Patent Description:
Traditionally, oscillating saw blades, including sagittal saw blades, for surgical applications are manufactured in one piece and preferably made from steel. The saw blades are manufactured using manufacturing methods such as punching, laser cutting, bending, grinding, etching, stamping, etc. and have a wide variety of shapes and geometries.

Sagittal saw blades are often used for osteotomies, wherein the sagittal saw cuts in the same plane as the body of the instrument.

Traditional saw blades are commonly characterized by having more weight with increasing length, width and thickness, which leads to increased noise and vibration levels, as well as to a higher mechanical load on the transmission system, e.g., the handpiece. However, a certain length and thickness is indispensable for the intended use of the saw blades to be fulfilled. <CIT> provides a surgical saw blade according to the preamble of claim <NUM>. <CIT>, <CIT>, <CIT>, <CIT> and <CIT> are examples of other prior art saw blades.

A brief summary of various exemplary embodiments is presented below. Some simplifications and omissions may be made in the following summary, which is intended to highlight and introduce some aspects of the various exemplary embodiments, but not to limit the scope of the invention. Detailed descriptions of an exemplary embodiment adequate to allow those of ordinary skill in the art to make and use the inventive concepts will follow in later sections.

Various embodiments disclosed herein relate to a saw blade that includes a blade body having a top surface and a bottom surface, wherein the blade body at least partially includes a composite material, a cutting edge on a distal end of the blade body, and a coupling on a proximal end of the blade body configured to connect the blade body to a handpiece adapted to oscillate the blade body.

Various embodiments further relate to a saw blade, wherein the saw blade further includes at least two of the materials selected from a group that includes steel, polymer, titanium and ceramic materials.

Various embodiments further relate to a saw blade, wherein at least one of the top surface and the bottom surface of the blade body includes an inlay portion including a composite material, such as a matrix material, a plastic material, a filling material and/ or a carbon fiber fabric material.

Various embodiments further relate to a saw blade system, wherein the composite inlay portion includes a plurality of holes extending along a longitudinal axis of the blade body.

Various embodiments further relate to a saw blade system, wherein the composite inlay portion is surrounded by a metal frame, such as a steel frame.

Various embodiments further relate to a saw blade, wherein the blade body and coupling both include a composite material.

In order to better understand various exemplary embodiments, reference is made to the accompanying drawings, wherein the saw blades illustrated by the <FIG>, <FIG> do not form part of the invention, and wherein:.

The description and drawings illustrate the principles of the invention. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described or shown herein, embody the principles of the invention. Furthermore, all examples recited herein are principally intended expressly to be for pedagogical purposes to aid the reader in understanding the principles of the invention and the concepts contributed by the inventor(s) to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions. Additionally, the term,"or," as used herein, refers to a non-exclusive or (i.e., and/or), unless otherwise indicated (eg. ,"or else" or"or in the alternative").

The present disclosure provides for a hybrid saw blade <NUM> manufactured from a combination of different materials. The weight and rigidity of the blade body <NUM> of the saw blade <NUM> is optimized in such a way that the vibration and noise load on the user as well as the mechanical load on any attached handpiece (transmission system) of an oscillating saw blade system are as low as possible without negatively affecting clinical output.

<FIG> illustrates an embodiment of the saw blade <NUM>. The saw blade <NUM> includes a coupling <NUM> at a proximal end <NUM>. In this embodiment, the coupling <NUM> includes a plurality of holes <NUM> and a U-shaped cutout <NUM> configured to connect a blade body <NUM> to a handpiece <NUM>, shown in <FIG>. However, the coupling <NUM> may be configured in any geometry, including those shown in <FIG>, that allows for attachment of the blade body <NUM> to a handpiece <NUM>. The blade body <NUM>, may also be configured in any geometry, including those shown in <FIG>, that allows for optimal weight and rigidity of the saw blade <NUM>. The handpiece <NUM> is adapted to oscillate the blade body <NUM>. The saw blade <NUM> additionally includes a cutting edge <NUM> at a distal end <NUM> including a plurality of teeth <NUM>. The blade body <NUM> may include a plurality of holes <NUM> extending longitudinally along axis X of the saw blade <NUM> that allows for mass reduction of the saw blade <NUM>, and consequent decrease in vibration, noise load, and mechanical load of the saw blade <NUM>.

<FIG> illustrates a top view of another embodiment of the saw blade <NUM> that includes a continuous blade body <NUM>, wherein the blade body <NUM> includes a top surface <NUM> that is manufactured from a different material than the coupling <NUM> and the cutting edge <NUM>.

In various embodiments, the top surface of the blade body <NUM> may be manufactured from a composite hybrid material, defined as a material made of two or more materials bonded together under high pressure and temperature. In various embodiments, the blade body <NUM> may include a carbon composite material. Suitable carbon composite materials include a matrix material, plastic, filling material, carbon fiber fabric material or combinations thereof. In some embodiments the carbon composite material includes a carbon fiber fabric material or combinations of carbon fiber fabric materials having different strengths to achieve an optimal stiffness of the saw blade <NUM>. Suitable strength classes of the carbon fiber fabric materials include high tenacity (HT), very high tenacity (UHT), low modulus (LM), intermediate modulus (IM), high modulus (HM), ultra modulus (UM), ultra high modulus (UHM), ultra modulus strength (UMS), high modulus (HMS), and combinations thereof.

The coupling <NUM> and cutting edge <NUM> shown in <FIG> may be manufactured from a metal material such as steel, titanium, titanium/ ceramic material and combinations thereof. In various embodiments, the top surface <NUM> may be joined to the coupling <NUM> and cutting edge <NUM> using any method known in the art used to join composite and metal materials to each other. Suitable methods include bonding using adhesive resins, and the like.

<FIG> illustrates a top view of another embodiment of the saw blade <NUM>, wherein the top surface <NUM> of the blade body <NUM> includes a composite inlay portion <NUM> surrounded by a metal frame <NUM>. In this embodiment, the metal frame <NUM> protects the composite inlay portion <NUM> from damage.

<FIG> illustrates a top view of another embodiment of the saw blade <NUM>, wherein the composite inlay portion <NUM> includes a plurality of holes <NUM>, that extend along a longitudinal axis of the composite inlay portion <NUM>, for additional mass reduction.

<FIG> illustrates a top view of another embodiment of the saw blade <NUM>. In this embodiment, the coupling <NUM> is also manufactured from a composite material.

<FIG> illustrates a cross-sectional view along axis S of <FIG> of an embodiment of the blade body <NUM>. In this embodiment, the blade body <NUM> includes a metal shaft <NUM> that includes cutouts on a top surface <NUM> and an opposing bottom surface <NUM> to accommodate a first composite inlay portion <NUM> positioned on the top surface <NUM> and a second composite inlay portion <NUM> positioned opposite the first composite inlay portion <NUM> on the bottom surface <NUM>.

<FIG> illustrates a cross-sectional view along axis S of <FIG> of a second embodiment of the blade body <NUM>. In this embodiment, the blade body <NUM> includes a metal shaft <NUM>. The first composite inlay portion <NUM> is layered on a top surface <NUM> of the metal shaft <NUM> so as to completely cover the top surface <NUM> and the second composite inlay portion <NUM> is layered on a bottom surface <NUM> of the metal shaft <NUM> so as to completely cover the bottom surface <NUM>.

<FIG> illustrates a cross-sectional view along axis S of <FIG> of a third embodiment of the blade body <NUM>, not forming part of the invention. In this embodiment, the blade body <NUM> includes a metal shaft <NUM> that includes a cutout to accommodate a single composite inlay portion <NUM> on a top surface <NUM>.

<FIG> illustrates a cross-sectional view along axis S of <FIG> of a fourth embodiment of the blade body <NUM>, not forming part of the invention. In this embodiment, the composite inlay portion <NUM> is surrounded on a top surface <NUM>, a bottom surface <NUM>, a first side surface <NUM> and a second side surface <NUM> by a metal shaft <NUM>.

<FIG> illustrates a cross-sectional view along axis S of <FIG> of a fifth embodiment of the blade body <NUM>, not forming part of the invention. In this embodiment, the blade body <NUM> includes a metal shaft <NUM>. The composite inlay portion <NUM> is layered on a top surface <NUM> of the metal shaft <NUM> so as to completely cover the top surface <NUM>.

<FIG> illustrates a cross-sectional view along axis S of <FIG> of a sixth embodiment of the blade body <NUM>, not forming part of the invention. In this embodiment, the blade body <NUM> includes a metal shaft <NUM>. The composite inlay portion <NUM> is layered on a bottom surface <NUM> of the metal shaft <NUM> so as to completely cover the bottom surface <NUM>.

In various embodiments, the saw blade <NUM> has a usable length of between about <NUM> to about <NUM>, a total length of about <NUM> to about <NUM> and width of about <NUM> to about <NUM>. The saw blade <NUM> preferably has a thickness of about <NUM>. The thickness of the saw blade <NUM> may be from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, or other thicknesses. The saw blade <NUM> is further characterized by a deflection value of about <NUM> to about <NUM>, and a mass moment of inertia of about <NUM>*mm2 to about <NUM>*mm2.

In various embodiments, the saw blade <NUM> is configured to limit flexing (e.g. as a result of skiving) of the saw blade <NUM> to about <NUM> or less upon application of a <NUM>. 2N load, preferably <NUM> or less, preferably about <NUM> or less. In various embodiments, the saw blade <NUM> is characterized by a weight low enough to achieve the flexing limit of <NUM> or less upon application of a <NUM>. 2N load, as described herein.

<FIG> illustrates a perspective view of an embodiment of the cutting edge <NUM>. The cutting edge <NUM> includes a plurality of teeth <NUM> and a connector <NUM> which includes a plurality of holes <NUM> distributed therethrough. During manufacture of the saw blade <NUM>, composite material may be filled into the plurality of holes <NUM> to allow for mechanical interlocking of the cutting edge <NUM> with the blade body <NUM>. In another embodiment, the connector <NUM> may be roughened and/or activated with primers or treated in such a way as to allow for mechanical interlocking of the cutting edge <NUM> with the blade body <NUM>. Suitable treatment procedures may include surface activation and/ or structuring procedures, such as plasma surface activation, UV surface cleaning and UV surface activation, plasma etching, fluorination, etching with acid to increase surface roughness, abrasive blasting to increase surface roughness, laser surface activation or structuring, or combinations thereof.

<FIG> illustrates a perspective view of another embodiment of the cutting edge <NUM>. The cutting edge <NUM> includes a plurality of teeth <NUM> and a connector <NUM>. The cutting edge <NUM> may further include a plurality of grooves <NUM> configured to aid in ejection of debris, e.g. bone chips, during use of the blade. The connector <NUM> includes a plurality of holes <NUM> distributed longitudinally along an axis of the connector <NUM> parallel to a saw blade shaft <NUM>. During manufacture of the saw blade <NUM>, composite material may be filled in the plurality of holes <NUM> to allow for mechanical interlocking of the cutting edge <NUM> with a blade body <NUM>. In this embodiment, the cutting edge <NUM> additionally includes a slot <NUM> configured to slidably receive the saw blade shaft <NUM>. <FIG> illustrate other embodiments of the cutting edge <NUM>. Additionally, in various embodiments, as shown in <FIG>, the thickness of the cutting edge <NUM> may be greater than the thickness of the blade body <NUM>.

In various embodiments, the connectors <NUM>, <NUM> may have any geometry that allows for optimal weight and rigidity of the saw blade <NUM>. In various embodiments, the plurality of teeth <NUM>,<NUM> may further have any geometry that allows for optimal functionality of the saw blade <NUM>.

<FIG> illustrates another embodiment of a saw blade <NUM> that includes a blade body <NUM> completely manufactured from a composite material, and a cutting edge <NUM>. The blade body <NUM> includes a first composite inlay portion <NUM>, layered on a top surface <NUM> of a saw blade shaft <NUM>, also manufactured from a composite material, so as to completely cover the top surface <NUM>, and a second composite inlay portion <NUM> layered on a bottom surface <NUM> of the saw blade shaft <NUM>, opposite the first composite inlay portion <NUM>, so as to completely cover the bottom surface <NUM>, as shown in more detail in <FIG>. The blade body <NUM>, further includes a coupling hole <NUM> configured to couple the saw blade <NUM> to a handpiece <NUM>, as shown in <FIG>. As shown in <FIG>, the cutting edge <NUM> is merged with the saw blade shaft <NUM> using a connector <NUM>, which is received within a U-shaped cutout <NUM>, located at a distal end of the saw blade shaft <NUM>.

In various embodiments, the first composite inlay portion <NUM> and second composite inlay portion <NUM> may be manufactured from the same composite material. In other embodiments the first composite inlay portion <NUM> and second composite inlay portion <NUM> may be manufactured using different composite materials. In various embodiments, the saw blade shaft <NUM> may alternatively be manufactured using other materials, such as unreinforced PEEK, and the like.

<FIG> illustrates another embodiment of a saw blade <NUM> that includes a coupling hole <NUM>, a blade body <NUM> and a cutting edge <NUM>. As shown in more detail in <FIG>, the blade body <NUM> includes a first composite inlay portion <NUM> layered on a top surface <NUM> of a first intermediate composite inlay portion <NUM> so as to completely cover the top surface <NUM> of the first intermediate composite inlay portion <NUM>. The blade body <NUM> additionally includes a second composite inlay portion <NUM> layered on a bottom surface <NUM> of a second intermediate composite inlay portion <NUM>, opposite the first composite inlay portion <NUM>, so as to completely cover the bottom surface <NUM> of the second intermediate composite inlay portion <NUM>. The first intermediate composite inlay portion <NUM> is layered on a top surface <NUM> of a saw blade shaft <NUM>, so as to completely cover the top surface <NUM> of the saw blade shaft <NUM>. The second intermediate composite inlay portion <NUM> is layered on a bottom surface <NUM> of the saw blade shaft <NUM>, opposite the first intermediate composite inlay portion <NUM>, so as to completely cover the bottom surface <NUM> of the saw blade shaft <NUM>. In various embodiments, the first composite inlay portion <NUM>, second composite inlay portion <NUM>, first intermediate composite inlay portion <NUM> and second intermediate composite inlay portion <NUM>, may be manufactured from the same composite material. In other embodiments, the first composite inlay portion <NUM>, second composite inlay portion <NUM>, first intermediate composite inlay portion <NUM> and second intermediate composite inlay portion <NUM> may each be manufactured from different composite materials. In various embodiments, the first composite inlay portion <NUM>, second composite inlay portion <NUM>, first intermediate composite inlay portion <NUM> and second intermediate composite inlay portion <NUM> may be manufactured using composite materials of any grade that would allow for optimal weight and rigidity of the saw blade <NUM>. In various embodiments, the saw blade shaft <NUM> may be manufactured from a metallic or composite material as described herein.

In some embodiments, the first composite inlay portion <NUM> and second composite inlay portion <NUM> may be manufactured using an unreinforced PEEK material. In some embodiments, the first intermediate composite inlay portion <NUM> and second intermediate composite inlay portion <NUM> may be manufactured using a unidirectional laminate material.

As shown in <FIG>, the saw blade shaft <NUM> may be merged with the cutting edge <NUM> by sliding the saw blade shaft <NUM> into slot <NUM> located on the connector <NUM>. In the embodiment of <FIG>, the saw blade shaft <NUM> and cutting edge <NUM> may be made from the same material, e.g. stainless steel, or different materials, e.g. aluminum, titanium, ceramic, in any combination as known to a person of ordinary skill in the art to produce a saw blade <NUM> of optimal weight and rigidity. In various embodiments, the saw blade shaft <NUM> and cutting edge <NUM> may further be heat treated independently from each other to confer optimal properties.

In various embodiments, the saw blade shaft <NUM> may be merged with the cutting edge <NUM> using any suitable merging method known to a person of ordinary skill in the art. Suitable merging methods include welding methods, such as laser welding, electrode beam welding, press-welding, friction welding and the like. In further embodiments, the plurality of holes <NUM> located on the connector <NUM> may be used for welding purposes with the saw blade shaft <NUM>, or may be used for mechanical interlocking with the composite layers <NUM>, <NUM>, <NUM>, <NUM>.

As shown in <FIG>, the saw blade shaft <NUM> and cutting edge <NUM> may also be manufactured as a single piece from the same material.

<FIG> illustrates in more detail, the saw blade <NUM> coupled using coupling hole <NUM> to a handpiece <NUM>.

Various features and structures are illustrated throughout the various embodiments described above in specific combinations of those features and structures. These various features and structures may also be combined into other specific combinations not explicitly shown.

Claim 1:
A saw blade (<NUM>) comprising
a blade body (<NUM>) having a top surface (<NUM>) and a bottom surface (<NUM>), wherein the blade body is at least partially comprised of a composite material;
a cutting edge (<NUM>) on a distal end (<NUM>) of the blade body [<NUM>]; and
a coupling (<NUM>) configured to connect the blade body [<NUM>] to a handpiece (<NUM>) adapted to oscillate the blade body [<NUM>],
wherein the top surface [<NUM>] of the blade body [<NUM>] comprises a first inlay portion [<NUM>] comprising a composite material,
characterised in that the bottom surface [<NUM>] of the blade body [<NUM>] comprises a second inlay portion [<NUM>] comprising a composite material.