Patent Description:
In a surgical procedure it is sometimes necessary to use a saw to remove tissue, including bone and cartilage. Often a powered saw is used to perform this procedure. Attached to the saw is a blade. A drive assembly internal to the saw oscillates the blade in a back and forth motion. Some saws and blades are designed so that, when the saw is actuated, the blade moves back and forth along its longitudinal axis. This type of blade is known as a reciprocating saw blade. This type of blade is provided with teeth that extend outwardly from a blade body.

As the blade moves back and forth along its longitudinal axis, the blade is often subject to stress near a portion of the blade held by the saw. It is desired to reduce such stress in the blade for a given load condition.

Document <CIT> describes a surgical blade cartridge that includes a blade bar in which a rack is moveably mounted. Teeth extend outwardly from the portion of the rack disposed outside the bar. The blade bar and rack are formed with a complementary static member and a slot such that the static member seats in the slot so as to retain the rack in the bar and allow the rack to reciprocate linearly.

A surgical blade assembly for a surgical saw is defined in claim <NUM>. The surgical blade assembly includes a blade comprising a body portion having a proximal end, a distal end, and a length between the proximal and distal ends. The body portion has opposed top and bottom surfaces and opposed first and second side surfaces between the top and bottom surfaces. The blade has one or more teeth that extend outwardly from at least one of the top and bottom surfaces of the body portion. The surgical blade assembly also includes a reinforcing member comprising a body portion having a proximal end, a distal end, and a length that extends between the proximal and distal ends. The reinforcing member comprises a first arm extending from the distal end of the body portion of the reinforcing member and a second arm extending from the distal end of the body portion of the reinforcing member. The second arm is spaced from the first arm to define a receiving portion configured to receive the proximal end of the body portion of the blade. The first and second arms are configured to abut the first and second side surfaces of the body portion of the blade to act as a strut to reinforce the blade when the receiving portion receives the proximal end of the body portion of the blade.

The reinforcing member may comprise a first coupling feature, and the blade may comprise a second coupling feature. The first and second coupling features may be configured to engage each other when the receiving portion receives the proximal end of the body portion of the blade to prevent separation of the reinforcing member from the blade.

One of the first and second coupling features may comprise a projection. The other of the first and second coupling features may comprise a surface defining one of a void and a recess.

The blade may further comprise a leg extending from the proximal end of the body portion of the blade. The leg may be adjacent the body portion of the reinforcing member when the receiving portion receives the proximal end of the body portion of the blade.

The body portion of the reinforcing member may comprise the first coupling feature and the leg of the blade may comprise the second coupling feature.

The second coupling feature may comprise a projection extending from the leg. The first coupling feature may comprise a surface of the body portion of the reinforcing member defining a void to receive the projection when the receiving portion receives the proximal end of the body portion of the blade.

The leg may be further defined as a first leg. The blade may comprise a second leg extending from the proximal end of the body portion. The second leg may be spaced from the first leg to define a channel configured to receive the distal end of the body portion of the reinforcing member when the receiving portion receives the proximal end of the body portion of the blade.

The second coupling feature may comprise a projection extending from the first leg into the channel. The first coupling feature may comprise a surface of the reinforcing member that may define a void to receive the projection when the receiving portion receives the proximal end of the body portion of the blade.

The projection may have a ramped portion to permit the channel to receive the distal end of the reinforcing member. The projection may have a stepped portion configured to abut the surface of the reinforcing member defining the void to prevent the reinforcing member from being separated from the blade when the receiving portion receives the proximal end of the body portion of the blade.

At least one of the blade and the reinforcing member may comprise a mount feature to releasably attach at least one of the blade and the reinforcing member to the surgical saw.

The mount feature may comprise a protrusion extending outwardly from at least one of the leg, the body portion of the blade, the first arm, the second arm, and the body portion of the reinforcing member.

The body portion of the blade may have a distal region connecting the top surface and the bottom surface. The distal region may be disposed between the first and second side surfaces. The blade may have one or more teeth that extend outwardly from the distal region of the body portion of the blade, with the one or more teeth that extend outwardly from the distal region of the body portion of the blade being configured to permit plunge cutting.

The length of the body portion of the blade may extend along an axis. At least one of the one or more teeth that extend outwardly from the distal region of the body portion of the blade may extend in a direction substantially aligned with the axis.

The length of the body portion of the blade may extend along an axis. At least one of the one or more teeth that extend outwardly from the distal region of the body portion of the blade may have a tooth face defining a face plane and a tooth back that may define a back plane intersecting the face plane. At least one of the one or more teeth that extend outwardly from the distal region of the body portion of the blade may define a reference plane bisecting the face and back planes, with the reference plane and the axis creating an angle relative to each other that is less than thirty degrees.

The blade and the reinforcing member are perpendicular to each other when the receiving portion receives the proximal end of the body portion of the blade.

The body portion of the blade may have a first region adjacent the proximal end of the body portion of the blade. The body portion of the blade may have a second region adjacent the first region. The opposed side surfaces may define a first thickness at the first region of the body portion of the blade and a second thickness larger than the first thickness at the second region of the body portion of the blade.

The receiving portion may be adapted to accommodate the second thickness of the body portion of the blade such that the first and second arms abut the first and second side surfaces of the body portion of the blade at the second region of the body portion of the blade when the receiving portion receives the proximal end of the body portion of the blade.

At least one of the blade and the reinforcing member may comprise stainless steel.

At least one of the blade and the reinforcing member may comprise martensitic stainless steel.

At least one or more teeth may extend outwardly from the body portion of the blade such that the one or more teeth are coplanar with the body portion of the blade.

The blade may be formed by laser cutting.

Preferably, the reinforcing member is coupled mechanically to the blade without materially altering the physical properties of at least one of the reinforcing member and the blade.

According to an exemplary embodiment, a surgical blade assembly includes a blade comprising a body portion having a proximal end, a distal end, and a length between the proximal and distal ends. The body portion has opposed top and bottom surfaces and opposed first and second side surfaces between the top and bottom surfaces. The first and second side surfaces are substantially parallel and define a thickness therebetween. The blade has one or more teeth that extend outwardly from at least one of the top and bottom surfaces of the body portion. The surgical blade assembly further includes a reinforcing member comprising a body portion having a proximal end, a distal end, and a length that extends between the proximal and distal ends. The body portion of the reinforcing member has opposed top and bottom surfaces being substantially parallel and defining a thickness therebetween. The body portion of the reinforcing member is coupled to the body portion of the blade such that the thickness of the body portion of the reinforcing member, i.e., the top and bottom surfaces of the reinforcing member, and the thickness of the body portion of the blade, i.e., the first and second side surfaces of the body portion of the blade, are substantially perpendicular to each other. The reinforcing member is coupled to at least one of the first and second side surfaces of the body portion of the blade to act as a strut to reinforce the blade.

A method of coupling a surgical blade assembly to a surgical saw including a saw chuck assembly is defined in claim <NUM>. The method comprises providing the surgical blade assembly, and the method further comprising providing a blade and a reinforcing member of the surgical blade assembly. The blade provided comprises a body portion having a proximal end, a distal end, and a length between the proximal and distal ends, with the body portion having opposed first and second side surfaces. The reinforcing member provided comprises a body portion having a proximal end, a distal end, and a length that extends between the proximal and distal ends. The reinforcing member provided comprises a first arm extending from the distal end of the body portion of the reinforcing member and a second arm extending from the distal end of the body portion of the reinforcing member and being spaced from the first arm to define a receiving portion. The reinforcing member provided is coupled to the blade such that the receiving portion of the reinforcing member receives the proximal end of the blade and the first and second arms abut the first and second side surfaces of the body portion of the blade to act as a strut to reinforce the blade. The reinforcing member and the blade are coupled to the saw chuck assembly such that a portion of each of the blade and the reinforcing member are received within the saw chuck assembly.

The method of coupling further comprises orienting the body portion of the blade perpendicular relative to the body portion of the reinforcing member prior to coupling the reinforcing member to the blade.

<FIG> shows a surgical saw <NUM> including a surgical blade assembly <NUM> in accordance with an example of the present disclosure. The surgical saw <NUM> comprises a saw housing <NUM>. In one configuration, the saw housing <NUM> includes a barrel <NUM> and a handgrip <NUM> extending from the barrel <NUM>. The surgical saw <NUM> further comprises a saw chuck assembly <NUM> coupled to the barrel <NUM> of the saw housing <NUM>. The surgical blade assembly <NUM> is configured to be releasably coupled to the saw chuck assembly <NUM>.

The barrel <NUM> defines an interior of a portion of the housing <NUM>. A motor <NUM>, shown schematically in <FIG>, is disposed within the interior of the barrel <NUM>. A transmission <NUM>, also shown schematically in <FIG>, is disposed within the interior of the barrel <NUM> and operatively coupled to the motor <NUM> and the saw chuck assembly <NUM>. In one configuration, the motor <NUM> is a DC motor. A battery (not shown) is attached to the handgrip <NUM>. The battery supplies current for energization of the motor <NUM>.

A trigger assembly <NUM> is coupled to the handgrip <NUM> and includes a trigger <NUM> movable relative to the handgrip <NUM>. The trigger <NUM> is operable from a first position projecting away from the handgrip <NUM> to a second position inward of the first position. The trigger <NUM> may be operable in one or more intermediate positions between the first position and the second position. A user may grasp the handgrip <NUM> and depress the trigger <NUM> toward the second position and a biasing mechanism (not shown) such as a spring may bias the trigger <NUM> toward the first position.

Internal to the handgrip <NUM> is a control module <NUM>, shown schematically in <FIG>, coupled to the motor <NUM> and the battery. The control module <NUM> includes one or more sensors <NUM> that generate one or more energization signals responsive to actuation of the trigger <NUM>. The motor <NUM> is configured to receive the energization signals and generate rotational energy. The transmission <NUM> is configured to convert rotational energy from the motor <NUM> to reciprocal movement of the saw chuck assembly <NUM> along an axis A, and thus reciprocal movement of the surgical blade assembly <NUM> parallel to the axis A when the surgical blade assembly <NUM> is coupled to the saw chuck assembly <NUM>. More specifically, the reciprocal movement of the saw chuck assembly <NUM> and the surgical blade assembly <NUM> is a back and forth movement along the axis A.

<FIG> shows the barrel <NUM> and the handgrip <NUM> arranged in a pistol configuration with the handgrip <NUM> substantially oriented perpendicularly from the barrel <NUM>. The user may grasp the handgrip <NUM> with one or both hands, and may further support the barrel <NUM> with the other hand. In another configuration, the handgrip <NUM> is integrated with the barrel <NUM> (e.g., the handgrip <NUM> is removed to define a substantially cylindrical housing) such that the user may grasp the barrel <NUM> with one or both hands to operate the surgical saw <NUM>. In other configurations, the surgical saw <NUM> has alternative structure to enable operation of the surgical saw <NUM> to provide reciprocal motion to the saw chuck assembly <NUM> and the surgical blade assembly <NUM> when the surgical blade assembly <NUM> is coupled to the saw chuck assembly <NUM>.

As shown in <FIG>, one example of the surgical blade assembly <NUM> is illustrated. The surgical blade assembly <NUM> comprises a blade <NUM> (shown in <FIG>) and a reinforcing member <NUM> (shown in <FIG>) configured to be coupled to the blade <NUM>. The blade <NUM> includes a body portion <NUM> having a proximal end <NUM>, a distal end <NUM>, and a length defined between the proximal and distal ends <NUM>, <NUM>. The length extends along a blade axis B that is parallel to the axis A such that the saw chuck assembly <NUM> reciprocates along the blade axis B. In the illustrated configurations, referring back to <FIG>, the blade axis B is collinear to the axis A such that the saw chuck assembly <NUM> reciprocates along the axis A and the blade axis B.

As shown in <FIG>, the body portion <NUM> of the blade <NUM> has opposed top and bottom surfaces <NUM>, <NUM> defining a blade width and opposed first and second side surfaces <NUM>, <NUM> between the top and bottom surfaces <NUM>, <NUM> defining a blade thickness. The blade width is greater than the blade thickness. In one configuration the blade width is six or more times larger than the blade thickness. In other configurations the blade width is between two and six times larger than the blade thickness. In some configurations the blade thickness is uniform along the length of the body portion <NUM> of the blade <NUM>. In other configurations, the blade thickness changes along the length of the body portion <NUM> of the blade <NUM>.

The blade <NUM> also has one or more teeth <NUM> that extend outwardly from at least one of the top and bottom surfaces <NUM>, <NUM> of the body portion <NUM> of the blade <NUM>. In the configurations shown in the figures, the blade <NUM> has a plurality of teeth <NUM> that extend outwardly from both the top and bottom surfaces <NUM>, <NUM> of the body portion <NUM> of the blade <NUM>.

As shown in <FIG>, the reinforcing member <NUM> includes a body portion <NUM> having a proximal end <NUM>, a distal end <NUM>, and a length that extends between the proximal and distal ends <NUM>, <NUM>. The reinforcing member <NUM> has opposed top and bottom surfaces <NUM>, <NUM> (bottom surface <NUM> is shown in <FIG>) defining a reinforcing member thickness and opposed first and second side surfaces <NUM>, <NUM> between the top and bottom surfaces <NUM>, <NUM> defining a reinforcing member width. The reinforcing member width is greater than the reinforcing member thickness. In one configuration the reinforcing member width is six or more times larger than the reinforcing member thickness. In other configurations the reinforcing member width is between two and six times larger than the reinforcing member thickness.

The reinforcing member <NUM> includes a first arm <NUM> extending from the distal end <NUM> of the body portion <NUM> of the reinforcing member <NUM> and a second arm <NUM> extending from the distal end <NUM> of the body portion <NUM> of the reinforcing member <NUM>. The second arm <NUM> is spaced from the first arm <NUM> to define a receiving portion <NUM> configured to receive the proximal end <NUM> of the body portion <NUM> of the blade <NUM>. A proximal end of the receiving portion <NUM> may define the distal end <NUM> of the body portion <NUM>, as illustrated in <FIG>. In other words, the body portion <NUM> of the reinforcing member <NUM> may be a portion of the reinforcing member <NUM> defined between the proximal end <NUM> of the body portion <NUM> and the proximal end of the receiving portion <NUM>.

The first and second arms <NUM>, <NUM> act as a strut to reinforce the body portion <NUM> of the blade <NUM> when the receiving portion <NUM> receives the proximal end <NUM> of the body portion <NUM> of the blade <NUM>. As the blade width is larger than the blade thickness, the first and second arms <NUM>, <NUM> mitigate deflection of the body portion <NUM> of the blade <NUM> that may otherwise occur normal to the first and second side surfaces <NUM>, <NUM> of the body portion <NUM> of the blade <NUM> during reciprocation of the surgical blade assembly <NUM>. In other words, the first and second arms <NUM>, <NUM> of the reinforcing member <NUM> reduce the stress associated with whip during operation of the surgical saw <NUM>. The mitigation of deflection of the body portion <NUM> further reduces stresses associated with external forces applied to the blade <NUM>, for example, from bony anatomy during reciprocation of the surgical blade assembly <NUM> with the bony anatomy.

In one configuration, as shown in <FIG>, the first and second arms <NUM>, <NUM> are coplanar in thickness with the body portion <NUM> of the reinforcing member <NUM>. In other configurations, the first and second arms <NUM>, <NUM> are thicker than the body portion <NUM> of the reinforcing member <NUM>. In still other configurations, the first and second arms <NUM>, <NUM> are thinner than the body portion <NUM> of the reinforcing member <NUM>.

As mentioned, the reinforcing member <NUM> acts as a strut to the blade <NUM> in a direction normal the thickness. This means that contact between the blade <NUM> and the reinforcing member <NUM> occurs when the blade <NUM> is deflected. However, it may or may not include contact between the blade <NUM> and the reinforcing member <NUM> when the blade <NUM> is deflected by less than certain amounts. In the configuration shown in <FIG>, the first and second arms <NUM>, <NUM> are spaced apart from one another such that the distance between approximates the thickness of the body portion <NUM> of the blade <NUM> so that the first and second arms <NUM>, <NUM> abut the first and second side surfaces <NUM>, <NUM> of the body portion <NUM> of the blade <NUM> when the receiving portion <NUM> receives the proximal end <NUM> of the body portion <NUM> of the blade <NUM>. In other configurations, the first and second arms <NUM>, <NUM> are spaced apart from one another such that the first and second arms <NUM>, <NUM> extend adjacent to but do not directly contact at least one of the first and second side surfaces <NUM>, <NUM> of the body portion <NUM> of the blade <NUM> when the receiving portion <NUM> receives the proximal end <NUM> of the body portion <NUM> of the blade <NUM>. In this configuration, the space between at least one of the first and second arms <NUM>, <NUM> and the body portion <NUM> of the blade <NUM> when the receiving portion <NUM> receives the proximal end <NUM> of the body portion <NUM> of the blade <NUM> is less than the anticipated deflection of the blade <NUM> during operation (e.g. less than <NUM>) for mitigating deflection of the body portion <NUM> of the blade <NUM> during reciprocation of the surgical blade assembly <NUM>.

In the illustrated configurations, the blade <NUM> and the reinforcing member <NUM> are perpendicular to each other when the receiving portion <NUM> receives the proximal end <NUM> of the body portion <NUM> of the blade <NUM>. More specifically, the blade thickness and the reinforcing member thickness are perpendicular to each other when the receiving portion <NUM> receives the proximal end <NUM> of the body portion <NUM> of the blade <NUM>. In other configurations, the blade <NUM> and the reinforcing member <NUM> are not perpendicular to each other when the receiving portion <NUM> receives the proximal end <NUM> of the body portion <NUM> of the blade <NUM> such that the blade <NUM> and reinforcing member <NUM> form oblique angles relative to each other when the receiving portion <NUM> receives the proximal end <NUM> of the body portion <NUM> of the blade <NUM>.

In some configurations, as shown in <FIG>, the body portion <NUM> of the blade <NUM> has a first region <NUM> adjacent the proximal end <NUM> of the body portion <NUM> of the blade <NUM> and a second region <NUM> adjacent the first region <NUM> between the first region <NUM> and the distal end <NUM> of the body portion <NUM> of the blade <NUM>. The opposed side surfaces <NUM>, <NUM> of the body portion <NUM> of the blade <NUM> define a first thickness at the first region <NUM> and a second thickness larger than the first thickness at the second region <NUM>.

As shown in <FIG>, the receiving portion <NUM> is adapted to accommodate the second thickness of the body portion <NUM> of the blade <NUM> such that the first and second arms <NUM>, <NUM> abut the first and second side surfaces <NUM>, <NUM> of the body portion <NUM> of the blade <NUM> at the second region <NUM> of the body portion <NUM> of the blade <NUM> when the receiving portion <NUM> receives the proximal end <NUM> of the body portion <NUM> of the blade <NUM>.

In the configuration shown in <FIG>, the receiving portion <NUM> is adapted to accommodate both the first and second thicknesses of the body portion <NUM> of the blade <NUM> such that the first and second arms <NUM>, <NUM> abut the first and second side surfaces <NUM>, <NUM> of the body portion <NUM> of the blade <NUM> at the first and second regions <NUM>, <NUM> of the body portion <NUM> of the blade <NUM> when the receiving portion <NUM> receives the proximal end <NUM> of the body portion <NUM> of the blade <NUM>. In other configurations, the receiving portion <NUM> is adapted to accommodate both the first and second thicknesses of the body portion <NUM> of the blade <NUM> such that the first and second arms <NUM>, <NUM> abut the first and second side surfaces <NUM>, <NUM> of the body portion <NUM> of the blade <NUM> only at the second region <NUM> of the body portion <NUM> of the blade <NUM> when the receiving portion <NUM> receives the proximal end <NUM> of the body portion <NUM> of the blade <NUM>. In still other configurations, the receiving portion <NUM> is adapted to accommodate the first thickness of the body portion <NUM> of the blade <NUM> such that the first and second arms <NUM>, <NUM> abut the first and second side surfaces <NUM>, <NUM> of the body portion <NUM> of the blade <NUM> only at the first region <NUM> of the body portion <NUM> of the blade <NUM>.

In some configurations, as shown in <FIG>, the blade <NUM> further includes a leg <NUM> extending from the proximal end <NUM> of the body portion <NUM> of the blade <NUM>. The leg <NUM> is configured to be adjacent the body portion <NUM> of the reinforcing member <NUM> when the receiving portion <NUM> receives the proximal end <NUM> of the body portion <NUM> of the blade <NUM>.

In one configuration, as shown in <FIG>, the leg <NUM> is coplanar in thickness with the body portion <NUM> of the blade <NUM>. In other configurations, the leg <NUM> is thicker than the body portion <NUM> of the blade <NUM>. In still other configurations, the leg <NUM> is thinner than the body portion <NUM> of the blade <NUM>.

In some configurations, as shown in <FIG>, the reinforcing member <NUM> includes a first coupling feature <NUM> and the blade <NUM> includes a second coupling feature <NUM>. The first and second coupling features <NUM>, <NUM> are configured to engage each other when the receiving portion <NUM> receives the proximal end <NUM> of the body portion <NUM> of the blade <NUM> to prevent separation of the reinforcing member <NUM> from the blade <NUM>. In the configurations shown, the body portion <NUM> of the reinforcing member <NUM> includes the first coupling feature <NUM>, and the leg <NUM> of the blade <NUM> includes the second coupling feature <NUM>.

In the configuration shown in <FIG>, the second coupling feature <NUM> includes a projection <NUM> extending from the leg <NUM>, and the first coupling feature <NUM> has a surface <NUM> of the body portion <NUM> of the reinforcing member <NUM> defining a void <NUM> for receiving the projection <NUM>. Referring to <FIG>, the surface <NUM> has a continuous perimeter to define the void <NUM>.

In other configurations, one of the first and second arms <NUM>, <NUM> of the reinforcing member <NUM> may include the first coupling feature <NUM> and the body portion <NUM> of the blade <NUM> includes the second coupling feature <NUM>. In such a configuration, the first coupling feature <NUM> may include a projection extending from the body portion <NUM> or first and second arms <NUM>, <NUM> of the reinforcing member <NUM> and the second coupling feature <NUM> has a surface of the body portion <NUM> or leg <NUM> of the blade <NUM> defining a void for receiving the projection. In still other configurations, the surface <NUM> may define a recess for receiving the projection <NUM>.

As shown in <FIG>, the reinforcing member <NUM> is coupled to the blade <NUM> by aligning the receiving portion <NUM> of the reinforcing member <NUM> with the proximal end <NUM> of the body portion <NUM> of the blade <NUM> and pressing the reinforcing member <NUM> and the blade <NUM> together. In one configuration the reinforcing member <NUM> and the blade <NUM> are pressed using a pneumatic press. In other configurations, the reinforcing member <NUM> and the blade <NUM> are pressed together in another manner known in the art. In the configuration shown in <FIG>, the reinforcing member <NUM> and blade <NUM> are pressed together in a direction transverse to the blade axis B. In alternative configurations to be described, the reinforcing member <NUM> and blade <NUM> are pressed together in a direction parallel to the blade axis B. The receiving portion <NUM> receives the proximal end <NUM> of the body portion <NUM> of the blade <NUM> and the void <NUM> receives the projection <NUM>.

In some configurations, the projection <NUM> is tapered such that at least one of a width and a thickness of the projection <NUM> is thicker proximal the leg <NUM> and thinner distal the leg <NUM> such that as the void <NUM> receives the projection <NUM>, the projection <NUM> and surface <NUM> of the body portion <NUM> of the reinforcing member <NUM> abut to provide an interference fit to couple the reinforcing member <NUM> to the blade <NUM>.

One of the blade <NUM> and the reinforcing member <NUM> may include one or more mount features to releasably couple at least one of the blade <NUM> and the reinforcing member <NUM> to the saw chuck assembly <NUM>. In some configurations, the mount feature includes a protrusion <NUM> extending outwardly from at least one of the leg <NUM>, the body portion <NUM> of the blade <NUM>, the first arm <NUM>, the second arm <NUM>, and the body portion <NUM> of the reinforcing member <NUM>. The protrusion <NUM> is releasably secured by the saw chuck assembly <NUM> to releasably couple the surgical blade assembly <NUM> to the saw chuck assembly <NUM> and thus reciprocate the surgical blade assembly <NUM> during operation of the surgical saw <NUM>. In many configurations, the body portion <NUM> of the reinforcing member <NUM> and the body portion <NUM> of the blade <NUM> each include two opposing protrusions <NUM> extending away from their respective bodies and each other. In this manner, the saw chuck assembly <NUM> is configured to be releasably coupled to the surgical blade assembly <NUM> at four locations arranged about the blade axis B with the protrusions <NUM> oriented ninety degrees apart from one another. In alternative configurations, the surgical blade assembly <NUM> includes three or fewer protrusions <NUM> arranged about the blade axis B. In other configurations, the surgical blade assembly <NUM> includes five or more protrusions <NUM> arranged about the blade axis B. The reinforcing member <NUM> of the present disclosure advantageously provides structural support to the blade <NUM> as well as facilitate improved mounting to the saw chuck assembly <NUM>. More specifically, portions of the both the blade <NUM> and the reinforcing member <NUM> may be disposed internal to the saw chuck assembly <NUM> when mounting the surgical blade assembly <NUM> to the saw chuck assembly <NUM>.

<FIG> show the surgical blade assembly <NUM> in accordance with another example of the present disclosure. In at least some respects the example shown in <FIG> is the same as the example previously described with like numbers indicating like components. As shown in <FIG>, the leg <NUM> is further defined as a first leg <NUM> and the blade <NUM> includes a second leg <NUM> extending from the proximal end <NUM> of the body portion <NUM> of the blade <NUM> and being spaced from the first leg <NUM> to define a channel <NUM> configured to receive the distal end <NUM> of the body portion <NUM> of the reinforcing member <NUM> when the receiving portion <NUM> correspondingly receives the proximal end <NUM> of the body portion <NUM> of the blade <NUM>. As shown in <FIG> and <FIG>, the first and second legs <NUM>, <NUM> are spaced apart from one another such that the distance between approximates the thickness of the body portion <NUM> of the reinforcing member <NUM> so that the first and second legs <NUM>, <NUM> abut the top and bottom surfaces <NUM>, <NUM> of the body portion <NUM> of the reinforcing member <NUM> when the channel <NUM> receives the distal end <NUM> of the body portion <NUM> of the reinforcing member <NUM>.

As shown in <FIG>, the second coupling feature <NUM> comprises a projection <NUM> extending from the first leg <NUM> into the channel <NUM>. In other words, the channel <NUM> may be at least partially defined by the first leg <NUM>, the second leg <NUM>, and the projection <NUM>. The first coupling feature <NUM> includes a surface <NUM> of the body portion <NUM> of the reinforcing member <NUM> defining a void <NUM> to receive the projection <NUM> when the receiving portion <NUM> receives the proximal end of the body portion <NUM> of the blade <NUM>. In this configuration, the surface <NUM> does not have a continuous perimeter defining the void <NUM>. In alternative configurations, the surface <NUM> has a continuous perimeter. In other configurations the surface <NUM> defines a recess such that the surface <NUM> does not extend between the top and bottom surfaces <NUM>, <NUM> of the reinforcing member <NUM>.

As shown in <FIG>, the projection <NUM> has a ramped portion <NUM> to assist the channel <NUM> to receive the distal end <NUM> of the body portion <NUM> of the reinforcing member <NUM>. The projection <NUM> has a stepped portion <NUM> configured to abut the surface <NUM> of the body portion <NUM> of the reinforcing member <NUM> that defines the void <NUM>. Engagement between the projection <NUM> and the surface <NUM> defining the void <NUM> prevents the reinforcing member <NUM> from being separated from the blade <NUM> when the receiving portion <NUM> receives the proximal end <NUM> of the body portion <NUM> of the blade <NUM>. In particular, as shown in <FIG>, the reinforcing member <NUM> is coupled to the blade <NUM> by aligning the receiving portion <NUM> of the reinforcing member <NUM> with the channel <NUM> of the blade <NUM> and pressing the reinforcing member <NUM> and the blade <NUM> together. As the receiving portion <NUM> receives the proximal end <NUM> of the body portion <NUM> of the blade <NUM> and the channel <NUM> receives the body portion <NUM> of the reinforcing member <NUM>, the ramped portion <NUM> of the projection <NUM> abuts the body portion <NUM> of the reinforcing member <NUM> to deflect one or both of the first and second legs <NUM>, <NUM> to create enough space to accommodate the body portion <NUM> of the reinforcing member <NUM>. Once the reinforcing member <NUM> and blade <NUM> have been pressed far enough for the void <NUM> to receive the projection <NUM>, one or both of the first and second legs <NUM>, <NUM> resiliently return to an original state with the projection <NUM> disposed with the void <NUM>. The abutting surfaces of the stepped portion <NUM> of the projection <NUM> and the surface <NUM> prevent separation of the reinforcing member <NUM> from the blade <NUM>. This feature maintains relative axial position between the blade <NUM> and the reinforcing member <NUM> and improves handling of the surgical blade assembly <NUM> without concern for the surgical blade assembly <NUM> accidentally disassembling in a surgical suite.

<FIG> show the surgical blade assembly <NUM> in accordance with another example of the present disclosure. In at least some respects the example shown in <FIG> is the same as the examples previously described with like numbers indicating like components. As shown in <FIG>, the second coupling feature <NUM> comprises a projection <NUM> extending from the first leg <NUM> into the channel <NUM>. The first coupling <NUM> feature includes a surface <NUM> of the body portion <NUM> of the reinforcing member <NUM>. The surface <NUM> defines a void <NUM> configured to receive the projection <NUM> when the receiving portion <NUM> correspondingly receives the proximal end <NUM> of the body portion <NUM> of the blade <NUM>. In this configuration, the surface <NUM> has a continuous perimeter defining the void <NUM>. In alternative configurations, the surface <NUM> does not have a continuous perimeter. As shown in <FIG>, the projection <NUM> has a stepped portion <NUM> configured to abut the surface <NUM> of the reinforcing member <NUM> that defines the void <NUM>. The abutment between the stepped portion <NUM> and the surface <NUM> prevents the reinforcing member <NUM> from being separated from the blade <NUM> when the receiving portion <NUM> receives the proximal end <NUM> of the body portion <NUM> of the blade <NUM>. Further, as shown in <FIG>, the reinforcing member <NUM> is coupled to the blade <NUM> by aligning the receiving portion <NUM> of the reinforcing member <NUM> with the channel <NUM> of the blade <NUM> and pressing the reinforcing member <NUM> and the blade <NUM> together. As the receiving portion <NUM> receives the proximal end <NUM> of the body portion <NUM> of the blade <NUM> and the channel <NUM> receives the body portion <NUM> of the reinforcing member <NUM>, the projection <NUM> abuts the body portion <NUM> of the reinforcing member <NUM>. One or both of the first and second legs <NUM>, <NUM> are deflected to create enough space to accommodate the body portion <NUM> of the reinforcing member <NUM>. Once the reinforcing member <NUM> and blade <NUM> have been pressed far enough for the void <NUM> to receive the projection <NUM>, the abutting surfaces of the stepped portion <NUM> of the projection <NUM> and the surface <NUM> defining the void <NUM> prevents separation of the reinforcing member <NUM> from the blade <NUM>. This feature maintains relative axial position between the blade <NUM> and the reinforcing member <NUM> and improves handling of the surgical blade assembly <NUM> without concern for the surgical blade assembly <NUM> accidentally disassembling in a surgical suite.

<FIG> show the surgical blade assembly <NUM> in accordance with another example of the present disclosure. In at least some respects the example shown in <FIG> is the same as the example previously described with like numbers indicating like components. As shown in <FIG>, the first coupling feature <NUM> includes a projection <NUM> extending from the body portion <NUM> of the reinforcing member <NUM>. The second coupling feature <NUM> has a surface <NUM> of the body portion <NUM> of the blade <NUM> defining a void <NUM> for receiving the projection <NUM>. Referring to <FIG>, the surface <NUM> has a continuous perimeter to define the void <NUM>. The surface <NUM> of the void <NUM> defines a first end <NUM> adjacent to the proximal end <NUM> of the body portion <NUM> of the blade <NUM> and a second end <NUM> opposite the first end <NUM> distal to the proximal end <NUM> of the body portion <NUM> of the blade <NUM>.

Referring to <FIG>, the first arm <NUM> extends from the projection <NUM> of the body portion <NUM> of the reinforcing member <NUM>. In the configuration shown, the first arm <NUM> of the reinforcing member <NUM> may be shorter than the second arm <NUM>. In other configurations, the first and second arms <NUM>, <NUM> have identical lengths. The reinforcing member <NUM> may include a tab <NUM> extending from the body portion <NUM> being spaced from the projection <NUM> to define a groove <NUM>. A length of the groove <NUM> between the projection <NUM> and the tab <NUM> approximates a distance between the proximal end <NUM> of the body portion <NUM> of the blade <NUM> and the first end <NUM> of the surface <NUM> defining the void <NUM>.

The reinforcing member <NUM> is coupled to the blade <NUM> by feeding the first arm <NUM> and the projection <NUM> through the void <NUM>. The receiving portion <NUM> of the reinforcing member <NUM> is configured to receive the second end <NUM> of the surface <NUM> defining the void <NUM>. The groove <NUM> is configured to receive a part of the body portion <NUM> of the blade <NUM> between the proximal end <NUM> of the body portion <NUM> of the blade <NUM> and the first end <NUM> of the surface <NUM> defining the void <NUM>. In some configurations, the projection <NUM> and the surface <NUM> defining the void <NUM> are configured to abut to provide an interference fit to secure the reinforcing member <NUM> to the blade <NUM>. In other configurations, the tab <NUM> and the projection <NUM> abut the proximal end <NUM> of the body portion <NUM> of the blade <NUM> and the first end <NUM> of the surface <NUM> defining the void <NUM>, respectively, to provide an interference fit to secure the reinforcing member <NUM> to the blade <NUM>. In still other configurations, the blade <NUM> and the reinforcing member <NUM> each have one or more mount features <NUM> coupling the blade <NUM> and the reinforcing member <NUM> to the saw chuck assembly <NUM>, with the saw chuck assembly <NUM> constraining the relative position of the reinforcing member <NUM> to the blade <NUM>.

In the examples described above and shown in <FIG> and <FIG>, an advantage to the described methods of assembly is that the reinforcing member <NUM> and the blade <NUM> are mechanically coupled together without materially altering the physical properties of at least one of the reinforcing member <NUM> and the blade <NUM> that may result during a joining process such as welding or brazing. A further advantage is that existing blades may be retrofitted without altering the physical properties, or the like.

<FIG> show the surgical blade assembly <NUM> in accordance with another example of the present disclosure. In at least some respects the example shown in <FIG> is the same as the examples previously described with like numbers indicating like components. As shown in <FIG>, the reinforcing member <NUM> and blade <NUM> do not have coupling features. Referring to <FIG>, the reinforcing member <NUM> is coupled to the blade <NUM> by aligning the receiving portion <NUM> of the reinforcing member <NUM> with the channel <NUM> of the blade <NUM> and pressing the reinforcing member <NUM> and the blade <NUM> together. The receiving portion <NUM> receives the proximal end <NUM> of the body portion <NUM> of the blade <NUM> and the channel <NUM> correspondingly receives the distal end <NUM> of the body portion <NUM> of the reinforcing member <NUM>. In one configuration, an adhesive may be applied to couple the reinforcing member <NUM> to the blade <NUM>. In another configuration, one or more of the first and second legs <NUM>, <NUM> and body portion <NUM> of the blade <NUM> may be fixed to one or more of the first and second arms <NUM>, <NUM> and body portion <NUM> of the reinforcing member <NUM> by one of welding, brazing, or another process known in the art for permanently joining components together. In another configuration, the blade <NUM> and the reinforcing member56 are not fixed together. Instead, the blade <NUM> and the reinforcing member <NUM> each have one or more mount features <NUM> coupling the blade <NUM> and the reinforcing member <NUM> to the saw chuck assembly <NUM>, with the saw chuck assembly <NUM> constraining the relative position of the reinforcing member <NUM> to the blade <NUM>. The absence of coupling features <NUM>, <NUM> in the example shown in <FIG> results in reduced complexity and low manufacturing costs. This example may also be particularly advantageous with retrofitting an existing blade <NUM> with the reinforcing member <NUM>.

In the configuration where the reinforcing member <NUM> is fixed to the blade <NUM>, the reinforcing member <NUM> may only have one of the first and second arms <NUM>, <NUM> abutting one of the first and second side surfaces <NUM>, <NUM> of the body portion <NUM> of the blade <NUM> for reinforcing the blade <NUM>. The one of the first and second arms <NUM>, <NUM> may be fixed to the body portion <NUM> of the blade <NUM> and in this manner would reinforce the blade <NUM> from deflecting toward and away from the one of the first and second arms <NUM>, <NUM>.

In the examples previously described, the reinforcing member <NUM> is a discrete structure adapted to be coupled to the blade <NUM>. It is also contemplated that the reinforcing member <NUM> may be integrally formed with the blade <NUM>, as shown in <FIG>. In one configuration, the reinforcing member <NUM> comprises a rib <NUM> that is formed adjacent the proximal end <NUM> of the body portion <NUM> of the blade <NUM>. In one configuration shown in <FIG>, the rib <NUM> extends from the second region <NUM> of the body portion <NUM> of the blade <NUM> and into the first region <NUM>. The rib <NUM> extends into the first region <NUM> at least far enough to be axially closer to the proximal end <NUM> of the body portion <NUM> of the blade <NUM> than the one or more mount features <NUM>. In such a configuration, the rib <NUM> acts as a strut to reinforce the body portion <NUM> of the blade <NUM> from deflecting in directions transverse to the first and second side surfaces <NUM>, <NUM>. The width of the rib <NUM> may be less than the width of the reinforcing member <NUM> described above in previous examples. In some examples, the width of the rib <NUM> is the thickness of the second region of the body portion <NUM> of the blade <NUM>. In one configuration, the rib <NUM> may be formed by removing material from the blade <NUM>. In other examples, the rib <NUM> is formed by stamping or forging.

As previously mentioned, the blade <NUM> is used to cut tissue, such as bone, during a surgical procedure. The blade <NUM> may be used to plunge cut involving reciprocating the blade <NUM> along the blade axis B in manners previously described. To that end, the body portion <NUM> of the blade <NUM> has a distal region <NUM> connecting the top surface <NUM> and the bottom surface <NUM> and being disposed between the first and second side surfaces <NUM>, <NUM>. The blade <NUM> includes one or more teeth <NUM> that extend outwardly from the distal region <NUM> of the body portion <NUM> of the blade <NUM>. The one or more teeth <NUM> that extend outwardly from the distal region <NUM> of the body portion <NUM> of the blade <NUM> are configured to permit plunge cutting. The one or more teeth <NUM> that extend outwardly from the distal region <NUM> generally extend more distally than the one or more teeth <NUM> along the top and bottom surfaces <NUM>, <NUM> of the blade <NUM> to enhance the ability of the blade <NUM> to penetrate tissue with the distal end <NUM> of the body portion <NUM> of the blade <NUM>. In some configurations, at least one tooth <NUM> of the one or more teeth <NUM> that extend outwardly from the distal region <NUM> of the body portion <NUM> of the blade <NUM> may extend in a direction substantially aligned with the blade axis B. In one such configuration, the top and bottom surfaces <NUM>, <NUM> of the body portion <NUM> of the blade <NUM> taper toward each other and join at the distal end <NUM> of the body portion <NUM> of the blade <NUM> to form the tooth <NUM> that is substantially aligned with the blade axis B to permit plunge cutting. In one configuration, the tooth <NUM> extends at an angle less than thirty degrees relative to the blade axis B. In another configuration, the tooth <NUM> extends at an angle less than twenty degrees relative to the blade axis B. In other configurations, the tooth <NUM> extends at an angle less than ten degrees relative to the blade axis B.

In one configuration, as shown in <FIG>, at least one of the one or more teeth <NUM> that extend outwardly from the distal region <NUM> of the body portion <NUM> of the blade <NUM> has a tooth face <NUM> defining a face plane <NUM>. The at least one of the one or more teeth <NUM> also has a tooth back <NUM> defining a back plane <NUM>. The face and back planes <NUM>, <NUM> intersect where the tooth face <NUM> and the tooth back <NUM> join together to form a point of the tooth to penetrate tissue. A reference plane <NUM> bisects the face and back planes <NUM>, <NUM>. An angle θ is created between the reference plane <NUM> and the blade axis B. In one configuration, the angle θ created between the reference plane <NUM> and the blade axis B is less than thirty degrees. In other configurations, the angle θ may be less than twenty degrees. In another configuration, the angle θ may be less than ten degrees. In some configurations, one or both the tooth back <NUM> and the tooth face <NUM> do not have planar surfaces to define the back plane <NUM> and face plane <NUM>, respectively. In configurations where the tooth back <NUM> is not planar, the back plane <NUM> is defined by a reference plane being tangent to a portion of the surface of the tooth back <NUM> that is adjacent to the tooth point where the tooth face <NUM> joins the tooth back <NUM>. In configurations where the tooth face <NUM> is not planar, the face plane <NUM> is defined by a reference plane being tangent to a portion of the surface of the tooth face <NUM> that is adjacent to the tooth point where the tooth face <NUM> joins the tooth back <NUM>.

In some configurations, as shown in the illustrated examples, the at least one or more teeth <NUM>, <NUM>, <NUM> extend outwardly from the body portion <NUM> of the blade <NUM>. The one or more teeth <NUM>, <NUM>, <NUM> may be coplanar with the thickness of the body portion <NUM> of the blade <NUM>. More specifically, the side surfaces of the one or more teeth <NUM>, <NUM>, <NUM> extend substantially parallel to the thickness of the body portion <NUM> of the blade <NUM>. In other words, the one or more teeth <NUM>, <NUM>, <NUM> extend substantially parallel to the first and second side surfaces <NUM>, <NUM> of the body portion <NUM> of the blade <NUM>. In other configurations, the one or more teeth <NUM>, <NUM>, <NUM> extend outwardly from the body portion <NUM> of the blade <NUM> at an oblique angle relative to the first and second side surfaces <NUM>, <NUM> of the body portion <NUM> of the blade <NUM>.

In one configuration, at least one of the blade <NUM> and the reinforcing member <NUM> comprises stainless steel. In one configuration the stainless steel comprises martensitic stainless steel. Further the martensitic stainless steel may comprise 7C27Mo2 martensitic stainless steel.

In one configuration, at least one of the blade <NUM>, reinforcing member <NUM>, and features of the blade <NUM> and reinforcing members <NUM> are formed by laser cutting.

Several examples have been discussed in the foregoing description. However, the examples discussed herein are not intended to be exhaustive or limit the invention to any particular form. The terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations are possible in light of the above teachings.

All terms used in the claims are intended to be given their ordinary meanings as understood by those knowledgeable in the technologies described herein unless an explicit indication to the contrary is made herein. In particular, use of the singular articles such as "a," "the," "said," etc. should be read to recite one or more of the indicated elements unless a claim recites an explicit limitation to the contrary.

It will be further appreciated that the terms "include," "includes," and "including" have the same meaning as the terms "comprise," "comprises," and "comprising. " Moreover, it will be appreciated that terms such as "first," "second," "third," and the like are used herein to differentiate certain structural features and components for the non-limiting, illustrative purposes of clarity and consistency.

As used herein, the adverb "substantially" means that a shape, structure, measurement, quantity, time, etc. may deviate from an exact described geometry, distance, measurement, quantity, time, etc., because of imperfections in materials, machining, manufacturing, transmission of data, computational speed, etc..

Claim 1:
A surgical blade assembly (<NUM>) for a surgical saw (<NUM>), the surgical blade assembly (<NUM>) comprising:
a blade (<NUM>) comprising a body portion (<NUM>) having a proximal end (<NUM>), a distal end (<NUM>), and a length between the proximal and distal ends (<NUM>, <NUM>), with the body portion (<NUM>) having opposed top and bottom surfaces (<NUM>, <NUM>) and opposed first and second side surfaces (<NUM>, <NUM>) between the top and bottom surfaces (<NUM>, <NUM>), and the blade (<NUM>) having one or more teeth (<NUM>) that extend outwardly from at least one of the top and bottom surfaces (<NUM>, <NUM>) of the body portion (<NUM>); and
a reinforcing member (<NUM>) comprising a body portion (<NUM>) having a proximal end (<NUM>), a distal end (<NUM>), and a length that extends between the proximal and distal ends (<NUM>, <NUM>), and the reinforcing member (<NUM>) comprising a first arm (<NUM>) extending from the distal end (<NUM>) of the body portion (<NUM>) of the reinforcing member (<NUM>) and a second arm (<NUM>) extending from the distal end (<NUM>) of the body portion (<NUM>) of the reinforcing member (<NUM>) and being spaced from the first arm (<NUM>) to define a receiving portion (<NUM>) configured to receive the proximal end (<NUM>) of the body portion (<NUM>) of the blade (<NUM>),
wherein the first and second arms (<NUM>, <NUM>) are configured to abut the first and second side surfaces (<NUM>, <NUM>) of the body portion (<NUM>) of the blade (<NUM>) to act as a strut to reinforce the blade (<NUM>) when the receiving portion (<NUM>) receives the proximal end (<NUM>) of the body portion (<NUM>) of the blade (<NUM>),
characterized in that
the blade (<NUM>) and the reinforcing member (<NUM>) are perpendicular to each other when the receiving portion (<NUM>) receives the proximal end (<NUM>) of the body portion (<NUM>) of the blade (<NUM>).