alternative surgical saw arrangement  300  comprising a plurality of cavities  302 . Similar to the arrangement  200  illustrated in  FIGS. 1 and 2 , surgical saw arrangement  300  comprises a distal portion or a first portion  304  and a proximal portion or a second portion  308 . The blade arrangement  300  further comprises a main body  310  that extends from the distal portion  304  to the proximal portion  308 . A cutting geometry  314  is provided along a distal end face  312  of the distal portion  304  of the reciprocating surgical saw blade  300 . Such a cutting geometry  314  may comprise a plurality of cutting teeth. 
     The main body  310  comprises an upper or a top surface  320  and a lower or a bottom surface  324 . The main body  310  further also comprises a first outer edge  330  that extends from the upper surface  320  of the main body  310  to the lower surface  324  of the main body  310 . Similarly, the main body  310  further comprises a second outer edge  336  extending from the upper surface  320  to the lower surface  324  of the main body  310 . The illustrated blade saw arrangement  300  also comprises a biocompatible polymer  340  that is disposed along at least one surface of the saw blade  300 . That is, the illustrated blade saw arrangement  300  comprises a biocompatible polymer  340  that is disposed along at least one of the upper surface  320 , the lower surface  324 , the first outer edge  330 , or the second outer edge  336  of the main body  310  of the reciprocating surgical saw blade  300 . In addition, the main body  310  defines a plurality of cavities  302  that extend between the upper surface  320  and the lower surface  324  of the main body  310 . As just one example, cavity  360  extends between the upper surface  320  and the lower surface  324  of the main body  310 . 
       FIG. 7  illustrates an alternative arrangement surgical saw arrangement  400 . Similar to the arrangement  200  illustrated in  FIGS. 2 and 3 , the arrangement  400  illustrated in  FIG. 7  comprises a distal portion  404 , a proximal portion  408 , a main body  410  extending from the distal portion  304  to the proximal portion  408 . The main body  410  comprises an upper surface  420  and a lower surface  424 , and a first outer edge  430  extending from the upper surface to the lower surface of the main body  410 , and a second outer edge  436  extending from the upper surface  420  to the lower surface  424  of the main body  410 . In addition, the reciprocating surgical saw blade  400  may comprise one or more recessed surfaces  470 . As illustrated, the reciprocating surgical saw blade  400  comprises two recessed surfaces  470 A,B provided along the upper or top surface  420  of the reciprocating surgical saw blade  400 . One or more recessed surfaces may also be provided along a bottom surface of the reciprocating surgical saw blade  400 . In one preferred arrangement, a biocompatible polymer  440  is provided to reside within the at least one recessed surface. 
     The biocompatible polymer  440  residing within the recessed surface or surfaces  470 A,B may or may not be flush with an upper surface of the distal portion  404  of the reciprocating surgical saw blade  400 . That is, a height defined by the biocompatible polymer  440  residing with the recessed surface  470 A,B may have a height greater than a height defined by the distal portion  404  of the reciprocating surgical saw blade  400 . One reason for providing for such a height difference is that where contact occurs between the blade and the guide (such as the guide illustrated in  FIG. 1 ), it will be the biocompatible polymer  440  that experiences friction and not the metal of the saw blade  400 . 
     In one arrangement, the recessed surface  470 A,B may also define a plurality of cavities  480 . Such cavities may aid with the formation and/or adhesion of a biocompatible polymer  440  along the surfaces of the main body  410 . 
     In one arrangement, the reciprocating surgical saw blade  400  illustrated in  FIG. 7  may further comprise at least one elastic barrier running along either the first outer edge  430  or the second outer edge  436  of the main body  410  of the reciprocating surgical saw blade  400 . For example, such the at least one elastic barrier can be configured to dampen a force received from the reciprocating surgical saw blade when the blade comes into contact with a cutting guide. 
     For example,  FIG. 8  illustrates an alternative reciprocating surgical saw blade  500  comprising at least one elastic barrier  590 . In this illustrated arrangement, three barriers  590 A,B,C are provided along a first edge  530  of the main body  510 . Similarly, three barriers  592 A,B,C are provided along a second edge  536  of the main body  510 . However, as those of ordinary skill in the art will recognize, alternative barrier arrangements may also be used. As just one example, an alternative reciprocating surgical saw blade may comprise at least one elastic barrier that extends from a distal portion  504  to a proximal portion  508  of the reciprocating saw blade  500 . 
     It should be understood that the illustrated components are intended as an example only. In other example embodiments, fewer components, additional components, and/or alternative components are possible as well. Further, it should be understood that the above described and shown embodiments of the present disclosure are to be regarded as non-limiting examples and that they can be modified within the scope of the claims. 
     While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope being indicated by the following claims, along with the full scope of equivalents to which such claims are entitled. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.