Patent ID: 12251115

DETAILED DESCRIPTION

Referring toFIGS.1and2, a tool10is disclosed, wherein in one example, the powered tool10is a surgical saw assembly. The tool10is for use during surgical procedures. The surgical procedures may be orthopedic surgeries, brain surgeries, cardiovascular surgeries or any other surgeries requiring the use of an energy applicator. Tools other than the saw assembly, including, but not limited to, drills, drivers, impactors, reamers or the like, are contemplated for use.

An accessory30is coupled to the tool10. In one implementation, the accessory is a surgical saw blade30. The blade30may be of various shapes and sizes such as a crescentic blade or a straight blade. The saw blade30can be a sagittal saw, reciprocating saw, rotary saw, or any other configuration of saw blade. Furthermore, accessories other than saw blades, including but not limited to, drill bits, driver probes, impactor accessories, reamer accessories or the like, are contemplated for use.

The tool10can attach to a powered device12. In one example, the powered device12can be an end effector of a surgical robotic manipulator (not shown) or the combination of the end effector and the robotic manipulator. The robotic manipulator comprises a plurality of joints and joint actuators forming an arm that is configured to move in multiple degrees of freedom. In other configurations, the powered device12is a hand-held powered tool, such as a hand-held powered saw, drill, impactor or reamer. In one example, the hand-held powered tool is supported by the arm and hand of the operator against the force of gravity. In other examples, the hand-held powered tool can be attached to and supported by a passive linkage assembly that is coupled to the patient or surgical table. For simplicity, the tool10and accessory30are the saw assembly10and saw blade30in the description below.

The saw assembly10shown inFIG.1has a coupler19for attaching to the powered device12. The coupler19can be a right-angle type or a straight type, as shown inFIG.2. The coupler19comprise a housing21for attaching to the powered device12. The housing21can include any components for attaching to the powered device12as well as any components of the saw assembly10, generally. A motor16may be located in the powered device12(as shown), in the housing21attached to the powered device12, or in a sub-system located remote from the powered device12. The motor16may be of any suitable type, including but not limited to a pneumatic or electrical motor. The motor16is configured to provide oscillating motion to the saw blade30. It is contemplated that the motor16may provide cyclical linear motion and/or cyclical angular motion, such as used for an oscillating sagittal saw.

The motor16is operatively coupled to a driver20. The driver20transfers drive torque from the motor16to the saw blade30. The driver20is at least partially disposed within the housing21and includes a drive hub22. The drive hub22is configured to releasably receive the saw blade30. As illustrated inFIG.1, the drive hub22may include one or more primary drive bosses24or drive members adapted to engage the saw blade30. The driver20, including the drive hub22, may oscillate due to torque from the motor16which in turn will oscillate the saw blade30about a rotation axis. In addition to the drive hub22, the driver20comprises additional components to convert torque from a drive shaft of the motor16into oscillating motion of the drive hub22. Examples of such components are shown and described in U.S. Pat. No. 8,100,912 to Marietta, hereby incorporated by reference. In other configurations, the drive shaft of the motor16may directly drive the drive hub22to rotate the drive hub22and may oscillate the drive hub22or rotate the drive hub22in complete rotations in one direction and/or another.

Referring toFIGS.1and2, the saw blade30includes an attachment portion32configured to be removably coupled to the drive hub22. Opposite the attachment portion32, the saw blade30includes a cutting portion36which has a plurality of teeth. A body portion34extends between the attachment portion32and the cutting portion36. The attachment portion32of the saw blade30, in the configuration shown, generally has a width greater than a width of the cutting portion36. In some configurations, the saw blade30is formed from a single piece of material, such as metal, by stamping and/or machining.

The attachment portion32includes a tapered section which gradually gets narrower until it reaches a transition section. Opposite the transition section from the attachment portion32is the body portion34. The body portion34may have a continuous width from the transition section to the cutting portion36. It is also contemplated that the body portion34may gradually get narrower in width as the body portion34approaches the cutting portion36. In other configurations, the body portion34may gradually get wider in width as the body portion34approaches the cutting portion36. Outer side surfaces of the saw blade30at the attachment portion32and the body portion34may be perpendicular to top and bottom surfaces of the saw blade30.

It is contemplated that the length of the attachment portion32is less than the length of the body portion34, however, many other configurations have been contemplated. Moreover, the length of the cutting portion36may be less than the length of the attachment portion32and less than the length of the body portion34. As illustrated, the body portion34is generally elongate and rectangularly shaped while at least a portion of the attachment portion32may include curves. It is also contemplated that the attachment portion32and/or the body portion34may be of various other configurations.

Moreover, as best shown inFIGS.1and2, the body portion34may reach a second transition section which is disposed between the body portion34and the cutting portion36. The second transition section may have a different, typically smaller, width than the width of the teeth and the width of the body portion34. It is also contemplated that the second transition section may taper inwards from the body portion34before once again tapering outwards towards the teeth of the cutting portion36.

As best illustrated inFIG.1, the saw blade30defines primary indents40on the attachment portion32. The primary indents40are disposed on opposite lateral sides of the attachment portion32and are disposed through the thickness of the saw blade30. Each of the primary indents40are defined by a first side, a second side, and a third side with the first and third side being generally perpendicular to the second side. Moreover, the second side is disposed between the first side and the third side. In the configuration shown, the second side4is integral and smoothly continuous with the first side and the third side by virtue of rounded profile transitions therebetween, described further below. An indent space is formed by the first side, the second side, and the third side.

Additionally, the saw blade30includes a central indent38. The central indent38is generally ‘U’ shaped and has a free space disposed between the primary indents40about the rotational axis. The central indent38may also include a notch. The notch may be configured to engage a portion of the drive hub22, such as a smaller boss (not shown) protruding upwardly into the notch. The notch may be disposed off-center or to one side of center of the central indent38so that the saw blade30is properly fitted with the top surface facing upwardly. Other configurations are contemplated. It is also contemplated that the notch may be disposed along any portion of the central indent38. An example of such a saw blade for use with the blade mounting assembly18and/or the surgical saw system10is shown and described in U.S. Pat. No. 10,456,142 to Shiels, hereby incorporated by reference.

Referring now toFIG.3, a partially exploded view of the blade mounting assembly18is illustrated. The drive hub22has a generally circular outer periphery and includes the primary drive bosses26. The drive hub22also includes a generally circular opening disposed in the center of the drive hub22. In the illustrated configuration, the drive hub22includes two primary drive bosses26disposed opposite to one another, but identical in configuration. Each of the primary drive bosses26protrude radially inwardly from the outer periphery of a support surface23of the drive hub22. Additionally, the drive hub22includes a central drive boss24disposed partially about the circular opening. Aside from the drive bosses24,26, the drive hub22has a generally flat support surface23adjacent to the drive bosses24,26on which the flat bottom surface of the attachment portion32of the saw blade30is supported. The support surface23may also be referred to as a platform. The drive bosses24,26may project and/or extend from the support surface23.

In the configuration of the blade mounting assembly18illustrated inFIG.3, the primary drive bosses26have a first surface, a second surface, and a third surface which are generally flat, with the first and third surfaces disposed parallel to one another. The primary drive bosses26also have an outer fourth surface that is continuous with the outer periphery. On the central drive boss24, opposite first and second surfaces are flat in shape while a third surface, disposed about the circular opening, is arcuate and identical in shape to a fourth surface. It is contemplated that various other shapes and sizes of drive bosses26are possible.

As illustrated inFIGS.1and3, the drive bosses26on the drive hub22are adapted to be removably placed within the primary indents38,40of the saw blade30when the saw blade30is attached to the drive hub22. In the configuration illustrated inFIG.1, the primary indents40are configured to receive the primary drive bosses26and the central indent38is configured to receive the central drive boss24. When the saw blade30is coupled to the corresponding drive bosses24,26at the primary indents38,40, the driver20translates motion from the motor16to the saw blade30, and moves the saw blade30in an oscillating motion to allow the plurality of teeth of the cutting portion36to cut during a surgical procedure. It is contemplated that in one configuration of the driver20, the primary diver boss(es)26may be configured to articulate the saw blade30and the central drive boss24may be configured to align the saw blade30within the blade mounting assembly18. Alternatively, it is also contemplated that the driver20may be configured such that the central diver boss24is configured to articulate the saw blade30and the primary drive boss(es)26may be configured to align the saw blade30within the blade mounting assembly18. In yet another configuration, the driver20may be configured such that both the primary diver boss(s)26and/or the central drive boss24are configured to articulate the saw blade30and to align the saw blade30within the blade mounting assembly18.

The blade mounting assembly18may further comprise a blade clamp42. As illustrated inFIG.2, the saw blade30may be secured to the drive hub22using a blade clamp42. The blade clamp42is adapted to be moveably coupled to the drive hub22such that the saw blade30may be disposed between the drive hub22and the blade clamp42. The blade clamp42may comprise a top surface41, a bottom surface45, and a side surface43disposed between the top41and bottom surfaces45. The blade clamp42may be round as illustrated inFIGS.2and3. While not illustrated in the figures, it is contemplated that the blade clamp42may comprise any shape, including oval or rectangular. It is contemplated that the blade clamp42is configured to move between a first position and a second position relative to the support surface23of the drive hub22as part of attaching, securing, and removing the saw blade30to the drive hub22. For example, the first position may be defined by the blade clamp42being spaced a first distance D1 from the support surface23of the drive hub22. The second position may be defined by the blade clamp42being spaced a fifth distance D5 (as shown inFIG.7B) from the support surface23of the drive hub22. These configurations will be described in more detail below. The first position may also be referred to as an open position or an exposed position, and the second position may be referred to as a closed position or a concealed position. The blade clamp42may be friction fitted onto the drive hub22or other portion of the driver20or may be secured by other mechanisms. The blade clamp42has been removed inFIG.1for to purpose of illustration.

The side surface43of the blade clamp42may comprise a safety indicator44configured to allow the user to identify whether the blade clamp42is in the first position of the second position. The safety indicator44may comprise a distinct color different from the rest of the blade clamp42and/or the other features of the blade mounting assembly18. For example, the safety indicator44may include red or yellow marking on the side surface of the blade clamp42. Alternatively, the safety indicator44may comprise a text, symbols, lights, or other similar indicia intended to get the user attention and notify them of the position the blade clamp42is in. Furthermore, the blade clamp42may be configured such that the safety indicator44is exposed when the blade clamp42is in the first position and the safety indicator44is concealed when the blade clamp42is in the second position, or vice versa. For example, the blade clamp42may be configured such that the safety indicator44is exposed when the blade clamp42is in the first position to notify the user the surgical saw assembly10is not safe to use because the blade clamp42is in the open or loading position suggesting the blade is not secured and/or locked into the blade mounting assembly18. Alternatively, the blade clamp42may be configured such that the safety indicator44is concealed when the blade clamp42is in the second position because the surgical saw assembly10is safe to use because the blade clamp42is in the closed or locked position and the blade is properly secured and/or locked into the blade mounting assembly18.

The blade mounting assembly18may further comprise a control mechanism28moveable between and open position and a closed position. The control mechanism28may be manipulatable by the user of the surgical saw assembly10move the blade clamp between the first position and the second position. For example, the control mechanism28may be configured such that when the control mechanism28is in the open position, the blade clamp42is in the first position for loading or removing a saw blade30from the blade mounting assembly18. Alternatively, the control mechanism28may be configured such that when the control mechanism28is in the closed position, the blade clamp42is in the second position and the saw blade30is secured and/or locked into the blade mounting assembly18. The control mechanism28may comprise a rotary knob (as shown inFIG.1), lever (as shown inFIGS.3-7), switch, button, or similar electromechanical device capable of manipulating the blade clamp42between the first position and the second position.

The blade mounting assembly18may further comprise a clamp guard48. The clamp guard48may be disposed between the blade clamp42and the drive hub22. The clamp guard may comprise a primary surface50and a side surface52. The primary surface50may comprise one or more apertures54,56. At least of the apertures56may be configured to receive at least a portion of the primary drive boss24. The side surface52of the clamp guard48may extend from the perimeter of the primary surface50such that the side surface encircles the primary surface50. Furthermore, the primary surface50and the side surface52may define a recess58. The recess58may be configured to receive at least a portion of the blade clamp42. For example, when the blade clamp42is in the second position, the blade mounting assembly18may be configured such that the blade clamp42is retracted within the recess58defined by the clamp guard48. Furthermore, the clamp guard48may be configured to conceal the safety indicator44disposed on the blade clamp42when the blade clamp42is in the second position and retracted within the recess58. Alternatively, when the blade clamp42is in the first position, the blade mounting assembly18may be configured such that the blade clamp42protrudes from the recess58defined by the clamp guard48, exposing the safety indicator44.

The blade mounting assembly18may further comprise a biasing mechanism46or biasing member disposed between the blade clamp42and the clamp guard48. The biasing mechanism46may be configured to urge the clamp guard48away from the blade clamp42. When the blade clamp42is in the first position and spaced a first distance D1 from the support surface23of the drive hub22, the biasing mechanism46may urge the clamp guard48away from the blade clamp42and toward the support surface23of the drive hub22. The force exerted by the biasing mechanism46on the clamp guard48is sufficient to urge the clamp guard48away from the blade clamp42allowing the blade clamp to protrude from and/or be exposed from the recess58of the clamp guard48, but the force is not so great that it cannot be overcome by a greater force action on the clamp guard48in the opposite direction. For example, exerting a force greater than the biasing mechanism46on the clamp guard in the opposing direction could cause the clamp guard to be move and reducing the distance between the clamp guard48and the blade clamp42. Alternatively, when the blade clamp42is in the second position and spaced a fifth distance D5 from the support surface23of the drive hub22, the biasing mechanism46may be compressed as the blade clamp42is pulled toward the support surface23of the drive hub22, with the clamp guard48being wedged between the blade clamp42and drive boss(es)24,26and/or the support surface23of the drive hub22. When the blade clamp42is in the second position and the biasing mechanism46may be compressed reducing the distance between the blade clamp42and the clamp guard48, a portion of the central drive boss24may be at least partially disposed in the aperture54in the primary surface50of the clamp guard48. The biasing mechanism46allows the clamp guard to float between the blade clamp42and the support surface23of the drive hub22as the blade clamp42moves between the first position and the second position.

Referring toFIGS.4A and4B, an exemplary configuration of the blade mounting assembly18in an at-rest state is illustrated. This may also be referred to as an open state. The control mechanism is in the open position causing the blade clamp42to be in the first position. As described above, when the blade clamp42is in the first position, the blade clamp is spaced a first distance D1 from the support surface23of the drive hub22. The biasing mechanism46is configured to urge the clamp guard48away from the blade clamp42and toward the support surface23of the drive hub22such that the clamp guard48is spaced a second distance D2 from the support surface23of the drive hub22. As the biasing mechanism46urges the clamp guard48away from the blade clamp42and toward the support surface23, the blade clamp42protrudes from the recess58of the clamp guard48exposing the safety indicator44. This notifies the user that the surgical saw assembly10is not ready for use. In the at-rest state, the blade mounting assembly18is ready to receive the attachment portion32of the saw blade30, but the saw blade has not engaged the blade mounting assembly18yet.

Referring toFIGS.5A and5B, an exemplary configuration of the blade mounting assembly18in an insertion state is illustrated. This may also be referred to as a loading or mounting state. Similar to when in the at-rest state, the control mechanism28is in the open position and the blade clamp42is in the first position. When the blade mounting assembly18is in the insertion state, at least a portion of the attachment portion32of the saw blade30is inserted into the blade mounting assembly18. When inserting the saw blade30, the attachment portion32is wedged between the drive boss(es)26and the clamp guard48. As the drive boss(es)26are stationary and/or fixed, wedging the attachment portion32between the drive boss(es)26and the clamp guard48causes a force to be applied to the clamp guard48in the opposite direction of the biasing mechanism46. This results in the clamp guard48being spaced a third distance D3 from the support surface23of the drive hub22, such that the third distance D3 is greater than the second distance D2. Expressed another way, wedging the attachment portion32between the drive boss(es)26and the clamp guard48causes a force to be applied to the clamp guard48in the opposite direction of the biasing mechanism46, causing the biasing mechanism46to be compressed and the distance between the clamp guard48and the blade clamp42to be reduced. This allows the attachment portion32of the saw blade30to be inserted over the drive boss(es)26

Referring toFIGS.6A and6B, an exemplary configuration of the blade mounting assembly18in a secured state is illustrated. Similar to in the at-rest state and the insertion state, the control mechanism28is in the open position and the blade clamp42is in the first position. At this point, the saw blade30has been fully inserted into the blade mounting assembly18, with the attachment portion abutting the support surface23of the drive hub22and the drive bosses24,26being seated within the central indent38and primary indent(s)40of the attachment portion of the blade, as described above. Once the attachment portion32is resting on the support surface23of the drive hub22, the saw blade30is no longer exerting a force on the clamp guard opposite the biasing mechanism46. This allows the biasing mechanism46to expand from its compressed stated (as experienced during the insertion state), urging the clamp guard48away from the blade clamp42, causing the clamp guard48to hold the saw blade30in place within the blade mounting assembly18. The force from the biasing mechanism causes the clamp guard48to be spaced a fourth distance D4 from the support surface23of the drive hub22. Depending on the properties of the saw blade30, such as the thickness of the attachment portion32, the fourth distance D4 may be equal to or greater than the second distance D2 that the clamp guard48is spaced from the support surface23of the drive hub22in the at-rest state. For example, a thicker attachment portion32may result in the biasing mechanism46causing the clamp guard to abut the attachment portion32and being space the fourth distance D4 from the support surface23such that the fourth distance D4 is greater than the second distance D2. Alternatively, if the attachment portion32is sufficiently thin enough, the biasing mechanism46may cause the clamp guard48to be spaced a fourth distance D4 from the support surface23such that the fourth distance D4 is equal to the second distance D2. While the force applied by the biasing mechanism46can be overcome by the user applying a force to the saw blade30to insert and/or remove the saw blade30, the force exerted on the clamp guard48by the biasing mechanism46is sufficient to hold the saw blade30within the blade mounting assembly18absent such additional force(s). One of the many advantages of such a configuration is that the clamp guard48, in combination with the biasing mechanism46, hold the saw blade30in place once it has been inserted in the blade mounting assembly18by the user. This can help prevent the saw blade30from falling out prior to the user fully securing the saw blade30in place by moving the blade clamp42to the second position. It can also prevent the saw blade30from becoming disengaged and/or misaligned with the drive boss(es)24,26as the blade clamp42is moved from the first position to the second position. While the blade mounting assembly18is in the secured state, the blade clamp42remains protruded from the clamp guard48such that the safety indicator44remains visible to the user notifying them that the surgical saw assembly10is not safe for operation.

The clamp guard48also assists in preventing the user from pinching their finger or another extremity. The clamp guard48, in combination with the biasing mechanism46, reduces the distance and/or gap between the support surface23and the nearest point of contact, i.e. the clamp guard48or the blade clamp42. For example, without the clamp guard48, when the blade clamp42is in the first position, the distance between the support surface23and the bottom surface45of the blade clamp42would be the first distance D1. Alternatively, using the blade mounting assembly18described above including a clamp guard48, the clamp guard48is spaced the second distance D2 from the support surface23when the blade clamp42is in the first position. The second distance D2 is less than the first distance, meaning there is less space for a finger or another objected to get wedged between the blade clamp42and the support surface23, reducing the likely hood of something getting pinched when the blade clamp42is moved from the first position to the second position.

Referring toFIGS.7A and7B, an exemplary configuration of the blade mounting assembly18in a closed state is illustrated. The control mechanism28is in the closed position causing the blade clamp42to be in the second position. As described above, when the blade clamp42is in the second position, the blade clamp42is retracted and is spaced a fifth distance D5 from the support surface23of the drive hub22. When the blade clamp42is retracted, the biasing mechanism46is compressed such that the blade clamp42is disposed within the recess58defined by the clamp guard48. As the blade clamp42is disposed within the recess58, the safety indicator44is concealed by the clamp guard48. The absence of the presence of the safety indicator suggests to the user that the surgical saw assembly10is safe to operate. Furthermore, the blade clamp42, in combination with the biasing mechanism46, press the clamp guard48against the saw blade30, locking the saw blade30within the blade mounting assembly18.

As can be understood from the foregoing description, the blade mounting assembly provides technical solutions to several technical problems. For example, the blade mounting assembly prevents potential that a user can be pinched by the clamp during clamping. The clamp is encapsulated and non-exposed, and hence, the user is protected from the path of the clamping force. Furthermore, the clamp guard provides flexibility to move for easy accessory installation while providing an intermediate level of securing of the accessory prior to full clamping. Hence, the clamp guard eliminates extra spacing around the accessory thereby reducing potential that the accessory can be loosely mounted before clamping. The clamp guard also prevents the accessory from potentially falling out from the tool before clamping. Additionally, the safety indicator provides a user with clear indication of full and proper clamping of the accessory. The safety indicator reduces potential of the possibility of the user proceeding to operate the tool on the incorrect assumption that the accessory is properly secured.

Several configurations have been discussed in the foregoing description. However, the configurations 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 and the invention may be practiced otherwise than as specifically described.