Patents by Inventor Brian A. Butler

Brian A. Butler has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Publication number: 20250235247
    Abstract: Various bone cement guides are disclosed that may connect directly to a fenestrated bone screw or connect to a spinal construct that is coupled to a fenestrated bone screw. In various embodiments, cement guides may include a three-part assembly including a hollow outer sleeve and a hollow inner sleeve with a removable inner rod. In various embodiments, the hollow inner sleeve may be movable between a retracted position and an extended position and in the extended position a distal end of the inner sleeve may splay outward and capture the head portion of a fenestrated bone screw. In other embodiments, a distal end of the outer sleeve may surround and capture tabs of an extended tulip head connector while the inner sleeve couples to an inside surface of the extended tulip head connector.
    Type: Application
    Filed: April 9, 2025
    Publication date: July 24, 2025
    Applicant: Warsaw Orthopedic, Inc.
    Inventors: Anela Camdzic Holdaway, Brian A. Butler, William Alan Rezach, Mark R. Grizzard, Julien J. Prevost, Aubrey R. Mills
  • Patent number: 12318124
    Abstract: The present disclosure provides for a bone screw formed of continuous fibers, for example. The bone screw may include a first portion having a cylindrical shape and extending in a longitudinal direction from a first end to a second end, for example. In various embodiments, the first portion may include a thermoplastic material and/or be substantially formed of a thermoplastic material. In various embodiments, the bone screw may include a second portion coupled to the first portion and surrounding the first portion, at least partly, for example. In various embodiments, the second portion may include a plurality of layers, each layer comprising a continuous fiber material, for example. In various embodiments, the continuous fibers may be oriented longitudinally, diagonally, helically, radially, etc. In various embodiments, the second portion may define an exposed thread pattern and a leading tip.
    Type: Grant
    Filed: November 29, 2021
    Date of Patent: June 3, 2025
    Assignee: WARSAW ORTHOPEDIC, INC.
    Inventors: Keith E. Miller, Brian A. Butler, William A. Rezach, Jonathan M. Dewey, Jeffrey W. Beale, Julien J. Prevost
  • Patent number: 12274479
    Abstract: Various bone cement guides are disclosed that may connect directly to a fenestrated bone screw or connect to a spinal construct that is coupled to a fenestrated bone screw. In various embodiments, cement guides may include a three-part assembly including a hollow outer sleeve and a hollow inner sleeve with a removable inner rod. In various embodiments, the hollow inner sleeve may be movable between a retracted position and an extended position and in the extended position a distal end of the inner sleeve may splay outward and capture the head portion of a fenestrated bone screw. In other embodiments, a distal end of the outer sleeve may surround and capture tabs of an extended tulip head connector while the inner sleeve couples to an inside surface of the extended tulip head connector.
    Type: Grant
    Filed: July 8, 2022
    Date of Patent: April 15, 2025
    Assignee: WARSAW ORTHOPEDIC, INC.
    Inventors: Anela Camdzic Holdaway, Brian A. Butler, William Alan Rezach, Mark R. Grizzard, Julien J. Prevost, Aubrey R. Mills
  • Patent number: 12004782
    Abstract: Systems, instruments, and methods for operating a surgical instrument are disclosed. The instrument may include a drive shaft axially aligned with a central axis of the surgical instrument. The drive shaft may include a first mating end and be rotatably supported within a drive housing having a contoured interior supporting the first mating end. The instrument may include an outer shaft having an outer receiver interface configured to selectively couple and uncouple to a connecting portion of a receiver. The instrument may also include a plunger that is axially aligned with the central axis and having a second mating end disposed within the contoured interior of the drive housing. In various embodiments, the second mating end may be axially aligned with and in contact with the first mating end. In various embodiments, the plunger may be configured to linearly translate along the central axis upon rotation of the drive shaft.
    Type: Grant
    Filed: February 4, 2021
    Date of Patent: June 11, 2024
    Assignee: WARSAW ORTHOPEDIC, INC.
    Inventors: Brian A. Butler, Aubrey R. Mills, Christel Italiaie, Bret M. Wilfong, Madeline G. Wilson
  • Publication number: 20240008909
    Abstract: Various bone cement guides are disclosed that may connect directly to a fenestrated bone screw or connect to a spinal construct that is coupled to a fenestrated bone screw. In various embodiments, cement guides may include a three-part assembly including a hollow outer sleeve and a hollow inner sleeve with a removable inner rod. In various embodiments, the hollow inner sleeve may be movable between a retracted position and an extended position and in the extended position a distal end of the inner sleeve may splay outward and capture the head portion of a fenestrated bone screw. In other embodiments, a distal end of the outer sleeve may surround and capture tabs of an extended tulip head connector while the inner sleeve couples to an inside surface of the extended tulip head connector.
    Type: Application
    Filed: July 8, 2022
    Publication date: January 11, 2024
    Applicant: Warsaw Orthopedic, Inc.
    Inventors: Anela Camdzic Holdaway, Brian A. Butler, William Alan Rezach, Mark R. Grizzard, Julien J. Prevost, Aubrey R. Mills
  • Patent number: 11730529
    Abstract: Systems, instruments, and methods for operating a surgical instrument. The methods comprising: receiving at least a portion of an external object in a recess of a hollow shank; rotating a first shaft disposed within the hollow shank; using rotation of the first shaft to cause translational movement of a second shaft of the surgical instrument in a first direction away from the first shaft and along a central axis of the surgical instrument; applying a pushing force on the external object using the second shaft that is experiencing the translational movement; and causing translational movement of the second shaft in a second direction opposed from the first direction after the pushing force has been applied to the external object.
    Type: Grant
    Filed: March 26, 2020
    Date of Patent: August 22, 2023
    Assignee: WARSAW ORTHOPEDIC, INC.
    Inventors: Brian A. Butler, Aubrey R. Mills, Christel Italiaie, Bret M. Wilfong, Madeline G. Wilson
  • Patent number: 11717331
    Abstract: A surgical instrument includes a body member and a leg having a first end integrated with and extending from the body member. A head cavity is in the leg portion to hold a head. A channel is formed along a longitudinal length of the leg. An elongated rocker assembly includes an elongated lever arm coupled within the channel about a fulcrum and a spring actuation. A projection of the arm projects in a direction of the head cavity. A rocker slide lock has a collar slidably coupled around the body member and having a first position located between the body member and the actuation tab, such that a portion of the collar is under the actuation tab to limit pivotal motion of the rocker assembly, and a second position having a clearance from under the actuation tab.
    Type: Grant
    Filed: February 9, 2021
    Date of Patent: August 8, 2023
    Assignee: WARSAW ORTHOPEDIC, INC.
    Inventors: William A. Rezach, Daniel P. Wall, Abel C. Kim, Brian A. Butler
  • Publication number: 20230165613
    Abstract: The present disclosure provides for a bone screw formed of continuous fibers, for example. The bone screw may include a first portion having a cylindrical shape and extending in a longitudinal direction from a first end to a second end, for example. In various embodiments, the first portion may include a thermoplastic material and/or be substantially formed of a thermoplastic material. In various embodiments, the bone screw may include a second portion coupled to the first portion and surrounding the first portion, at least partly, for example. In various embodiments, the second portion may include a plurality of layers, each layer comprising a continuous fiber material, for example. In various embodiments, the continuous fibers may be oriented longitudinally, diagonally, helically, radially, etc. In various embodiments, the second portion may define an exposed thread pattern and a leading tip.
    Type: Application
    Filed: November 29, 2021
    Publication date: June 1, 2023
    Applicant: Warsaw Orthopedic, Inc.
    Inventors: KEITH MILLER, Brian A. Butler, William A. Rezach, Jonathan M. Dewey, Jeffrey W. Beale, Julien J. Prevost
  • Patent number: 11627998
    Abstract: Systems, instruments, and methods for performing a medical procedure. The methods comprise: obtaining a surgical instrument that combines a head positioner and a driver into a single integrated part (the driver being at least partially inserted through an elongate aperture formed in the head positioner so as to extend from a proximal end of the head positioner to a distal end of the head positioner); using an actuable structure of the head positioner to limit an amount that the driver can linearly travel in a first direction within the elongate aperture formed in the head positioner; causing a screw to threadingly engage an object via rotation of the driver in at least a first direction around a central axis of the surgical instrument; and changing an orientation of a receiver via rotation of the head positioner about a portion of the driver.
    Type: Grant
    Filed: December 11, 2020
    Date of Patent: April 18, 2023
    Assignee: WARSAW ORTHOPEDIC, INC.
    Inventors: William A. Rezach, Brian A. Butler
  • Patent number: 11617602
    Abstract: A system comprising surgical instruments of different types. Each surgical instrument includes a body member and a leg having a first end integrated with and a leg portion extending from the body member. The instrument includes a head cavity formed in a free end of the leg. The cavity holds a head. A channel is formed along a portion of a longitudinal length of the leg. The instrument includes an elongated rocker assembly pivotally coupled within the channel, with a spring actuation tab in proximity to the body member. The instrument includes a collar slidably coupled around the body member and having a first position located between the body member and the actuation tab such that a portion of the collar is under the actuation tab to limit pivotal motion of the rocker assembly and a second position of the collar has a clearance from under the actuation tab.
    Type: Grant
    Filed: February 8, 2021
    Date of Patent: April 4, 2023
    Assignee: MEDTRONIC, INC.
    Inventors: William A. Rezach, Daniel P. Wall, Abel C. Kim, Brian A. Butler
  • Publication number: 20220387084
    Abstract: A surgical instrument includes a first member being engageable to an inner surface of a spinal implant. An actuator is connected to a second member such that the second member is translatable relative to the first member for connecting the spinal implant to a bone fixation device. Systems, spinal constructs, implants and methods are disclosed.
    Type: Application
    Filed: June 22, 2022
    Publication date: December 8, 2022
    Applicant: WARSAW ORTHOPEDIC INC.
    Inventors: William Alan Rezach, Brian A. Butler
  • Patent number: 11439442
    Abstract: A universal surgical instrument includes an elongated member having a first end and a second end, the second end having flexible prongs with a head cavity to hold therebetween a polyaxial head. The universal surgical instrument includes a cuff member at the first end to interface with interchangeable surgical instruments. The universal surgical instrument includes an I-shaped clamp coupled to the elongated member and being configured to unlock and separate the flexible prongs to expand the head cavity for placement of the polyaxial head therein and to lock the head cavity in response to application of a force to slide the I-shaped claim along the elongated member to a locked position. A system of surgical instruments include the universal instrument and interchangeable surgical instruments that can be interchanged in the cuff member of the universal instrument.
    Type: Grant
    Filed: April 16, 2020
    Date of Patent: September 13, 2022
    Assignee: WARSAW ORTHOPEDIC, INC.
    Inventors: Brian A. Butler, Molly K. Rice
  • Patent number: 11432851
    Abstract: A surgical instrument includes a first member including an inner surface. A second member is movable relative to the first member and defines a first opening for disposal of a first implant support. The second member is disposable with the inner surface to define a second opening for movement of a second implant support relative to the inner surface and a third opening is configured for movement of a third implant support relative to the inner surface. The first implant support is fixed with the second member. Systems, spinal constructs, implants and methods are disclosed.
    Type: Grant
    Filed: February 4, 2021
    Date of Patent: September 6, 2022
    Assignee: Warsaw Orthopedic, Inc.
    Inventors: William Alan Rezach, Brian A. Butler
  • Publication number: 20220240984
    Abstract: A surgical instrument includes a first member including an inner surface. A second member is movable relative to the first member and defines a first opening for disposal of a first implant support. The second member is disposable with the inner surface to define a second opening for movement of a second implant support relative to the inner surface and a third opening is configured for movement of a third implant support relative to the inner surface. The first implant support is fixed with the second member. Systems, spinal constructs, implants and methods are disclosed.
    Type: Application
    Filed: February 4, 2021
    Publication date: August 4, 2022
    Applicant: Warsaw Orthopedic, Inc.
    Inventors: William Alan Rezach, Brian A. Butler
  • Publication number: 20220183725
    Abstract: Systems, instruments, and methods for performing a medical procedure. The methods comprise: obtaining a surgical instrument that combines a head positioner and a driver into a single integrated part (the driver being at least partially inserted through an elongate aperture formed in the head positioner so as to extend from a proximal end of the head positioner to a distal end of the head positioner); using an actuable structure of the head positioner to limit an amount that the driver can linearly travel in a first direction within the elongate aperture formed in the head positioner; causing a screw to threadingly engage an object via rotation of the driver in at least a first direction around a central axis of the surgical instrument; and changing an orientation of a receiver via rotation of the head positioner about a portion of the driver.
    Type: Application
    Filed: December 11, 2020
    Publication date: June 16, 2022
    Applicant: Warsaw Orthopedic, Inc.
    Inventors: WILLIAM A REZACH, Brian A. Butler
  • Publication number: 20220125488
    Abstract: A surgical instrument includes a first member being engageable to an inner surface of a spinal implant. An actuator is connected to a second member such that the second member is translatable relative to the first member for connecting the spinal implant to a bone fixation device. Systems, spinal constructs, implants and methods are disclosed.
    Type: Application
    Filed: October 23, 2020
    Publication date: April 28, 2022
    Inventors: William Alan Rezach, Brian A. Butler
  • Patent number: 11202661
    Abstract: A surgical instrument includes spinal implant reduction instrument defining a longitudinal axis. The spinal implant reduction instrument includes a first member connected to a body. The first member includes a tapered projection configured to interlock to a first mating recess of a bone fastener. A second member is connected to the body. The second member includes a tapered projection configured to interlock to a second mating recess of the bone fastener. At least one of the members is rotatable relative to the longitudinal axis for connecting the members to the bone fastener. Systems, spinal constructs, implants and methods are disclosed.
    Type: Grant
    Filed: October 30, 2020
    Date of Patent: December 21, 2021
    Assignee: Warsaw Orthopedic, Inc.
    Inventors: William Alan Rezach, Brian A. Butler
  • Patent number: 11191574
    Abstract: Systems, instruments, and methods for advancing a set screw in an object. The methods comprise: disposing a shank tip of a set screw reducer in a socket of the set screw; causing a sleeve integrated with the set screw reducer to slidingly engage a shank of the set screw reducer and move in a direction towards the shank tip; transferring torque from the set screw reducer to the set screw such that the set screw is advanced in a threaded hole of the object; and using the sleeve of the set screw reducer to substantially prevent splaying of at least one sidewall of the object while the torque is being transferred from the set screw reducer to the set screw.
    Type: Grant
    Filed: March 17, 2020
    Date of Patent: December 7, 2021
    Assignee: Warsaw Orthopedic, Inc.
    Inventors: Brian A. Butler, William A. Rezach, Molly K. Rice
  • Publication number: 20210322064
    Abstract: A system comprising surgical instruments of different types. Each surgical instrument includes a body member and a leg having a first end integrated with and a leg portion extending from the body member. The instrument includes a head cavity formed in a free end of the leg. The cavity holds a head. A channel is formed along a portion of a longitudinal length of the leg. The instrument includes an elongated rocker assembly pivotally coupled within the channel, with a spring actuation tab in proximity to the body member. The instrument includes a collar slidably coupled around the body member and having a first position located between the body member and the actuation tab such that a portion of the collar is under the actuation tab to limit pivotal motion of the rocker assembly and a second position of the collar has a clearance from under the actuation tab.
    Type: Application
    Filed: February 8, 2021
    Publication date: October 21, 2021
    Applicant: Warsaw Orthopedic, Inc.
    Inventors: William A. Rezach, Daniel P. Wall, Abel . C. Kim, Brian A. Butler
  • Publication number: 20210322067
    Abstract: A universal surgical instrument includes an elongated member having a first end and a second end, the second end having flexible prongs with a head cavity to hold therebetween a polyaxial head. The universal surgical instrument includes a cuff member at the first end to interface with interchangeable surgical instruments. The universal surgical instrument includes an I-shaped clamp coupled to the elongated member and being configured to unlock and separate the flexible prongs to expand the head cavity for placement of the polyaxial head therein and to lock the head cavity in response to application of a force to slide the I-shaped claim along the elongated member to a locked position. A system of surgical instruments include the universal instrument and interchangeable surgical instruments that can be interchanged in the cuff member of the universal instrument.
    Type: Application
    Filed: April 16, 2020
    Publication date: October 21, 2021
    Applicant: Warsaw Orthopedic, Inc.
    Inventors: Brian A. Butler, Molly K. Rice