Surgical saw blade device and system

• US 8,672,943 B2
• Filed: 05/12/2009
• Issued: 03/18/2014
• Est. Priority Date: 05/12/2009
• Status: Active Grant

• Current Assignee: Synvasive Technology Incorporated (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Synvasive Technology Incorporated (Zimmer Biomet Holdings, Inc.)
• Inventors: Fisher, Michael, Chana, Barjinder
• Primary Examiner(s): WOODALL, NICHOLAS W
• Application Number:
  US12/464,825
• Publication Number:
  US 20100292701A1
• Time in Patent Office: 1,771 Days
• Field of Search: 606/79, 606 82- 85, 606167-186, 301/43, 301/51, 301/55
• 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

Abstract

A saw blade assembly for use with a driver having an oscillatory drive member comprises an elongate sheath and an elongate monolithic blade. The sheath'"'"'s proximal end is removably mountable on the driver. The sheath has an open interior which receives the blade. The blade'"'"'s proximal end is pivotably mounted to the sheath'"'"'s proximal end. The blade'"'"'s distal cutting end extends out of the sheath'"'"'s distal end and is transverse to the blade'"'"'s central longitudinal axis. When cutting bone, the drive member pivots the blade'"'"'s cutting end back and forth in an arc about a pivot point at the blade'"'"'s proximal end while the driver holds the sheath stationary to protect surrounding tissues from the motions of the remainder of the blade. The long pivot radius between the proximal pivot point and the distal cutting end contributes to minimizing the angle of engagement of the cutting end to the bone.

Claims

1. A saw blade assembly for use with a driver having an oscillatory drive member for performing surgical cuts to bone tissue with minimal injury to surrounding tissue, said saw blade assembly comprising:

an elongate sheath having a proximal end, a distal end, a first side, an opposing second side, an open interior defined between the first side and the second side, and an aperture through one of the first side and the second side, said proximal end being removably mountable on the driver to be held stationary relative to the driver when said saw blade assembly performs surgical cuts;

an elongate monolithic blade received within the open interior of the sheath, said monolithic blade having a unitary construction, with no moveably connected parts, a central longitudinal axis, a proximal end that extends through the aperture of the elongate sheath to removably couple to the oscillatory drive member of the driver when the proximal end of the elongate sheath is mounted on the driver, a single pivot point located at the proximal end, a first side, an opposing second side, and a distal cutting end transverse to the central longitudinal axis and extending from the distal end of the sheath;

wherein the first side of the blade faces the first side of the sheath and the second side of the blade faces the second side of the sheath;

wherein a majority of the blade is housed within the interior of the sheath,

wherein the sheath has no moving internal parts other than the elongate monolithic blade; and

wherein the oscillatory drive member pivots the distal cutting end back and forth about the pivot point at the proximal end of the monolithic blade when the proximal end of the monolithic blade is coupled to the oscillatory drive member to perform surgical cuts.

2. The saw blade assembly of claim 1, wherein the distal cutting end is configured to engage bone tissue at an angle of less than about 10 degrees.

3. The saw blade assembly of claim 2, wherein the distal cutting end is configured to engage bone tissue at an angle of less than about 6 degrees.

4. The saw blade assembly of claim 3, wherein the distal cutting end is configured to engage bone tissue at an angle of less than about 3 degrees.

5. The saw blade assembly of claim 1, wherein the saw blade assembly further comprises at least one elongate support rib.

6. The saw blade assembly of claim 5, wherein the at least one elongate support rib is coupled to the elongate sheath.

7. The saw blade assembly of claim 5, wherein the at least one elongate support rib is formed in the elongate sheath.

8. The saw blade assembly of claim 1, wherein the distal cutting end of the monolithic blade is perpendicular to the central longitudinal axis of the monolithic blade.

9. The saw blade assembly of claim 1, wherein the distal cutting end of the monolithic blade comprises a plurality of teeth, each tooth comprising a distal tip.

10. The saw blade assembly of claim 9, wherein the tips of each tooth are positioned on a single straight line perpendicular to the central longitudinal axis of the elongate monolithic blade.

11. The saw blade assembly of claim 9, wherein each tooth is identically shaped.

12. The saw blade assembly of claim 9, wherein the plurality of teeth comprises an even number of teeth.

13. The saw blade assembly of claim 9, wherein each tooth is shaped as a right triangle, each tooth having a right angle, a hypotenuse opposite the right angle, and a longitudinal side adjacent the hypotenuse, wherein the right angle of each tooth is oriented at least one of toward or away from the central longitudinal axis of the blade.

14. The saw blade assembly of claim 13, wherein the longitudinal side of each tooth is disposed along a radial line extending from the tip of the tooth to the pivot point at the proximal end of the monolithic blade.

15. The saw blade assembly of claim 13, wherein the longitudinal sides of each tooth are parallel with one another.

16. The saw blade assembly of claim 13, wherein the right angle of each tooth is oriented away from the central longitudinal axis of the monolithic blade.

17. The saw blade assembly of claim 16, wherein the distal cutting end further comprises a centrally positioned tooth shaped as an isosceles triangle, said centrally positioned tooth being formed by two right triangular teeth sharing the same longitudinal side disposed along the central longitudinal axis of the blade.

18. The saw blade assembly of claim 13, wherein the cutting surface further comprises a centrally positioned tooth shaped as an isosceles triangle.

19. The saw blade assembly of claim 9, wherein the tips of the plurality of teeth are disposed along an arc centered about the pivot point at the proximal end of the monolithic blade.

20. The saw blade assembly of claim 9, wherein each tooth is identically shaped as an approximately isosceles triangle and the tips of the plurality of teeth are disposed along a lateral line perpendicular to the central longitudinal axis of the monolithic blade.

21. The saw blade assembly of claim 9, wherein the plurality of teeth comprises a plurality of inner teeth and a plurality of outer teeth, and wherein the tips of the plurality of inner teeth are disposed on a first single straight line perpendicular to the central longitudinal axis, the tips of the plurality of the outer teeth are disposed on a second single straight line perpendicular to the central longitudinal axis, the first single straight line being different than the second single straight line.

22. The saw blade assembly of claim 1, wherein at least a portion of the monolithic blade comprises at least one of metal, stainless steel, composite, carbon fiber composite, polymer, titanium, or ceramic.

23. A surgical saw system for performing surgical cuts to bone tissue with minimal injury to surrounding tissue, the surgical saw system comprising:

the saw blade assembly of claim 1; and

a drive assembly comprising the driver having the oscillatory drive member, said drive assembly being configured to couple to the saw blade assembly to pivotably drive the monolithic blade of the saw blade assembly to cut tissue.

24. The surgical saw system of claim 23, further comprising an external battery pack coupleable to the drive assembly to power the drive assembly.

25. The surgical saw system of claim 23, wherein the drive assembly is hand-holdable.

26. The surgical saw system of claim 23, wherein the drive assembly comprises a locking mechanism having an open configuration and a closed configuration, wherein the saw blade assembly is insertable into the locking mechanism in the open configuration to couple the saw blade assembly to the drive assembly, and wherein the locking mechanism in the closed configuration holds the sheath of the saw blade assembly stationary relative to the driver and couples to the elongate monolithic blade when the drive assembly is coupled to the saw blade assembly.

27. The surgical saw system of claim 26, wherein the locking mechanism comprises a lever actuatable to switch the locking mechanism between the open and closed configurations.

28. The surgical saw system of claim 26, wherein the proximal end of the monolithic blade defines an aperture at the pivot point, and wherein the linkage mechanism comprises a knob which fits into the aperture of the proximal end of the monolithic blade when the linkage mechanism is in the closed configuration when the drive assembly is coupled to the saw blade assembly.

29. The surgical saw system of claim 26, wherein the locking mechanism comprises a saw blade assembly slot adapted to hold a proximal end of the saw blade assembly stationary relative to the driver when the saw blade assembly is inserted into the locking mechanism.

30. The surgical saw system of claim 23, wherein the oscillatory drive member comprises a blade slot adapted to hold the proximal end of the monolithic blade when the saw blade assembly is inserted into the locking mechanism.

31. The surgical saw system of claim 23, wherein the drive assembly comprises an electric motor and an eccentric mechanism coupled to the electric motor.

32. The surgical saw system of claim 31, wherein the eccentric mechanism is coupled to the oscillatory drive member to oscillate the blade about the pivot point when the saw blade assembly is coupled to the drive assembly.

33. The surgical saw system of claim 31, wherein the drive assembly further comprises a trigger pressable to activate the electric motor.

34. The surgical saw system of claim 31, wherein the electric motor is removable from the drive assembly.

35. The surgical saw system of claim 23, further comprising a noise absorbent sheath for covering at least a portion of the drive assembly.

36. The surgical saw system of claim 23, further comprising at least one cutting guide configured to guide the saw blade assembly in cutting bone tissue.

37. A saw blade assembly for use with a driver having an oscillatory drive member and for performing surgical cuts to bone tissue with minimal injury to surrounding tissue, the saw blade assembly comprising:

an elongate sheath having a proximal end, a distal end, and an aperture through one side, the proximal end being mountable on the driver to be held stationary relative to the driver when said saw blade assembly performs surgical cuts; and

an elongate monolithic blade, a majority of which is disposed within the sheath, wherein the blade has a unitary construction, with no moveably connected parts, a central longitudinal axis, a proximal end that extends through the aperture of the elongate sheath to removably couple the blade to the oscillatory drive member of the driver when the proximal end of the elongate sheath is mounted on the driver, and a distal cutting end transverse to the central longitudinal axis and extending from the distal end of the sheath,

wherein the one side extends substantially parallel to a top surface of the blade,

wherein the oscillatory drive member pivots the distal cutting end back and forth about a pivot point at the proximal end of the monolithic blade when the proximal end of the monolithic blade is coupled to the oscillatory drive member to perform surgical cuts, and

wherein the sheath has no moving internal parts other than the elongate monolithic blade.