Counter-balanced oscillating surgical saw

• US 5,846,244 A
• Filed: 09/05/1997
• Issued: 12/08/1998
• Est. Priority Date: 09/18/1995
• Status: Expired due to Fees

• Current Assignee: Exactech, Inc.
• Original Assignee: Exactech, Inc.
• Inventors: Cripe, Phil
• Primary Examiner(s): Buiz, Michael
• Assistant Examiner(s): Shai, Daphna
• Application Number:
  US08/924,296
• Time in Patent Office: 459 Days
• Field of Search: 606/79, 606/82, 606/161, 606/169, 606/171, 606/176, 606/178, 606/183, 30/165, 30/166.3
• US Class Current: 606/82
• CPC Class Codes: A61B 17/142 with reciprocating saw blades, e.g. with cutting edges at the distal end of the saw blades
• CPC Class Codes: B27B 19/008 having a plurality of saw blades or saw blades having plural cutting zones

Abstract

A counter-balanced oscillating surgical saw for use in surgical procedures is described which greatly reduces the vibrations caused when the saw blades contact the patient'"'"'s anatomy. The reduction of vibration is achieved by the present saw which uses two oscillating blades to counter the kinetic energy typically lost when only one blade is used. The preferred embodiment of the present invention includes at least two cutting blades mounted on at least two actuator blocks. The actuator blocks are preferably mounted on at least two shafts which extend from the top of the saw handle: a pivot shaft and a rotatable shaft which is rotated by an electric motor. At least two eccentric bearings are mounted to the rotatable shaft (one bearing for each actuator block) such that the bearings orbit about the rotatable shaft 180° out-of-phase with respect to one another. The actuator blocks are positioned adjacent the eccentric bearings so that they move in a reciprocating manner about the rotatable shaft of the saw. The to-and-fro motion of the actuator blocks is transformed into a counter-balanced oscillating motion of the cutting blades. Mechanical vibration, rotational and linear momentum of the saw is greatly reduced during surgery because as the cutting blades oscillate about the point of incision, the momentum produced by one cutting blade is offset by the momentum produced by its counterpart cutting blade.

Claims

1. A surgical saw, comprising:

(a) a rotatable drive shaft;

(b) a first and a second eccentric bearing coaxially mounted to the drive shaft, wherein the eccentric bearings are spaced apart from each other on the drive shaft;

(c) a first and a second actuator block, each block having a first and a second end, wherein the first actuator block is coupled at its first end with the first eccentric bearing, and the second actuator block is coupled at its first end with the second eccentric bearing, and wherein the second end of each actuator block is adapted to be attached to a respective cutting blade; and

(d) a pivot shaft, mounted through the first and second actuator blocks in a position between the first and second ends of the blocks, wherein, upon rotation of the drive shaft, the actuator blocks are concurrently driven about the pivot shaft in an oscillatory motion relative to each other.

2. The saw of claim 1, additionally comprising a first and a second cutting blade, each blade having a first and a second end, wherein the first ends of the cutting blades are adapted to slidably engage the second ends of the actuator blocks, and wherein the first cutting blade is slidably engaged at its first end to the second end of the first actuator block, and wherein the second cutting blade is slidably engaged at its first end to the second end of the second actuator block, and wherein, upon rotation of the drive shaft, the cutting blades are concurrently driven about the pivot shaft in an oscillatory motion relative to each other.

3. The saw of claim 2, wherein the second ends of the cutting blades have cutting edges.

4. The saw of claim 2, wherein the cutting blades are detachably engaged with the actuator blocks.

5. The saw of claim 2, wherein the first and second cutting blades are bowed in a direction toward each other such that the second ends of the cutting blades are held in close proximity toward each other during use.

6. The saw of claim 5, wherein the first and second cutting blades are pre-loaded so that the blades are biased in a direction toward each other.

7. The saw of claim 2, additionally comprising a blade locking mechanism, rotatably mounted to the actuator blocks, wherein the blade locking mechanism comprises a rotatable blade lock mounted adjacent to a lock actuator block, and wherein the rotatable blade lock holds the first ends of the first and second cutting blades in close proximity to one another within the second ends of the actuator blocks when the lock actuator block is rotated by a user into a first position, and wherein the rotatable blade lock allows the cutting blades to be removed from the actuator blocks when the lock actuator block is rotated by the user into a second position.

8. The saw of claim 1, wherein the eccentric bearings reciprocate about the axis defined by the drive shaft, and wherein the eccentric bearings reciprocate about the drive shaft 180°

out-of-phase with one another.

9. The saw of claim 1, wherein the drive shaft is driven by an electric motor.

10. The saw of claim 9, wherein the electric motor operates at speeds of less than 5,000 revolutions per minute.

11. The saw of claim 1, wherein the drive shaft is driven by a pneumatic power source.

12. The saw of claim 1, additionally comprising a user selectable switch, wherein a user can place the switch in a selected one of a plurality of settings, and wherein the drive shaft rotates at a selected one of a plurality of speeds according to the switch setting selected by the user.

13. A surgical saw, comprising:

(a) a rotatable drive shaft;

(b) a first and a second eccentric bearing coaxially mounted to the drive shaft, wherein the eccentric bearings are spaced apart from each other on the drive shaft, and wherein the first eccentric bearing reciprocates about the drive shaft axis in an orbit which is 180°

out-of-phase with the orbit reciprocated about the drive shaft by the second eccentric bearing;

(c) a first and a second actuator block, each block having a first and a second end, wherein the first actuator block is slidably engaged at its first end with the first eccentric bearing, and the second actuator block is slidably engaged at its first end with the second eccentric bearing, and wherein the second end of each actuator block is adapted to slidably receive a respective cutting blade;

(d) a pivot shaft, mounted through the first and second actuator blocks in a position between the first and second ends of the actuator blocks;

(e) a first and a second cutting blade, each blade having a mounting end and a cutting end, wherein the first cutting blade is slidably engaged at its mounting end to the second end of the first actuator block, and wherein the second cutting blade is slidably engaged at its mounting end to the second end of the second actuator block; and

(f) a pivot pin, mounted through the cutting blades in a position between the mounting ends and the cutting ends of the cutting blades, wherein, upon rotation of the drive shaft, the actuator blocks pivot back and forth about the pivot shaft, concurrently driving the blades about the pivot pin and causing the cutting ends of the blades to move in an oscillatory motion relative to each other.

14. A surgical saw, comprising:

(a) a rotatable drive shaft;

(b) a first and a second eccentric bearing, coaxially mounted to the drive shaft, wherein the eccentric bearings are spaced apart from each other on the drive shaft, and wherein the eccentric bearings reciprocate about the drive shaft axis in orbits which are 180°

out-of-phase with one another;

(c) a first and a second actuator block, each block having a first and a second end, wherein the first actuator block is slidably engaged at its first end with the first eccentric bearing, and the second actuator block is slidably engaged at its first end with the second eccentric bearing, and wherein the second ends of the actuator blocks are adapted to detachably receive a blade cartridge assembly;

(d) a pivot shaft, mounted through the first and second actuator blocks in a position between the first and the second ends of the actuator blocks;

(e) a blade cartridge assembly, having a first and a second end, wherein the first end is detachably mounted to the second ends of the actuator blocks, and wherein the second end of the blade cartridge assembly is adapted to slidably receive a plurality of cutting blades;

(f) a first and a second cutting blade, each blade having a mounting end and a cutting end, wherein the cutting blades are slidably engaged at their mounting ends to the second end of the blade cartridge assembly; and

(g) a pivot pin, mounted through the blade cartridge assembly in a position between the first end and the second end of the assembly, wherein, upon rotation of the drive shaft, the actuator blocks rotate about the pivot shaft and the cutting blades are concurrently driven by the actuator blocks about the pivot pin in an oscillatory movement relative to each other.

15. The surgical saw of claim 14, additionally comprising:

a blade locking mechanism, positioned adjacent one end of the pivot shaft, wherein the blade locking mechanism is rotatably mounted to engage the pivot pin and the blade cartridge assembly, and wherein the blade locking mechanism holds the blade cartridge assembly within the second ends of the actuator blocks when rotated by a user into a first position, and wherein the blade locking mechanism allows the blade cartridge assembly to be removed from the actuator blocks when rotated by the user into a second position.

16. A surgical saw, comprising:

(a) a rotatable drive shaft;

(b) a first and a second eccentric bearing coaxially mounted to the drive shaft, wherein the eccentric bearings are spaced apart from each other on the drive shaft;

(c) a first and a second cutting blade, each blade having a first and a second end, wherein the first cutting blade is slidably engaged at its first end with the first eccentric bearing, and the second cutting blade is slidably engaged at its first end with the second eccentric bearing; and

(d) a pivot shaft, mounted through the cutting blades in a position between the first and second ends of the blades, wherein, upon rotation of the drive shaft, the cutting blades are concurrently driven about the pivot shaft in an oscillatory motion relative to each other.