Surgical Saw Blade And Thermal Management System

A method of making a surgical saw blade comprising the steps of:

• providing a first material for use in forming a distal portion and a pair of opposed first flanking members of the saw blade;
• providing a second material having a higher thermal conductivity than the first material;
• forming a laminate in the form of a blade blank sheet assembly including the first material and the second material, with a first layer, and a second layer, and an intermediate layer disposed in-between;
• wherein the first layer is in the form of a substantially planar first sheet of the first material and having a first planar area;
• wherein the second layer is in the form of a substantially planar second sheet of the first material and having a second planar area substantially equal to the first planar area;
• forming a plurality of pockets in the intermediate layer;
• forming a plurality of thermal transit cores from the thermally conductive second material;
• placing each of the plurality of thermal transit cores into one of the plurality of pockets of the intermediate layer, the relative size of each of the plurality of pockets and each of the plurality of thermal transit cores selected to provide a press fit of the thermal transit core into the pocket, or a slip fit to allow easy placement of the thermal transit core within the pocket;
• placing the substantially planar first sheet over a first surface of the intermediate layer, in alignment therewith and fixing it to the intermediate layer, wherein the intermediate layer and the first sheet are connected together;
• placing the substantially planar second sheet over a second surface of the intermediate layer, the second surface being opposite the first surface, in alignment therewith and fixing it to the intermediate layer, wherein the intermediate layer and the second sheet are connected together;
• and
• wherein the first flanking members comprise part of the intermediate layer, connecting what will become inner parts of a proximal portion and a distal portion that are also comprised by part of the intermediate layer such that the first flanking members and the portions of the proximal portion and the distal portion formed of the intermediate layer are formed as an integral unit.

A method of making a surgical saw blade comprising the steps of:

• placing a thermal transit core into a pocket of a third sheet, the relative sizes of the pocket and the thermal transit core selected to provide a press fit of the thermal transit core into the pocket, or a slip fit to allow easy placement of the thermal transit core within the pockets;
• placing a first substantially planar sheet over a first surface of the third sheet, in alignment therewith and is fixed to the third sheet, the third sheet and the first substantially planar sheet being connected together;
• placing a second substantially planar sheet over a second surface of the third sheet, the second surface being opposite the first surface, in alignment therewith and is fixed to the third sheet, the third sheet and the second substantially planar sheet being connected together;
• and
• wherein vertical flanking members comprise part of the third sheet, connecting what will become inner parts of a proximal portion and a distal portion that are also comprised by part of the third sheet.