Patent Description:
The invention relates generally to a driver for drilling screws at a surgical site and, more particularly, to a driver assembly with a rotatable and interchangeable cannulated driver shaft for drilling a variety of fasteners.

Screws are often used in orthopedic surgeries. A manual driver is frequently used to torque the screws to a specific position or depth at a surgical site. In a surgical environment, fluids can make gripping these drivers more difficult. This is especially true when saline, blood, and/or lipids are involved. When the conditions are such that gripping the driver is more difficult, there is less torque to drill the screws at the surgical site. As a result, the surgeon must take additional time to drill the screw to the desired depth; otherwise, the screw will be loose. When the screw is loosely drilled at the surgical site, the screw may pull from the drilling location and cause additional trauma to the patient, requiring further repair and/or surgery.

There have been attempts to provide a better grip for the driver, including altering the size of the handle. As shown in <FIG>, for example, the handle of a certain conventional driver is oversized to provide additional surface area for gripping the driver. However, the oversized handles are fixed to the driver shaft. Thus, the driver shaft is at a fixed angle relative to the handle. Therefore, the driver shaft can be difficult to manipulate for certain surgical sites and drilling locations. In addition, the driver shaft has a driving end that is fixed and cannot be interchanged to drill a variety of different types of fasteners. Further, as the driver shaft is fixed to the handle, components of traditional drivers cannot be reused or disposed. <CIT> discloses an example of such a conventional T-handle driver.

Therefore, there is a need for a driver for providing additional torque at multiple angles with a variety of fasteners.

The solution to the above object is achieved by the driver assembly defined in the appended claims. The present disclosure is directed to embodiments of driver assembly with a rotatable and interchangeable cannulated driver shaft for drilling a variety of fasteners. The driver assembly can include an elongated body having a proximal end and a distal end with a first channel extending from the distal end into the elongated body and a second channel extending from a first side of the elongated body into the elongated body. The driver assembly can also include a locking mechanism connected within the elongated body. The locking mechanism is rotatable between a first configuration and a second configuration. A cannulated driver shaft is removably attached to the locking mechanism and is rotatable between the first configuration and the second configuration via the locking mechanism.

According to another aspect, the driver assembly can include an elongated body having a proximal end and a distal end. A first channel extends from the distal end into the elongated body and a second channel extends from a side of the elongated body into the elongated body. The first channel and the second channel converge at a recess in the elongated body. The driver assembly can also include a cannulated hub rotatably connected to the elongated body in the recess. The cannulated hub is rotatable between a first configuration and a second configuration and a locking mechanism integrated therewith. A cannulated driver shaft is removably attached to the locking mechanism and is rotatable between the first configuration and the second configuration via the locking mechanism.

The foregoing and other objects, features, and advantages of the invention are apparent from the following description taken in conjunction with the accompanying drawings in which:.

Aspects of the present invention and certain features, advantages, and details thereof, are explained more fully below with reference to the non-limiting examples illustrated in the accompanying drawings. Descriptions of well-known structures are omitted so as not to unnecessarily obscure the invention in detail. It should be understood, however, that the detailed description and the specific non-limiting examples, while indicating aspects of the invention, are given by way of illustration only, and are not by way of limitation. Various substitutions, modifications, additions, and/or arrangements, within the spirit and/or scope of the underlying inventive concepts will be apparent to those skilled in the art from this disclosure.

Referring now to the figures, wherein like reference numerals refer to like parts throughout, <FIG> shows an exploded view schematic representation of a driver assembly <NUM>. In the depicted embodiment, the driver assembly <NUM> comprises an elongated body <NUM> extending between a proximal end <NUM> and a distal end <NUM>. The elongated body <NUM> and any of other component parts of the driver assembly <NUM> can be composed of disposable or reusable material. Further, the driver assembly <NUM> can be manufactured or otherwise assembled to prevent or allow disassembly. The elongated body <NUM> can be ergonomically designed to improve the grip of the user on the elongated body <NUM>. In the embodiment shown in <FIG>, the elongated body <NUM> comprises a first piece <NUM> and a second piece <NUM> both sized and configured to align and connect, forming an inner volume <NUM> of the elongated body <NUM>.

Still referring to <FIG>, the second piece <NUM> of the elongated body <NUM> comprises a first channel <NUM> and a second channel <NUM> extending partially therethrough. The first and second channels <NUM>, <NUM> extend from separate exit points <NUM>, <NUM> along the elongated body <NUM> and converge at a central recess <NUM> in the second piece <NUM>, as shown. In the depicted embodiment, the first channel <NUM> extends from an exit point <NUM> at the distal end <NUM> of the second piece <NUM> and the second channel <NUM> extends from an exit point <NUM> on a first side <NUM> of the elongated body <NUM> between the proximal and distal ends <NUM>, <NUM>. In the embodiment shown in <FIG>, the first channel <NUM> extends perpendicular to the second channel <NUM>. However, other angular relationships between the first channel <NUM> and the second channel <NUM> can be implemented in the elongated body <NUM> (as should be understood by a person of ordinary skill in the art in conjunction with a review of this disclosure).

As shown in <FIG>, one or more connectors <NUM>, such as screws or dowel pins, are used to connect the first piece <NUM> and the second piece <NUM> of the elongated body <NUM> as well as other components of the driver assembly <NUM>. A cannulated hub <NUM> is sized or otherwise configured to fit into the recess <NUM> within the second piece <NUM>, and is configured to rotate a driver shaft <NUM>. The cannulated hub <NUM> is rotatable within the recess <NUM> via a locking mechanism <NUM>. The locking mechanism <NUM> can be used to hold the driver shaft <NUM> in the first configuration and the second configuration with a predetermined force that can be overcome with relatively low force (automatic spring action, or manual user actuation) to allow the driver shaft <NUM> to rotate about the cannulated hub <NUM>. In the depicted embodiment, the locking mechanism <NUM> is a spring-loaded detent; however alternative similar connectors may be used.

An alternative embodiment of the driver assembly <NUM> is shown in <FIG>. In the embodiment shown in <FIG>, the locking mechanism <NUM> can be one or more keys to be inserted into slots, a spring-loaded detent, or other known locking devices. In <FIG>, the cannulated hub <NUM> is held in the first or second configuration by a spring assembly <NUM>/<NUM>, such as a wave spring, for example. A key stock <NUM> locks the cannulated hub <NUM> in the first or second configuration.

Turning now to <FIG>, there is shown a close-up perspective view schematic representation of a cannulated hub <NUM>, according to an embodiment. In the depicted embodiment, the cannulated hub <NUM> has a circular side <NUM> and one flat side <NUM>. The flat side <NUM> comprises a threaded aperture <NUM> extending at least partially through the cannulated hub <NUM>. The threaded aperture <NUM> is sized or otherwise configured to receive the driver shaft <NUM> (<FIG>). The cannulated hub <NUM> has a first surface <NUM> and a second surface <NUM> with the circular side <NUM> and the flat side <NUM> extending therebetween. The first surface <NUM> comprises one or more detent features <NUM>. In the depicted embodiment, the first surface <NUM> comprises two detent features <NUM>. The detent features <NUM> are located on the first surface <NUM> such that they correspond to the threaded aperture <NUM> aligned with the first channel <NUM> and the second channel <NUM>. In other words, the location of the detent features <NUM> on the first surface <NUM> of the cannulated hub <NUM> depend on the desired configurations of the driver shaft <NUM> and the positioning of the first and second channels <NUM>, <NUM> (e.g., the first channel <NUM> extends at <NUM> degrees from the second channel <NUM>). Both the first surface <NUM> and the second surface <NUM> of the cannulated hub <NUM> also comprise one or more central features <NUM> extending therefrom. The central features <NUM> interact with the first piece <NUM> and second piece <NUM>, respectively, of the elongated body <NUM>. The interactions between the central features <NUM> and the first and second pieces <NUM>, <NUM> of the elongated body <NUM> allow the driver shaft <NUM> to rotate about the axis of the central features <NUM>.

An alternative embodiment of the cannulated hub <NUM> is shown in <FIG>. The cannulated hub <NUM> in <FIG> also has a first surface <NUM> and a second surface <NUM> with a circular side <NUM> and one flat side <NUM> extending therebetween. However, in the embodiment shown in <FIG>, the aperture <NUM> extending at least partially through the flat side <NUM> of the cannulated hub <NUM> is a geometric aperture <NUM>. The geometric aperture <NUM> is shaped, sized, or otherwise configured to receive a driver geometry <NUM> at a locking end <NUM> of a driver shaft <NUM> (<FIG>). _The cannulated hub <NUM> in <FIG> also has a first surface <NUM> and a second surface <NUM> with a circular side <NUM> and one flat side <NUM> extending therebetween. As shown, the first surface has one or more slot features <NUM> extending from the circular side <NUM> through at least a portion of the first surface <NUM>. The slot features <NUM> lock the driver shaft <NUM> in the first and second configurations. The slot features <NUM> extend through the first surface <NUM> up to the central feature <NUM>. In the depicted embodiment, there are four slot features <NUM>. The number of slot features <NUM> can vary based on a number of factors, such as the relative positioning of the first and second channels <NUM>, <NUM> and the desired degree of rotation of the driver shaft <NUM>. In addition, the location of the slot features <NUM> on the first surface <NUM> of the cannulated hub <NUM> depend on the desired configurations of the driver shaft <NUM> and the positioning of the first and second channels <NUM>, <NUM> (e.g., the first channel <NUM> extends at <NUM> degrees from the second channel <NUM>).

Referring briefly to <FIG>, there is shown a perspective view schematic representation of a driver shaft <NUM>, according to an embodiment. In the depicted embodiment, the driver shaft <NUM> is a cannulated driver shaft <NUM> (i.e. with a lumen <NUM> extending therethrough). The driver shaft <NUM> has a threaded locking end <NUM> which is configured to mate with or otherwise engage with the threaded aperture <NUM> (<FIG>) to secure the driver shaft <NUM> within the cannulated hub <NUM>. The driver shaft <NUM> in <FIG> also has an opposing driving end <NUM>. As shown, the driving end <NUM> has a driver geometry <NUM> to transmit torque. The driver geometry <NUM> can be hex, torque, or any other geometry required to properly transmit torque to a fastener (e.g., screw).

In an alternative embodiment of the driver shaft <NUM> shown in <FIG>, the driver shaft <NUM> comprises driver geometry <NUM> at the locking end <NUM> to mate or otherwise engage with the geometric aperture <NUM> on the flat side <NUM> of the cannulated hub <NUM>. As with the embodiment described above and shown in <FIG>, the driver shaft <NUM> of <FIG> includes the driver geometry <NUM> at the driving end <NUM>. The driver geometry <NUM>, at the locking end <NUM> and the driving end <NUM>, can be hex, torque, or any other geometry required to properly transmit torque to a fastener (e.g., screw). Also in the embodiment of <FIG>, the driver shaft <NUM> can include a driver locking feature <NUM>, which locks into the elongated body <NUM>. In the depicted embodiment, the driver locking feature <NUM> is a ring extending around the driver shaft <NUM> and abutting the locking end <NUM> of the driver shaft <NUM>. The driver shaft <NUM> locks into the elongated body <NUM> in each of the first and second configurations. The elongated body <NUM> allows for the driver shafts <NUM> to be interchanged when the cannulated hub <NUM> is rotated from the first configuration to the second configuration.

Turning to <FIG>, there is shown another exploded view schematic representation of the driver assembly <NUM>, according to an embodiment. In the depicted embodiment, the elongated body <NUM> comprises one or more relief areas <NUM> for a guide pin (not shown) and the driver shaft <NUM>. The relief areas <NUM> provide an uninterrupted space for the guide pin as the driver shaft <NUM> rotates between the first channel <NUM> and the second channel <NUM>. In the depicted embodiment, a relief area <NUM> (a quadrant stepped down from at least one other quadrant, where the channels <NUM>, <NUM> are further stepped down) is on an inner surface <NUM> of the second piece <NUM>. The first and second pieces <NUM>, <NUM> each comprise a flange (or lip) <NUM>, <NUM>, wherein the flanges <NUM>, <NUM> are configured to align and lock together, as shown in <FIG>, overcoming the spring force of the cannulated hub <NUM> while the driver assembly <NUM> is fastened together during manufacturing. The interfacing flanges <NUM>, <NUM> also prevent the first and second pieces <NUM>, <NUM> from breaking apart or otherwise separating when the driver shaft <NUM> rotates between the first and second channels <NUM>, <NUM>. The flanges <NUM>, <NUM> also simplify manufacturing by reducing the number of fasteners of the driver assembly <NUM>.

Referring now to <FIG> and <FIG>, there are shown perspective views schematic representations of the driver assembly <NUM> in the fully assembled first configuration and the second configuration, respectively, according to embodiments. As shown in <FIG>, in the first configuration, the driver shaft <NUM> extends through the first channel <NUM> in the elongated body <NUM> and out through the distal end <NUM> of the elongated body <NUM>. The driver shaft <NUM> is then rotated via the cannulated hub <NUM> through a first slot <NUM> (or other space) in the first side <NUM> of the elongated body <NUM> between the first piece <NUM> and second piece <NUM> to the second channel <NUM> in order to achieve the second configuration. <FIG> show the driver shaft <NUM> extending through the second channel <NUM> in the elongated body <NUM> and out through the first side <NUM> of the elongated body <NUM>. In embodiments depicted in <FIG>, the driver shaft <NUM> rotates <NUM> degrees between the first configuration (<FIG>) and the second configuration (<FIG>).

An alternative embodiment of the driver assembly <NUM> in the first configuration is shown in <FIG>. The elongated body <NUM> comprises an actuator <NUM> for rotating the driver shaft <NUM>. In the depicted embodiment, the actuator <NUM> is a button on an outer surface <NUM> of the first piece <NUM> of the elongated body <NUM>. By engaging the button <NUM>, the spring assembly <NUM>/<NUM> (coupled thereto) holding the cannulated hub <NUM> in either the first or second configuration is depressed to allow for rotation (automatic via a biasing member/spring, or via manual actuation) of the driver shaft <NUM> between the first and second configuration.

Turning to <FIG> and <FIG>, there are shown perspective views schematic representations of the driver assembly <NUM> in the first configuration and the second configuration, respectively, with a guide pin <NUM> inserted therethrough, according to embodiments. As shown in <FIG>, in the first configuration, a guide pin <NUM> is inserted through the proximal end <NUM> of the elongated body <NUM> and into the lumen <NUM> of the cannulated driver shaft <NUM>. As the driver shaft <NUM> extends through the first channel <NUM> and out through the distal end <NUM> of the elongated body <NUM> in the first configuration, the guide pin <NUM> also extends out of the distal end <NUM> of the elongated body <NUM>. The driver shaft <NUM> and guide pin <NUM> are then rotated via the cannulated hub <NUM> to achieve the second configuration shown in <FIG>. Upon rotation of the driver shaft <NUM> through the first slot <NUM>, the guide pin <NUM> rotates through a second slot <NUM> between the first piece <NUM> and second piece <NUM> of the elongated body <NUM> on a second side <NUM> of the elongated body <NUM>. <FIG> shows the guide pin <NUM> extending through the second slot <NUM> on the second side <NUM> of the elongated body <NUM> through the driver shaft <NUM> (in the second channel <NUM>) and out through the first side <NUM> of the elongated body <NUM>. In embodiment depicted in <FIG>, the driver shaft <NUM> and guide pin <NUM> rotate <NUM> degrees between the first configuration (<FIG>) and the second configuration (<FIG>).

All definitions, as defined and used herein, should be understood to control over dictionary definitions and/or ordinary meanings of the defined terms.

While various embodiments have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the function and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the embodiments described herein. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings is/are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims, embodiments may be practiced otherwise than as specifically described and claimed.

It will be further understood that the terms "comprise" (and any form of comprise, such as "comprises" and "comprising"), "have" (and any form of have, such as, "has" and "having"), "include" (and any form of include, such as "includes" and "including"), and "contain" (any form of contain, such as "contains" and "containing") are open-ended linking verbs. As a result, a method or device that "comprises", "has", "includes" or "contains" one or more steps or elements. Likewise, a step of method or an element of a device that "comprises", "has", "includes" or "contains" one or more features possesses those one or more features, but is not limited to possessing only those one or more features.

Claim 1:
A driver assembly (<NUM>), comprising:
an elongated body (<NUM>) having a proximal end (<NUM>) and a distal end (<NUM>);
a first channel (<NUM>) extending from the distal end (<NUM>) into the elongated body (<NUM>);
a second channel (<NUM>) extending from a first side of the elongated body (<NUM>) into the elongated body (<NUM>);
wherein the first channel (<NUM>) and the second channel (<NUM>) converge at a recess (<NUM>) in the elongated body (<NUM>);
a cannulated hub (<NUM>) rotatably connected to the elongated body (<NUM>) in the recess (<NUM>), the cannulated hub (<NUM>) rotatable between a first configuration and a second configuration;
a locking mechanism (<NUM>) integrated with the cannulated hub (<NUM>); and
a driver shaft (<NUM>) removably attached to the locking mechanism (<NUM>),
characterized in that the driver shaft (<NUM>) is cannulated and rotatable via the cannulated hub (<NUM>) between the first configuration where the cannulated driver shaft (<NUM>) extends through the first channel (<NUM>) and the second configuration where the cannulated driver shaft (<NUM>) extends through the second channel (<NUM>).