USRE44896E1 - Dissecting high speed burr for spinal surgery - Google Patents

Abstract

A rotatable surgical burr (100, 200, 300, 500) having a protective hood (120, 220, 320, 520, 620, 720) with a dissecting foot plate (119, 219, 319, 519, 619, 719) is provided to improve and enable various spinal decompression procedures. The surgical burr's protective hood has a dissecting foot plate that may be shaped to resemble a curette, a Woodson, or other appropriate dissecting tools to allow insertion of the tool between the spinal nerve and the compressing bone. The protective hood surrounds the burr bit (130, 230, 530) exposing only a portion of the burr bit for burring of the offending bone and protects the nerve from the burr tip. The instrument may also be configured with a soft tissue resecting tip (330) for soft tissue resection.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 60/531,209 filed on Dec. 19, 2003, the contents of which is incorporated herein by reference.

FIELD OF THE INVENTION

This invention relates to a surgical instrument and more particularly to a surgical high-speed burr for use in spinal surgical procedures.

BACKGROUND OF THE INVENTION

Spinal stenosis is a degenerative condition of the spine that afflicts primarily the elderly population. Patients with lumbar spinal stenosis suffer from severe radiating pain, which limits their ability to ambulate and can cause weakness and numbness in the legs and in severe cases, loss of bowel and bladder control may occur. It is the development of hypertrophic bone spurs off the facet joints, protrusions of the disc annulus, as well as hypertrophy of the ligamentum flavum that combine to narrow the space available for the nerves in the spinal canal.

The standard surgical procedure to treat lumbar spinal stenosis is known as the lumbar laminectomy and foraminotomy. During this procedure, the surgeon removes the spinous processes, the interspinous ligaments and the central portion of the spinal lamina to gain a line of sight into the lateral recess and into the foramen so that the nerve compression can be relieved in these areas. The current standard tools for performing this procedure are the Kerrison punch and angled curettes and in severe instances, osteotomes. To remove the offending bone using these instruments, a surgeon places the instrument into the interval between the compressing bone and the underlying nerve that is being compressed and the bone is then removed from the dorsal aspect of the nerve where it is impinged, thereby relieving compression exerted on the spinal nerve. In situations where the compression on the nerve is not very severe, one can safely insert the Kerrison footplate or the curette into the interval between the nerve root and the surrounding bone to perform the necessary bone removal.

However, when there is a severe amount of compression at the neural foramen or the lateral recess, the interval between the nerve root and the encroaching bone may not be sufficient to safely conduct the neural decompression using the conventional tools, such as a Kerrison punch or a curette. Insertion of a Kerrison footplate or a curette into a severely stenotic interval may cause compressive injury to an already compressed nerve root. In these situations, the only conventionally available method of successfully decompressing the neural compression, especially in the foramen, has been to pass a small curved osteotome in the plane that is superior to the nerve root and osteotomize the bone that is encroaching on the nerve root from above. This maneuver, however, poses risk to the nerve root because there is a possibility that the osteotome will slip or advance too deep, thereby damaging the exiting nerve. Thus, there is a need for an improved instrument that would allow a safer, more controlled method of foraminal lateral recess decompression that minimizes risks to the nerve roots, especially in severely stenotic situations.

Additionally, the need to remove the interspinous ligament, the spinous processes and the central portion of the lamina in open lumbar laminectomy is only to allow the surgeon to have a line of sight into the lateral recess and foramen to remove pressure on the compressed nerve. In surgery, the surgeon works from the opposite side of the table to get the appropriate line of sight and angle of attack at the encroaching bone and soft tissue in the lateral recess in the foramen. Working from the contralateral side of the table is necessary in order to be able to undercut the facet joints and thereby preserve spinal stability with these procedures. This line of attack is necessary because of the shape of the current standard instruments, such as a Kerrison punch, curette or osteotome, and the necessary vector of applied force that is required using those instruments. There is therefore an additional need for an instrument that would allow for ipsilateral decompression of the lateral recess and the foramen. This instrument would need to allow for undercutting of the facet joints and removal of compressive bone and soft tissue in the lateral recess and the foramen on the ipsilateral side of the patient (decompression on the same side of the table as opposed to working across the spinal canal from the contralateral side of the table). Such an instrument would also allow for the application of minimally invasive techniques to perform lumbar decompressions and would allow for the maximal preservation of bone and ligaments thereby preserving spinal stability.

One tool that is available to a spine surgeon to remove bone, in a controlled fashion, is a high speed burr. The burr is used from the dorsal surface of the bone heading towards the neural elements and the bone is thinned down until it is wafer thin and can be picked away with curettes. If one is too aggressive with the burr, then neural injury can occur by penetrating the dura or wrapping the neural elements in the burr bit. Because the risk of catching the neural elements with the conventional high speed burr bit is too high, the use of conventional high speed burrs to perform the lateral recess and foraminal decompression has not been practicable. Thus, an improved novel high speed burr for removing bone in such tight spaces is desired.

SUMMARY

A surgical instrument according to an embodiment of the invention comprises a hand piece, a rigid shaft portion extending from the hand piece and having a distal end and a proximal end, and a drive shaft disposed for rotation within the shaft portion. The drive shaft has a distal end and a proximal end thereof and a surgical tool bit is connected to the distal end of the drive shaft. A protective hood including a dissecting foot plate portion is connected to the distal end of the shaft portion. And the surgical tool bit resides within the protective hood, partially exposed, and the protective hood is rotatable relative to the surgical tool bit along the longitudinal axis of the surgical tool bit, exposing a different portion of the surgical tool bit.

A surgical instrument according to another embodiment comprises a hand piece, a power drive mechanism provided within the hand piece, a rigid shaft portion extending from the hand piece and having a distal end and a proximal end, and a drive shaft disposed for rotation within the shaft portion. The drive shaft has a distal end and a proximal end thereof, and the proximal end is connected to the power drive mechanism. A surgical tool bit is connected to the distal end of the drive shaft and a protective hood including a dissecting foot plate portion is attached to the distal end of the shaft portion. The surgical tool bit resides within the protective hood, partially exposed, and the protective hood is rotatable relative to the surgical tool bit along the longitudinal axis of the tool bit, exposing a different portion of the surgical tool bit.

The dissecting soft tissue resector embodiment could also be used, with an extended kind of a Woodson type tip, to get in between compressive tissue and the nerve root that is sometimes found in the foramen that can continue to cause residual compression on the nerve, even after a dorsal bony decompression has been performed. The dissecting soft tissue resector may be used to debride annulus, ligamentum flavum, disc and or cartilage that are encroaching the nerve root in the axilla or in the foramen.

In addition to allowing a safer foraminal decompression in the open setting, the dissecting burr according to an embodiment of the invention is also suited for performing lumbar decompression in minimally invasive surgical settings while sparing bone and ligament that are in close proximity to the surgical site.

BRIEF DESCRIPTION OF THE DRAWING

The drawings are schematic and the like reference numerals used in the figures denote like parts throughout the various figures.

FIG. 1a is a side elevational view of a dissecting burr according to an embodiment of the invention.

FIG. 1b is a detailed side elevational view of region A inFIG. 1a.

FIG. 1c is a front elevational view of the region A inFIG. 1a.

FIG. 1d is a front elevational view of the dissecting burr ofFIG. 1c with an alternative shape for the dissecting foot plate according to another embodiment of the invention.

FIG. 1e is an illustration of a dissecting foot plate of a dissecting burr according to another embodiment.

FIG. 2a is a side elevational view of the distal end of another dissecting burr according to another embodiment of the invention.

FIG. 2b is a front elevational view of the dissecting burr ofFIG. 2a.

FIG. 2c is a front elevational view of the dissecting burr ofFIG. 2b with an alternative shape for the dissecting foot plate according to another embodiment of the invention.

FIG. 3a is a side elevational view of a dissecting soft tissue resector according to another embodiment of the invention.

FIG. 3b is a front elevational view of the dissecting soft tissue resector ofFIG. 3a.

FIG. 3c is a front elevational view of the dissecting soft tissue resector ofFIG. 3a having an alternative shaped dissecting foot plate according to another embodiment of the invention.

FIG. 4a is a side elevational view of an inner shaft member of the dissecting burr ofFIG. 1.

FIG. 4b is a cross-sectional schematic illustration of the inner shaft member ofFIG. 4a;

FIG. 5a is a cross-sectional schematic illustration of a protective hood of the dissecting burr ofFIG. 1;

FIG. 5b is a cross-sectional schematic illustration of the protective hood ofFIG. 5a with the inner shaft member ofFIG. 4a disposed therein.

FIG. 5c is a cross-sectional schematic illustration of region B inFIG. 5a.

FIG. 6A is an isometric view of a dissecting burr according to an embodiment of the invention.

FIG. 6B is a plan view illustration of the dissecting burr ofFIG. 6A.

FIG. 7A is a more detailed view of the distal end of the dissecting burr ofFIG. 6A.

FIG. 7B is a longitudinal sectional view of the distal end of the dissecting burr ofFIG. 6A.

FIG. 8 is a longitudinal sectional view of the proximal end of the dissecting burr ofFIG. 6A.

FIGS. 9A-9F are various illustrations of the flexible neck portion of the distal end of the dissecting burr ofFIG. 6A.

FIGS. 10A-10C are detailed illustrations relating to how the flexible neck portion bends.

FIGS. 11A-11D are detailed illustrations of a burr hood according to an embodiment of the invention.

FIGS. 12A-12C and13A-13C are detailed illustrations of a burr hood according to another embodiment of the invention.

DETAILED DESCRIPTION

Various embodiments of the dissecting high speed burr according to the invention will now be described in reference to theFIGS. 1 through 5. The embodiments illustrated in these drawings are presented as examples of various embodiments of the invention only. These illustrations are not meant to limit the invention to these examples. The illustrations are not to scale and, thus, the relative dimensions of some of the aspects of the instrument may be exaggerated.

Referring toFIGS. 1a-1d, a dissectingburr100 according to an embodiment of the invention is disclosed. The dissectingburr100 comprises ahand piece114 at itsproximal end112 and a bone burring surgical tool bit, aburr bit130, at itsdistal end110 housed in aprotective hood120. A generally hollowouter tube115 connects thehand piece114 to theprotective hood120.

In an embodiment of the invention, theouter tube115 may be angled at aregion117 near thedistal end110 to allow the instrument to reach into the neural foramen of a patient during a foraminal decompression. Theangled region117 may be configured and adapted to have a fixed angle or provided with a hinged or other articulated flexible joints to allow the angle of thedistal end110 of the instrument to be adjusted as desired.

In another embodiment, theouter tube115 may be straight without anyangled neck portion117. Such straight burr instrument may not be suitable for foraminal decompression but could be used in situations where the bone spurs are encroaching the foramen from the posterior lip of the ventral vertebral bodies. The straight dissecting burr may be used to go in underneath a nerve root and remove the ventrally encroaching bone. Currently, there are no tools that allow for the safe removal of bone ventral to the nerve root in the foramen.

Thehand piece114 functions as a handle for the surgeon to hold and manipulate the dissectingburr100 and may house a power drive mechanism, such as an electrical motor or a pneumatic drive mechanism, to drive theburr bit130 of the dissectingburr100. The burr bit130 also may be driven by other suitable driving means. An elongatedouter tube115 connects thehand piece114 and theprotective hood120. Theouter tube115 houses an appropriate mechanical linkage that connects the power drive mechanism to theburr bit130.

Theprotective housing120 has anopening122 exposing one portion of theburr bit130. Generally, the superior or dorsally facing surface of theburr bit130 is exposed while the undersurface of theburr bit130 is protected by aprotective hood120. Theprotective hood120 includes a dissectingfoot plate portion119, the portion of theprotective hood120 from about the widest portion to thedistal tip118, that is shaped to enable thedistal end110 of the dissectingburr100 to be inserted between the encroaching bone and the nerve root during a foraminal decompression procedure, for example. Theprotective hood120 enshrouding theburr bit130 protects the surrounding soft tissue, such as the nerve root, from being damaged by theburr bit130 during the bone burring procedure.

The dissectingfootplate119 is shaped like a surgical dissection tool such as a curette, the Woodson, etc. During surgery, thedistal end110 of the dissectingburr100 is placed in the neural foramen with the exposedburr bit130 oriented towards the offending bone. The rest of theburr bit130 is covered by theprotective hood120, which rests against the underlying nerve root thereby protecting the nerve from theburr bit130.

FIGS. 1b and 1c are detailed side view and a frontal view, respectively, of thedistal end110 of the dissectingburr100. Theprotective hood120 may be axially rotatably attached to theouter tube115 so that theprotective hood120 is rotatable about alongitudinal axis10 of thedistal end110 of the dissectingburr100. Theopening122 of theprotective hood120 is sized and configured to expose a desired amount of theburr bit130 appropriate for the bone removal to be performed with the instrument. By having an axially rotatableprotective hood120, the burr bit's exposed cutting portion can be repositioned to accommodate to the varying geometric relationship of the offending bone to the compressed nerve. In other words, theprotective hood120 may be axially rotated, changing the angle of attack of theburr bit130. The dissectingburr100 is mechanically configured such that the rotational motion of theprotective hood120 is manipulable by the surgeon from thehand piece114. Thus, the surgeon can change the direction of the bone resection without moving the whole instrument, the dissectingburr100, just by manipulating the orientation of theprotective hood120 from thehand piece114.

Conversely, theprotective hood120 is positioned to maximally protect the underlying nerve from the exposed burr face. This configuration allows the angular orientation of theopening122 in theprotective hood120 to be changed about its longitudinal axis and change the direction of the exposed burr bit.

Theburr bit130, theprotective hood120 and the dissectingfoot plate portion119 of the dissectingburr100 may be made in any desired sizes. In one embodiment, theprotective hood120 and the dissectingfoot plate portion119 may be provided in the following dimensions that are useful for foraminal decompression. In this example, the dissectingfoot plate119 of the instrument is illustrated with a shape resembling a Woodson tip. InFIGS. 1c and 1d, a dissecting burr instrument having Woodson-type dissectingfoot plate119 according to an embodiment of the invention is disclosed. InFIG. 1e, a dissecting burr instrument having a curette-type dissectingfoot plate119 according to another embodiment is disclosed.

TABLE
Burr Bit Diameter	2 mm	3 mm	4 mm

Protective Hood Size	3mm	8 mm	4 mm	9 mm	5mm	10 mm
(diameter at the
widest portion)

Dissecting Foot	1 to 8 mm long with taper depending on the
Plate Size	width of the protective hood.

The protective hood sizes are the diameter W1 (FIG. 1c) of the hood measured at the widest portion. In these examples, there are two sizes ofprotective hood120 for each burr bit size. The larger diameter protective hoods are primarily intended for central laminectomy whereas the smaller protective hoods are primarily intended for foraminotomy. This preference is determined by the amount of protection needed for the nerve tissue depending on the type of procedure and the location in which the instrument is being used to remove bony tissues from the patient. Some procedures require more protection from the burr for the other tissues surrounding the surgical site.

During surgery, the surgeon inserts the dissectingfoot plate portion119 of the dissectingburr100 into the interval between the nerve root and the overlying compressing bone and continue to insert the instrument into the interval until the burr is positioned at a suitable location for removing the encroaching bone. The dissectingburr100 is then turned on at high speed and theburr bit130 is generally pushed forward into the encroaching bone. As such the whole width of the dissectingburr100 is not forced into the interval between the bone and the nerve root. This minimizes any additional compression that may be exerted by the dissectingburr100 because as the burr is advanced, the overlying bone is resected. The amount of bone that is removed depends on the combined girth or the diameter of theburr bit130 and theprotective hood120 that is inserted into the interval.

FIG. 2a is a schematic side view illustration of a dissectingburr200 according to another embodiment of the invention. The dissectingburr200 of this embodiment is similar to that illustrated inFIGS. 1a-1c. The dissectingburr200 comprises an axially rotatableprotective hood220 that houses aburr bit230. Theprotective hood220 is axially rotatably attached toouter tube215. The diameter of theouter tube215 and the diameter of the rotatingprotective hood220 are substantially similar throughout their lengths without the bulgedportion128 of theprotective hood120 in the embodiment of the dissectingburr100. Such configuration provides smoother profile that may be beneficial during a surgical procedure.

FIG. 2b is a schematic frontal view illustration of the dissecting burr ofFIG. 2a. Theprotective hood220 has anopening222 exposing one portion of theburr bit230. Generally, the superior or dorsally facing surface of theburr bit230 is exposed while the undersurface of theburr bit230 is protected by aprotective hood220. Again, the shape of the dissectingfoot plate portion219 of theprotective hood220 may be made in a variety of shapes as appropriate to meet the variety of dissecting action required in various spinal decompression procedures or any other bone removing procedures in which these instruments may be useful. For example, the dissectingfoot plate portion219 may be shaped like a curette or a Woodson surgical dissection tool.

Theprotective hood220 may be rotatable about thelongitudinal axis20 of the distal end of the instrument to allow the surgeon to change the direction of the burring action of the burr bit. Theprotective hood220 will generally be fixed so that it does not rotate while the dissectingburr200 is in operation (i.e. the burr bit is rotating). Adjustments in the orientation of the protective hood may be made when the instrument is turned off. InFIG. 2c, an alternative shape for the dissectingfoot plate portion219 is illustrated, which is a Woodson-type tip.

Referring toFIGS. 3a-3c, a dissectingsoft tissue resector300 according to another embodiment of the invention. The dissectingsoft tissue resector300 comprises ahand piece314 and anouter tube315 that functions as the shaft of thesoft tissue resector300. In this embodiment, however, the surgical tool disposed within a rotatingprotective hood320 is a softtissue resector bit330 rather than aburr bit130,230. Theprotective hood320 has an opening322 exposing a portion of the softtissue resecting bit330. The portion of theprotective hood320 between the widest portion W2 of the protective hood and thedistal tip318 of theprotective hood320 is a dissectingfoot plate portion319, shaped to resemble a surgical dissection tool, such as a curette or a Woodson. Theouter tube315 may be angled to allow the instrument to reach into the neural foramen or other surgical sites with ease.

Theprotective hood320 may be axially rotatably attached to theouter tube315. Theprotective hood320 is rotatable about alongitudinal axis30 of the distal end310 of the dissectingsoft tissue resector300. The opening322 is sized and configured to expose a desired amount of theburr bit330 appropriate for the bone removal to be performed with the instrument. This rotatable attachment allows the soft tissue resecting bit's exposed cutting portion to be repositioned to accommodate the varying geometry at the surgical site. In other words, theprotective hood320 may be axially rotated, changing the angle of attack of the softtissue resecting bit330. The side with the exposed softtissue resecting bit330 would generally be the dorsal side of thesoft tissue resector300. The softtissue resecting bit330 is similar to that of the meniscal debriders that are used in arthroscopic surgery.

The dissectingsoft tissue resector300 may preferably have a suction means attached to it to remove the resected tissue debris from the surgical site. Vacuum may be drawn through theouter tube315 and to the softtissue resecting bit330. Preferably, the tissue resecting bit's cutting teeth333 are spaced apart to provide sufficiently large open spaces335 between the cutting teeth333, allowing removal of the resected tissue debris through those open spaces by the vacuum. Thesoft tissue resector300 may be configured with channel(s) or passage(s) within the instrument so that vacuum may be applied through the instrument, the open spaces between the cutting teeth333 of the softtissue resector bit330 functioning as the intake opening.

The dissectingsoft tissue resector300 embodiment could also be used, with an extended kind of a Woodson-typefoot plate portion319 as shown inFIGS. 3b and 3c, to get in between compressive tissue and the nerve root that is sometimes found in the foramen that can continue to cause residual compression on the nerve, even after a dorsal bony decompression has been performed. The dissecting soft tissue resector may be used to debride annulus, ligamentum flavum, disc and or cartilage that are encroaching the nerve root in the axilla or in the foramen.

FIG. 4a is a schematic illustration of aninner shaft140 of a dissectingburr100 according to an embodiment of the invention with aburr bit130 provided at its distal end.FIG. 4b is a cross-sectional schematic illustration of aninner shaft140 and aburr bit130 showing an example of how they may be joined together. In this example, theburr bit130 has abase portion137 that is inserted into the inner shaft and secured. Thebase portion137 and theinner shaft140 may be secured together by any appropriate methods such as press fitting, welding, ultrasonic welding. Alternatively theburr bit130 may be secured to theinner shaft140 using an adhesive. Theburr bit130 has helical cutting or abradingedges131 on the head portion and abase portion137 for attaching theburr bit130 to theinner shaft140. Theinner shaft140 is shown as a hollow tube in this example, but it may also be a flexible solid shaft made from such elastic material as Nitinol metal alloy.

Thesoft tissue resector300 discussed in reference toFIG. 3 may also utilize a similar inner shaft. In that embodiment, a softtissue resector bit330 would be disposed at the distal end of the inner shaft. And to enable the vacuum tissue removal feature of thesoft tissue resector300, the inner shaft in this embodiment would have a tubular structure (as the inner shaft illustrated inFIG. 4b) with one or more channels therein. The softtissue resector bit330 may be provided with one or more channels or pathways through its base portion so that the open spaces335 between the tissue cutting teeth333 of thetissue resector bit330 are communicatively connected to the one or more channels of the inner shaft. A vacuum drawn through the inner shaft of the instrument can then remove soft tissue debris from the surgical site using the open spaces335 between the tissue cutting teeth333 as the intake openings.

Referring toFIGS. 5a-5c, exemplary detailed views of the rotatableprotective hood120 and theburr bit130 assembly will be discussed.FIG. 5a is a cross-sectional schematic illustration of theouter tube115 and the rotatingprotective hood120 of the dissectingburr100 ofFIG. 1. The rotatingprotective hood120 is rotatably attached to the distal end of theouter tube115. The distal end of the protective hood is the dissectingfoot plate119. Theprotective hood120 has an open space121 in which the burr bit130 (or a softtissue resector bit330 in the dissecting soft tissue resector embodiment300) attached to theinner shaft140 may be disposed.

FIG. 5b is a schematic illustration of theprotective hood120 ofFIG. 5a with theinner shaft140 and theburr bit130 disposed therein occupying the open space121 inside theprotective hood120. Theinner shaft140 is disposed inside theprotective hood120 and theouter tube115 in such manner so that theinner shaft140 can rotate about thelongitudinal axis10. The inner surface of theouter tube115 comprises a first innercylindrical side wall123 having a first diameter and a second innercylindrical side wall124 having a second diameter that is smaller than the first diameter. This second inner cylindricalside wall surface124 provides a bearing means151 that comes in contact with theinner shaft140 allowing theinner shaft140 to rotate about thelongitudinal axis10 with low friction. A portion of theburr bit130 is shown exposed by theopening122 in theprotective hood120.

FIG. 5c is a detailed schematic illustration of region B inFIG. 5a. This illustration is one example of the rotational engagement between theprotective hood120 and theouter tube115. The proximal end of theprotective hood120 may form anouter sleeve126 and the distal end of the outer tube may form aninner sleeve116 that mate with one another and a suitable bearing means152 is disposed between the mating sleeve surfaces to allow the protective hood to rotate about thelongitudinal axis10 of the distal end of the instrument. The rotatable joint between theouter tube115 and theprotective hood120 may be formed in a variety of other configurations that are well known in the art.

The power drive mechanism for rotating the inner shaft/burr bit assembly may be any one of the known mechanisms known in the art. Many examples can be found in many conventional high speed surgical burrs, abraders, and other hand held power surgical instruments. Electrical motors or pneumatic power driven driving mechanisms commonly found in such instruments may be used to power the instrument of the invention.

As illustrated inFIGS. 1a,2a and3a, theouter tube115,215,315 of the instruments of the invention may preferably include anangled neck portion117,217,317 whose angle may be variably controlled. The power drive mechanism utilized in those embodiments would have to accommodate the angled neck. Many known flexible coupling mechanisms may be utilized here to transmit the rotational motion of the power drive mechanism, usually housed in thehand piece114,214,314, to theburr bit130,230 or the softtissue resector bit330. Such flexible coupling mechanism may be, for example, multiple hinged linkages used to drive socket wrenches or helical coil flexible connectors often used with hand held drills. In another embodiment, theflexible neck portion117,217,317 of the instrument may be hollow structures and a solid shaft made of elastic materials such as Nitinol metal alloy provided therethrough may connect the power drive mechanism to thetool bits130,230,330 for actually driving the tool bits. One example of a flexible coupling mechanism is disclosed in U.S. Pat. No. 5,411,514 (Fucci et al.), the disclosure of which is incorporated herein by reference.

Referring toFIGS. 6A and 6B, a dissectingburr500 according to another embodiment of the invention is disclosed. The dissectingburr500 is well suited for the surgical operations discussed herein. The dissectingburr500 has an elongated shape with a dissecting burr tool at thedistal end510 and ahand piece514 at the proximal end. Connecting thehand piece514 and thedistal end510 of the dissectingburr500 is ashaft portion515. The dimensions of theshaft portion515 and thedistal end510 of the dissectingburr500 are such that they can be inserted through a cannula to reach the surgical site percutaneously. Provided at thedistal end510 is a burr bit partially enclosed by aprotective hood520. Theprotective hood520 and the burr bit are connected to theshaft portion515 by aflexible neck portion517. Theflexible neck portion517 is controllably bendable in dorsal direction marked by an arrow U inFIG. 6A. Thehand piece514 may be provided withthumb wheels610 and620, one for controlling the rotational position of theprotective hood520 and the latter for controlling the bending angle of theflexible neck portion517. Thehand piece514 may house a power drive mechanism for driving the burr bit. Such power drive mechanism may be any suitable source that can rotate the burr bit at high speeds, such as an electric motor or a pneumatic drive mechanism.

More detailed views of thedistal end510 of the dissectingburr500 are illustrated in side elevational viewFIG. 7A and a longitudinal sectional viewFIG. 7B. Theprotective hood520 includes a dissectingfoot plate portion519 which partially covers theburr bit530 leaving theburr bit530 partially exposed in one direction for removing bone material. Theprotective hood520 is rotatable about the longitudinal axis L of the burr bit530 (which is also the longitudinal axis of the dissectingburr500. Theprotective hood520 has abase portion525 that is connected to thetubular shaft515 via aflexible sleeve518, which in turn is connected to thethumb wheel610. The user can turn or rotate theprotective hood520 by turning thethumb wheel610 to adjust the exposure direction or the angle of attack for theburr bit530 as desired during a surgical procedure.

As illustrated in the sectional view ofFIG. 7B, the connection between thebase portion525 of theprotective hood520 and theflexible sleeve518 may be achieved by a friction fit. InFIGS. 7A and 7B, theflexible sleeve518, which is a helical coil type in this exemplary embodiment, is only shown at the two ends so that the internal structures of theflexible neck517 can be better illustrated. The proximal end of theflexible sleeve518 is affixed to thetubular shaft515. Again, this connection may be a friction fit connection.

FIG. 8 is a sectional view of thehand piece514 and the arrangement of thethumb wheels610 and620 is illustrated. Thetubular shaft515 is affixed to thefirst thumb wheel610 so that turning thethumb wheel610 also turns thetubular shaft515 which, in turn, turns theflexible sleeve518, which then turns theprotective hood520. Theflexible sleeve518 may be a helical coil type as illustrated inFIGS. 7A and 7B. Thethumb wheel610, thetubular shaft515, theflexible sleeve518, and theprotective hood520, all share a common rotational axis, which is the longitudinal axis L of the dissectingburr500. Thethumb wheel610 may be provided with an appropriate mechanism (not shown) to lock thethumb wheel610 from rotating in order to lock the orientation of theprotective hood520 after being adjusted. A variety of locking mechanism may be used for such purpose and it would be obvious to one of ordinary skill in the art to employ such mechanisms.

Nested inside thetubular shaft515 is a first inner tube712 (FIGS. 7B and 7C). The firstinner tube712 at the proximal end extends into thehand piece514 and is friction fitted or affixed by other appropriate means to thehand piece514 to prevent it from turning about the longitudinal axis L. At its distal end, the firstinner tube712 is connected to a series ofouter links710 which extend through theflexible sleeve518 and hingeably connects to a burr drive spindle housing536 (FIG. 7B). As illustrated inFIG. 7A, theouter links710 are hingeably linked to each other by ahinge711. Because the firstinner tube712 is non-rotatably affixed to thehand piece514, theouter links710 also are not rotatable about the longitudinal axis L. The linkage formed by theouter links710 are, however, bendable in one direction, the dorsal direction U, marked inFIG. 6A. This is because theouter links710 are lined up so that the rotational axis M (FIG. 9A) through theirhinges711 are orthogonal to the dorsal direction U.

As illustrated inFIG. 7B, nested inside the firstinner tube712 is a secondinner tube722. The secondinner tube722 at its proximal end extends into thehand piece514 and it is friction fitted or affixed by other appropriate means to thesecond thumb wheel620. At its distal end, the secondinner tube722 is connected to a series ofinner links720 which extend through theouter links710, with the lastinner link720′ stopping at the end of theflexible neck portion517. Thus, theinner links720 are not connected to anything at the distal end. Theinner links720 are hingeably linked to each other by hinge pins737 (FIG. 9B). As will be further discussed below in more detail, turning thesecond thumb wheel620 rotates theinner links720 and causes the assembly formed by theouter links710 to bend up or down in the dorsal direction U.

As shown inFIG. 7B, nested inside the secondinner tube722 is adrive shaft542. Thedrive shaft542 may be a rigid shaft and at its proximal end it extends into thehand piece514 and is affixed to adrive linkage544 which connects thedrive shaft542 to apower drive unit550. Thepower drive unit550 may be an electric motor, a pneumatic drive unit, or any other suitable mechanism that can turn thedrive shaft542 at desired speeds. Thedrive shaft542 at its distal end is affixed to asecond drive shaft540 that is flexible. Thesecond drive shaft540 may be made of strong and elastic material such as Nitinol alloy. Thesecond drive shaft540 extends through theinner links710 and at the distal end is affixed to aburr drive spindle535. Theburr drive spindle535 is, in turn, connected to aburr bit530. Alternatively, thesecond drive shaft540 may be directly connected to theburr bit530 without the intermediate structure such as thespindle535. Alternatively, the flexiblesecond drive shaft540 may extend all the way to thedrive linkage544 in thehand piece514 so that a single piece drive shaft extends from thedrive linkage544 to theburr bit530 or theburr bit spindle535. The interface between thespindle535 and thespindle housing536 is provided with a suitable lubricant or bearing arrangement so that thespindle535 may rotate with minimal frictional interference. Similarly, the interface between thespindle housing536 and thebase portion525 of theprotective hood520 is also provided with a suitable lubricant or bearing arrangement.

Referring toFIGS. 9A-9F and10A-10C, the controllably bending mechanism of theflexible neck portion517 achieved by theouter links710 and theinner links720 in this exemplary dissectingburr500 will be described. As mentioned above, theouter links710 form a non-rotating assembly that is bendable in one direction. The bending enabled by thehinges711 connecting each outer links. Each of theouter links710 havecenter hole714 so that theouter links710 form a bendable tube-like structure within which sits the structure formed by theinner links720. The inner links are hingeably connected to each other by the hinge pins737. Each of theinner links720 also have center hole724 (FIG. 9F). Eachinner link720 has a pair oflower ears720b and a pair ofupper ears720a, transversely oriented from thelower ears720b. The hingeable links between theinner links720 are formed by a cross-shaped pin subassembly730 (FIG. 9D). Thepin subassembly730 comprises a pair of short hinge pins737. The hinge pins737 mate with thelower ears720b of theinner links720 thereby hingeably connecting them. Thepin subassembly730 also comprises a pair of long camming pins735 whose longitudinal axis Y is oriented transverse to the longitudinal axis X of the short hinge pins737. Thepin subassembly730 is assembled in between twoinner links720 so that the camming pins735 extend through theupper ears720a of theinner links720 and into camming spaces S formed between theouter links710. Thepin subassembly730 is provided withcenter hole734 that aligns with thecenter hole724 of theinner links724.

Referring toFIG. 10A, eachouter link710 has afirst surface716 that is flat and asecond surface717 that is specifically contoured. Thesecond surface717 forms the camming surface for the camming pins735 which extends into the camming space S formed between theouter links710. Thecamming surface717 is contoured so that as the camming pins735 rotates in the camming space S, the two adjacentouter links710 are forced to bend about thehinge711 in the dorsal direction U and back to the straight configuration. Thecamming surface717 of theouter link710 is contoured to have at least 6 regions marked as A, B, C, D, E, and F inFIG. 10A.FIG. 10B illustrates the configuration where two adjacentouter links710 and710′ are in a straight arrangement. Thus, this represents the configuration where theflexible neck517 of the dissectingburr500 is, in turn, straight. Theinner links720 have been rotated so that one end of theircamming pin735 is positioned in the camming space S. Thecamming pin735 is at the region A of thecamming surface717. The opposite end (not shown) of thecamming pin735 is on the opposite side at the region C of thecamming surface717. This position of thecamming pin735 will be referred to as the A-C position. Illustrated inFIG. 10C is the configuration in which theouter links710 and710′ are at their maximum bending angle θ. Thecamming pin735 is now at the regions D and B of thecamming surface717. This position of thecamming pin735 will be referred to as the B-D position. As illustrated inFIGS. 10B and 10C, the thickness T1 of theouter link710 at camming region A is thinner than the thickness T2 of theouter link710 at the camming region D. Correspondingly, the camming space S1 is larger than the camming space S2. Thus, as thecamming pin735 transitions from the A-C position to the B-D position, thecamming pin735 pushes theouter links710 and710′ apart at the S2 side and causing the outer links to pivot relative to each other about thehinge711. By rotating theinner links720 and moving thecamming pin735 back to the A-C position, thecamming pin735 now pushes theouter links710 and710′ apart at the S1 side pivoting the outer links back to the straight configuration shown inFIG. 10B.FIG. 9A illustrates the outer link assembly in a position where the camming pins735 are somewhat close to the A-C position andFIG. 9E illustrates the outer link assembly in a position where the camming pins735 are somewhat closer to the B-D position. It should be noted that the maximum range for the amount of bending that may be manipulated for a given dissectingburr500 can be varied as desired by changing the contour of thecamming surface717 of the outer links and the number of outer links used to form theflexible neck portion517.

FIGS. 11A-11D are more detailed illustrations of theprotective hood520 of the dissectingburr500 ofFIG. 6A. The side view,FIG. 11A, and the sectional viewFIG. 11B, show that the dissectingfoot plate portion519 of theprotective hood520 partially enclose theburr bit530. The dissectingfoot plate portion519 in this exemplary embodiment is similarly shaped to the Woodson dissecting tool, with the dissectingfoot plate519 extending from the widest portion W of theprotective hood520 towards thedistal tip518 beyond theburr bit530 providing aspace521. The burr bit end of the dissectingburr500 can be inserted into a surgical site, such as the interval between the nerve root and the encroaching bone in a neural foramen without the need for a separate dissecting tool and without the risk of damaging the surrounding soft tissue such as the nerve root. The surgeon would rotate theprotective hood520 so that thefoot plate portion519 is positioned to be between theburr bit530 and the nerve root as the surgeon inserts the burr bit end of the instrument into the surgical site.

FIGS. 12A-12C are illustrations of anotherprotective hood820 for the dissectingburr500 having another dissectingfoot plate619 having a pointed or tapereddistal tip618 according to another embodiment. As mentioned above, the dissecting foot plate portion may be configured and adapted to have many different shapes that are appropriate for a particular application but all for providing a dissecting function.

FIGS. 13A-13C are illustrations of anotherprotective hood720 for the dissectingburr500 having a curette-type dissectingfoot plate719 according to another embodiment. The curette-type dissectingfoot plate719 of this embodiment does not extend out beyond theburr bit530 as much as the Woodson-type dissectingfoot plates519,619. The curette-type dissectingfoot plate719 has a short curved shape.

The dissectingfoot plate portions519,619 and719 have length Z of about 7.5 mm and a diameter at the widest portion W of about 4.5 mm. For surgical applications involving lumbar decompression surgical procedures such as lumbar laminectomy and foraminotomy, the dissecting foot plate portion may have a length of about 1 mm (currette-like tip) to about 8 mm (Woodson-like tip). The diameter of the foot plate portion at the widest portion W may be about 2 mm to 10 mm depending on the burr bit size.

With current minimally invasive lumbar decompression techniques, a retracting cannula is placed at the interspace percutaneously via sequential dilators. This technique works well for disc herniations where the pathology can be accessed at the interspace. The draw back to this technique with lumbar decompressions is that the ipsilateral lateral recess and foramen are extremely difficult to decompress because the line of sight afforded by the cannula does not allow the surgeon to get a direct view into the recess or the foramen on the ipsilateral side. Therefore, some surgeons have modified the technique and taken the cannula and directed it contralaterally to afford a view at the contralateral lateral recess and foramen. The drawback of this technique is that you disrupt the interspinous ligament and reaching across the dural space risks tearing the dura. In addition, attempting a foraminal decompression and lateral recess decompression in this fashion is technically extremely demanding because of the limited view and the limited maneuverability afforded by the small working diameter of the cannula. The cannulas typically have a diameter of about 2 centimeters. This could be made even more technically demanding in a patient with an extremely stenotic lateral recess and foramen.

The spinal instruments of the invention provides many advantages over the conventional instruments in performing minimally invasive lumbar decompressions. Lateral recess decompression can be performed on the ipsilateral side and also a foraminotomy can be performed on the ipsilateral side. Therefore, the interspinal ligaments can be preserved and all that is necessary to complete a full decompression is making a midline incision to bring the cannula to one side of the spinous process and the interspinous ligaments to perform one side of the lateral decompression. The cannula is then pulled out and reenter the spine on the contralateral side, through the same incision, on the other side of the spinous process and interspinous ligament and perform the contralateral lumbar lateral recess and foraminal decompression. In this way the interspinous ligament and the spinous processes are preserved and that posterior tension band is not violated. In order to perform the lateral recess decompression, an endoscope must be placed, similar to the conventional scopes that can be attached to the retracting cannula, however, it needs to be angled at a 60-70 degree angle so that it has a view directly into the lateral recess and the foramen.

Because the highspeed dissecting burr100,200 of the invention does not require a large amount of force or a large arc of motion to perform a bone resection, the lateral recess and foraminal decompression can be performed safely and accurately in minimally invasive setting. Because of the precision of bone resection allowed by the highspeed dissecting burr100,200 of the invention, the actual amount of bone that is resected can be minimized just to the bone that is encroaching on to the nerve root or the dural elements in the lateral recess. Thus, the amount of bony resection can be minimized to what is necessary to adequately decompress the neural elements. This maximally preserves the facet joints, thereby minimizing post-decompression instability.

A number of benefits are realized by the use of the surgical instruments of the invention described herein. For example, by performing the bone and ligament sparing lumbar decompression, the lamina can be preserved. The ligamentum just needs to be removed at the interspace, which often is the main source of compression, and the bone encroaching the lateral recess from facet hypertrophy and the foraminal stenosis can be adequately decompressed using the high speed dissecting burr and dissecting spinal soft tissue resector.

Since the amount of facet resection can be minimized and the posterior spinal ligaments preserved by using the high speed dissecting burr of the invention, it may be possible to clinically avoid fusion in patients with mild instability and mild spondylolisthesis because most of the spinal stability and the spinal integrity can be preserved. However, in patients where fusions are deemed to be warranted, the decompressions can be performed in a minimally invasive setting and since the lamina are preserved, one can attempt an interlaminar spinal fusion. Also, because the intertransverse plane is not dissected, there is no lateral soft tissue stripping that needs to be performed lateral to the facets and the intertransverse plane, therefore the morbidity to the patient is significantly minimized and the patient's postoperative recovery will be enhanced. Thus, there is no additional soft tissue dissection that is required than is done with a normal laminectomy.

By using the surgical instruments of the invention, preservation of bone and interspinal ligaments can be maximized during spinal decompression procedures. And since a good portion of the spinal stability is maintained by preserving the bone and interspinal ligaments, the overall patient satisfaction will be much improved in the strictly lumbar decompression patients. Furthermore, by combining the decompression performed with the instruments of the invention with a minimally invasive interlaminar fusion, possibly supplemented with minimally invasive pedicle screw system, the spinal segment fusion can be performed with a higher union rate and faster recovery times since the intertransverse muscle plane can be spared.

The surgical instruments of the invention also have applications in other areas of the spine. In the cervical spine, for example, the dissecting burr may be used for posterior foraminotomies. In such procedure, the dorsal surface of the spinal nerve root is first located and the dissecting burr is inserted overlying the nerve root under microscopic visualization and a foraminotomy may be performed that maximally preserves the cervical facet joint.

The dissecting burr of the invention may also enhance anterior cervical surgery, for example, during anterior cervical corpectomies. The width of the corpectomy trough is limited by concerns of the vertebral artery being violated at the lateral margin. Often the lateral decompression is incomplete because of fear of violating the vertebral artery, which can be catastrophic. With the use of the dissecting burr of the invention, the dissecting portion of the burr can be inserted into the interval between the vertebral artery and the lateral margins of the anterior cervical vertebral body and resect the lateral bony edge. This would allow the surgeon to perform a complete cervical corpectomy rather than a partial one.

Also, for anterior cervical disc work, the dissecting burr of the invention can be used to perform anterior cervical foraminotomies and osteophytectomies by inserting the burr into the interval between the lateral margin of the uncus and the vertebral artery by protecting the vertebral artery and allowing complete resection of the uncovertebral joint and thereby decompressing the foramina laterally and allowing preservation of the disc space medially and avoiding cervical fusion.

According to an aspect of the invention, the various embodiments of the instruments described herein may be configured so that irrigation fluid may be delivered to the surgical site via the instrument. There are many examples of surgical instruments known in the art having such irrigating feature that may be incorporated into the instruments of the invention. Example of burring or similar type of instruments with irrigation feature are described in, for example, U.S. Pat. No. 5,782,795 (Bays); U.S. Pat. No. 6,068,641 (Varsseveld); and U.S. Pat. No. 6,503,263 (Adams), the disclosures of which are incorporated herein by reference. In both the dissecting burr and the dissecting soft tissue resector embodiments of the invention, channels or pathways may be provided within the instrument for supplying irrigation fluid to the surgical site. Irrigation fluid would serve to assist in removal of tissue debris from the surgical site as well as cooling the surgical tool tip, theburr bits130,230 and the softtissue resector bit330, during the surgical procedure. Keeping the tool tip cool prevents damaging bone, nerve, or surrounding tissues during the surgical procedure. The irrigation can also help to collect the bone or other tissue debris for removal from the surgical site.

The instruments of the invention may also be configured for removing the tissue debris from the surgical site by vacuum. As discussed in reference to the soft tissue resector embodiment of the invention, the surgical tool tip may be configured to have open spaces between the cutting or abrading teeth sufficiently large for removal of tissue debris. Theprotective hood120,220,320 or theouter tube115,215,315 may also be configured with openings that may serve as intake ports for removing tissue debris by suction from in and around the surgical site. Many examples of surgical burrs and other abraders having such tissue removal features are known in the industry.

While the foregoing invention has been described with reference to the above embodiments, various modifications and changes can be made without departing from the spirit of the invention. Accordingly, all such modifications and changes are considered to be within the scope of the appended claims.

Claims (17)

What is claimed is:

1. A surgical instrument comprising:

a hand piece having a distal end and a proximal end;

a shaft portion extending from the distal end of the hand piece and having a distal end and a proximal end;

a drive shaft disposed for rotation within the shaft portion, the drive shaft having a distal end and a proximal end thereof;

a surgical tool bit connected to the distal end of the drive shaft;

a protective hood including a dissecting foot plate portion connected to the distal end of the shaft portion, wherein the surgical tool bit resides within the protective hood, partially exposed, and the protective hood is rotatable relative to the surgical tool bit exposing a different portion of the surgical tool bit; and

a rotatable member provided in the hand piece, said rotatable member operably connected to the proximal end of the shaft portion and manipulation of the rotatable member controls the rotation of the protective hood relative to the hand piece and the drive shaft via the shaft portion; and

a flexible neck portion connecting the protective hood to the distal end of the shaft portion, wherein the drive shaft comprises a flexible drive shaft portion at the distal end thereof and extending through the flexible neck portion to connect to the surgical tool bit,

wherein the flexible neck portion is communicatingly connected to the hand piece and the flexible neck portion's flexing motion is actuated and controlled from the hand piece.

2. The surgical instrument ofclaim 1, wherein the dissecting foot plate portion has a length of about 1 to 8 mm.

3. The surgical instrument ofclaim 1, further comprising a flexible neck portion connecting the protective hood to the distal end of the shaft portion, wherein the drive shaft comprises a flexible drive shaft portion at the distal end thereof and extending through the flexible neck portion to connect to the surgical tool bit.

4. The surgical instrument ofclaim 3, wherein the flexible neck portion is communicatingly connected to the hand piece and the flexible neck portion's flexing motion is actuated and controlled from the hand piece.

5. The surgical instrument of claim3 1, wherein the flexible drive shaft portion is made of Nitinol alloy.

6. The surgical instrument ofclaim 1, wherein the shaft portion is a rigid member.

7. The surgical instrument ofclaim 1, wherein the surgical tool bit is a bone removing bit.

8. The surgical instrument ofclaim 1, wherein the surgical tool bit is a soft tissue resecting bit.

9. The surgical instrument ofclaim 1, wherein the rotatable member is a thumb wheel.

10. A surgical instrument comprising:

a hand piece having a distal end and a proximal end;

a power drive mechanism provided within the hand piece;

a shaft portion extending from the distal end of the hand piece and having a distal end and a proximal end;

a drive shaft disposed for rotation within the shaft portion, the drive shaft having a distal end and a proximal end thereof, wherein the proximal end is connected to the power drive mechanism;

a surgical tool bit connected to the distal end of the drive shaft;

a protective hood including a dissecting foot plate portion attached to the distal end of the shaft portion, wherein the surgical tool bit resides within the protective hood, partially exposed, and the protective hood is rotatable relative to the surgical tool bit exposing a different portion of the surgical tool bit; and

a rotatable member provided in the hand piece, said rotatable member operably connected to the proximal end of the shaft portion and manipulation of the rotatable member controls the rotation of the protective hood relative to the hand piece and the drive shaft via the shaft portion; and

a flexible neck portion connecting the protective hood to the distal end of the shaft portion, wherein the drive shaft comprises a flexible drive shaft portion at the distal end thereof and extending through the flexible neck portion to connect to the surgical tool bit,

wherein the flexible neck portion is communicatingly connected to the hand piece and the flexible neck portion's flexing motion is actuated and controlled from the hand piece.

11. The surgical instrument ofclaim 10, further comprising a flexible neck portion connecting the protective hood to the distal end of the shaft portion, wherein the drive shaft comprises a flexible drive shaft portion at the distal end thereof and extending through the flexible neck portion to connect to the surgical tool bit.

12. The surgical instrument ofclaim 11, wherein the flexible neck portion is communicatingly connected to the hand piece and the flexible neck portion's flexing motion is actuated and controlled from the hand piece.

13. The surgical instrument of claim11 10, wherein the flexible drive shaft portion is made of Nitinol alloy.

14. The surgical instrument ofclaim 10, wherein the shaft portion is a rigid member.

15. The surgical instrument ofclaim 10, wherein the surgical tool bit is a bone removing bit.

16. The surgical instrument ofclaim 10, wherein the surgical tool bit is a soft tissue resecting bit.

17. The surgical instrument ofclaim 10, wherein the rotatable member is a thumb wheel.

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