Ultrasonic surgical handpiece assembly

Abstract

The present disclosure relates to an ultrasonic surgical handpiece assembly including a surgical handpiece for use with an irrigation sleeve and an ultrasonic tip. The surgical handpiece may include a piezoelectric transducer disposed within a housing and configured to manipulate an ultrasonic tip. One or more lumens and / or a flexible circuit including an antenna may be disposed within the surgical handpiece housing. The lumen may be configured to provide irrigation and / or aspiration to the irrigation sleeve and / or the ultrasound tip. The irrigation sleeve may include a second antenna configured to communicate with the ultrasound handpiece antenna. The irrigation sleeve may further include an alignment and / or coupling feature configured to removably secure the irrigation sleeve to the housing and orient the second antenna relative to the ultrasound handpiece antenna. The irrigation sleeve may further include a lumen for supplying irrigation and / or suction to the ultrasound tip.

Description

[0001] This application is a divisional application of the invention patent application with the application date of September 24, 2019, application number 201980062597.3, and invention name “Ultrasonic surgical handpiece assembly”.

[0002] Related Applications

[0003] This application claims priority to U.S. Application No. 62 / 735,445, filed on September 24, 2018, the entire contents of which are incorporated herein by reference. Summary of the invention

[0004] The present disclosure generally relates to an ultrasonic surgical handpiece assembly. The ultrasonic surgical handpiece assembly may include a handpiece including a transducer and a horn, wherein the transducer is configured to manipulate the horn to actuate a cutting tip coupled to the horn to cut or remove biological material.

[0005] An exemplary configuration provides a sleeve for use with an ultrasound handpiece including a coupling housing having a handpiece transceiver, and configured to surround a portion of an ultrasound tip including a cutting feature. The sleeve may include a hub including a proximal portion, a distal portion, and a first lumen extending through the hub. The proximal portion may have a first face configured to abut the ultrasound handpiece and a second face located distal to the first face. The sleeve may further include a body including a distal end and a proximal end. The body may extend from the distal portion of the hub and be configured to define a second lumen in fluid communication with the first lumen of the hub. The second lumen may be configured to surround the portion of the ultrasound tip. The sleeve may also include a tube hole in the inner surface of the second lumen. The tube hole may be positioned at an intermediate point along the second lumen between the proximal and distal ends of the body, and the tube hole is inwardly facing the second lumen. An irrigation catheter may be adjacent to the second lumen, the irrigation catheter being configured to extend from the proximal end of the body to the tube hole. The irrigation hole and the tip hole are in the first face, and the tip hole is configured to communicate with the first lumen. The irrigation connector can be positioned within the irrigation hole of the first face of the hub and be in fluid communication with the irrigation tube. The sleeve can also include at least one retaining finger protruding proximally from the first face, the retaining finger configured to engage a coupling housing of the ultrasound handpiece. The sleeve can further include a cavity defined in the proximal portion of the hub, the cavity including an opening in the first surface. The sleeve transceiver can be positioned within the cavity and configured to communicate with a corresponding handpiece transceiver.

[0006] In another exemplary configuration, an ultrasonic surgical handpiece may be configured for use with an ultrasonic tip assembly comprising a sleeve comprising at least one retaining member. The ultrasonic surgical handpiece may include a housing comprising a proximal end and an opposite distal end, the housing being configured to define a volume space. The ultrasonic surgical handpiece may also include: a transducer disposed at least partially within the volume space defined by the housing; and a horn comprising a first end and an opposite second end. The horn may be configured to be disposed at least partially within the volume space defined by the housing, the first end of the horn being operably coupled to the transducer. Wherein, the transducer is configured to vibrate / oscillate the horn when operated. The ultrasonic surgical handpiece may also include an attachment area formed in the distal end of the housing. The attachment area may define a recess comprising a face and a plurality of side walls configured to receive the sleeve. An attachment element is in the face of the recess, wherein the attachment element may be configured to receive the at least one retaining member of the sleeve to removably couple the sleeve to the ultrasonic surgical handpiece. The ultrasonic surgical handpiece may further include a first connector extending from a face of the recessed portion and may be configured to removably couple with the sleeve to provide irrigation to the sleeve, and wherein the second end of the flared portion is configured to protrude from the face.

[0007] In yet another exemplary configuration, an ultrasonic handpiece assembly may be configured for use with an elongated cutting instrument comprising a suction lumen extending over the length of the elongated cutting instrument. The assembly may include an ultrasonic handpiece comprising: a housing comprising a proximal end and an opposite distal end, the housing defining a volume space, and the distal end having a distal surface. The handpiece may also include a transducer configured to define a first conduit, the transducer being at least partially disposed within the volume space defined by the housing. The handpiece may also include a flare, the flare comprising a first end and an opposite second end, the flare configured to be at least partially disposed within the volume space defined by the housing. The flare may include a second conduit in the flare, the second conduit being configured to extend between the first end and the second end of the flare. The flare may also include a threaded connector on the second end of the flare, the threaded connector being configured to extend from the distal end of the housing and to removably couple the flare to the elongated cutting instrument. The assembly may further include an irrigation outlet connector extending from the distal end of the housing and configured to discharge irrigation fluid from the housing. The assembly may further include an irrigation sleeve. The irrigation sleeve may include a hub defining a first lumen and including an irrigation inlet connector, the irrigation inlet connector configured to engage the irrigation outlet connector to receive irrigation fluid discharged from the ultrasonic handpiece. The sleeve may further include a sleeve body extending distally from the hub, the sleeve body defining a second lumen, the second lumen being configured to surround a portion of the elongated cutting instrument when the elongated cutting instrument is inserted into the irrigation sleeve. The sleeve may further include a tube hole in the inner surface of the second lumen, the tube hole being positioned at a midpoint along the second lumen between the proximal and distal ends of the sleeve body, so that the tube hole faces the second lumen to provide irrigation fluid to the surgical site and cool the elongated cutting instrument. The sleeve may also include an irrigation conduit extending adjacent to the second lumen, the irrigation conduit being configured to extend from an irrigation inlet connector of the sleeve body to the tube bore to form a fluid passage for communicating irrigation fluid to the elongated cutting instrument, wherein the irrigation outlet connector on the housing may be configured to engage the irrigation inlet connector on the irrigation sleeve when the irrigation sleeve is coupled to the housing, allowing irrigation fluid to flow completely within the ultrasonic handpiece and the hub. In addition, the first end of the flared portion may be operably coupled to the transducer such that the first conduit of the transducer and the second conduit of the flared portion may define a continuous passage extending from the proximal end to the distal end of the housing.

[0008] In yet another exemplary configuration, an ultrasonic handpiece assembly may be configured for use with an elongated cutting instrument. The assembly may include an ultrasonic handpiece including a housing, a transducer, and a horn. The housing may include a proximal end and an opposite distal end, the housing defining a volume space, and the distal end having a distal surface. The transducer may be configured to define a first conduit, the transducer being at least partially disposed within the volume space defined by the housing. The horn may include a first end and an opposite second end, the horn being configured to be at least partially disposed within the volume space defined by the housing. The horn may include a second conduit in the horn, the second conduit being configured to extend between the first end and the second end of the horn. An irrigation outlet connector extends from the distal end of the housing and is configured to discharge irrigation fluid from the housing. A threaded connector may be disposed on the second end of the horn, configured to engage the elongated cutting instrument. A recess may be provided in the distal end of the housing, the recess including a concave surface and a plurality of side walls configured to define an asymmetric shape. The assembly may further include a handpiece transceiver including a handpiece coil having a first axis, the handpiece transceiver being positioned within one of the plurality of side walls. The assembly may also include a flushing sleeve including a hub including a proximal portion and a distal portion, the proximal portion being configured to define an asymmetric protrusion extending proximally from the distal portion and sized to be inserted into a recess of the housing. The flushing sleeve may also include an abutment portion configured to contact the distal side of the ultrasound handpiece when the asymmetric protrusion is inserted into the recess of the housing. The asymmetric protrusion may be configured to ensure proper alignment of the flushing sleeve with the housing. The flushing sleeve may further include a sleeve transceiver including a sleeve coil and a storage unit that stores information related to optimal drive parameters for the elongated cutting instrument. The sleeve coil may have a second axis, wherein the sleeve transceiver is disposed in a cavity defined in the asymmetric protrusion of the hub such that the second axis of the sleeve coil is oriented parallel to the first axis of the handpiece coil.

[0009] In another exemplary configuration, the conduit connector may be configured to integrally connect an irrigation line, a suction line, and a conductor to a proximal portion of an ultrasonic surgical handpiece, wherein the ultrasonic surgical handpiece includes an irrigation connector and a suction connector extending proximally from the proximal portion of the handpiece. The conduit connector may include a base, the base including a distal end and a proximal end. The conduit connector may also include a first lumen in the base, the first lumen being configured to form a fluid passage extending from the distal end of the base to the proximal end through the base. The first lumen may be configured to receive the suction line near the proximal end of the base. The base may define a groove extending between the proximal region to the distal region of the base in the periphery of the base, the groove being configured to receive a conductor. A portion of the first lumen near the distal end of the base is configured to be detachably coupled to the suction connector of the ultrasonic surgical handpiece via a friction fit, and wherein the conduit connector is configured to reduce the strain of the irrigation line and the suction line when coupled to the surgical handpiece.

[0010] These and other configurations, features and advantages of the present disclosure will be apparent to those skilled in the art. The present disclosure is not intended to be limited to or by these configurations, embodiments, features and / or advantages. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Reference is now made to the drawings, in which exemplary illustrations are shown in detail. Although the drawings represent exemplary embodiments, the drawings are not necessarily drawn to scale and certain features may be exaggerated to better illustrate and explain the innovative aspects of the illustrative embodiments. Furthermore, the exemplary illustrations described herein are not intended to be exhaustive or otherwise limited or constrained to the precise forms and configurations shown in the drawings and disclosed in the following detailed description.

[0012] Advantages of the present invention will become better understood and readily appreciated when the following detailed description is considered in conjunction with the accompanying drawings, in which:

[0013] Figure 1 is a side view of an ultrasonic surgical handpiece assembly, which includes an ultrasound handpiece, an irrigation sleeve, an ultrasound tip, and a console.

[0014] Figure 2 yes Figure 1 A top view of an ultrasonic surgical handpiece assembly.

[0015] Figure 3 yes Figure 1 A cross-sectional view of an ultrasonic surgical handpiece assembly.

[0016] Figure 4 yes Figure 3 An enlarged (enlarged) cross-sectional view of the rear shell portion of the ultrasound handpiece.

[0017] Figure 5 yes Figure 1A perspective view of the front housing portion of an ultrasound handpiece.

[0018] Figure 6 yes Figure 4 Exploded view of the front housing portion.

[0019] Figure 7 yes Figure 6 Front view of the ultrasound handpiece.

[0020] Figure 8 yes Figure 1 A partially exploded view of an ultrasonic surgical handpiece assembly of is shown, illustrating an example configuration of an interface between a front housing portion of the ultrasonic handpiece and an irrigation sleeve.

[0021] Fig. 9 is an enlarged (enlarged) cross-sectional view of a front housing portion of an ultrasound handpiece coupled to an irrigation sleeve.

[0022] Fig.10 It is used with the ultrasound handpiece Figure 1 A perspective view of the irrigation sleeve and ultrasonic tip of an ultrasonic surgical handpiece assembly.

[0023] Fig.11A yes Fig.10 Bottom view of the irrigation sleeve and ultrasonic tip.

[0024] Fig. 11B yes Fig.10 Cross-sectional view of the irrigation sleeve and ultrasonic tip.

[0025] Fig.12 is with Figure 1 A perspective view of an example configuration of a tubing connector for use with an ultrasonic surgical handpiece assembly, including an ultrasonic handpiece shown in phantom.

[0026] Fig.13 yes Fig.12 A first perspective view of a pipe connector.

[0027] Fig.14 yes Fig.12 A second perspective view of the pipe connector.

[0028] Fig.15 yes Fig.12 A third perspective view of a pipe connector.

[0029] Fig.16 It is connected to the ultrasound head Fig.12 A cut-away cross-sectional view of a tubing connector having power, suction, and irrigation lines extending therefrom. DETAILED DESCRIPTION

[0030] As medical professionals strive to reduce the size of incisions and shorten the recovery time required after invasive medical procedures, the size of medical instruments used in various medical procedures has been reduced. Many medical instruments used in performing various medical procedures may include the use of cutting accessories, such as ultrasonic handpieces, high-speed drills, rotary files, fenestrated scrapers, etc. Many of these cutting accessories may require the use of irrigation or suction (i.e., evacuation) to reduce heat and / or remove debris from the surgical site. Similarly, irrigation can be used to lubricate the cutting accessories.

[0031] An example of a surgical instrument that can utilize an irrigation and aspiration system is an ultrasonic handpiece. Typically, one or more pipelines can be coupled to the ultrasonic handpiece to provide irrigation and evacuation. The ultrasonic handpiece can also include a sleeve having one or more lumens that can be used to direct fluid from an irrigation source to a surgical site and a cutting attachment, i.e., an ultrasonic tip. The irrigation and / or aspiration lines are typically already coupled to the outside of the ultrasonic handpiece to be coupled to the sleeve. The sleeve and / or the cutting attachment can be disposable, resulting in the sleeve and / or the cutting attachment being only temporarily attached to the ultrasonic handpiece. Introducing additional elements such as irrigation and / or aspiration lines to the outside of the handpiece can result in an increase in the size, profile, and / or overall volume of the ultrasonic handpiece. This may obstruct the view of a medical professional and / or distract the attention of a medical professional during the operation of a medical instrument during a medical procedure. Similarly, the positioning of the irrigation and / or aspiration lines relative to the ultrasonic handpiece may affect the ergonomics of the ultrasonic handpiece, thereby inhibiting the ability of a medical professional to operate the ultrasonic handpiece.

[0032] Thus, the ultrasonic surgical handpiece assembly 10 may be configured to include an ultrasonic surgical handpiece 12 having internal irrigation and aspiration lumens to reduce the size of the handpiece and improve ergonomics, e.g. Figure 1-3 An ultrasonic surgical handpiece assembly 10 is shown.

[0033] Reference Figure 1 and Figure 2 , an example configuration of an ultrasonic surgical handpiece assembly 10 is shown. The ultrasonic surgical handpiece assembly 10 may include an ultrasonic handpiece 12, which includes a proximal end and a distal end. The ultrasonic surgical handpiece assembly 10 may also include a sleeve 18 and an ultrasonic tip 20, which may be coupled to the distal end of the ultrasonic handpiece 12. The sleeve 18 may be configured to provide irrigation to the ultrasonic tip 20 and / or the surgical site. It is further contemplated that the sleeve 18 may also be configured to provide suction to the ultrasonic tip 20. The ultrasonic tip 20 may include a cutting feature 34, which is configured to cut, shape and / or remove biological tissue.

[0034] The ultrasonic tip 20 may have various features as described in U.S. Pat. Nos. 6,497,715; 6,955,680; and 6,984,220, the entire contents of which are incorporated herein by reference.

[0035] The ultrasonic surgical handpiece assembly 10 may also include a cable 30 or other power cord including a power connector 28 or adapter configured to couple the ultrasonic surgical handpiece assembly 10 to a power source, such as a console 13 configured to adjust various aspects of the ultrasonic handpiece 12. For example, the console 13 may be configured to adjust the power and signals provided to the ultrasonic handpiece 12. The console 13 may also be configured to adjust the irrigation and / or aspiration functions of the ultrasonic handpiece 12 to optimize the performance of the ultrasonic surgical handpiece assembly 10.

[0036] refer to Figure 3 , provides Figure 1 sectional view of an ultrasonic surgical handpiece assembly 10. The ultrasonic handpiece 12 may include a proximal housing portion 14 and a distal housing portion 16, each of which may be configured to define a void. The proximal housing portion 14 and the distal housing portion 16 may be configured as two separate components and may be coupled together by laser welding or a similar coupling process. Alternatively, the proximal housing portion 14 and the distal housing portion 16 may include respective coupling features configured to couple the proximal housing portion 14 and the distal housing portion 16 together. It is also contemplated that the proximal housing portion 14 and the distal housing portion 16 may be configured as a single integral component.

[0037] The transducer 44 can be disposed in a void defined by the ultrasound head 12. The transducer 44 can include a plurality of driver elements 46, such as piezoelectric crystals arranged in a stacked configuration. The piezoelectric crystals 46 can expand and contract based on a varying electrical application. The transducer 44 can include a tube 43 defining an inner cavity 45 extending from a proximal end to a distal end of the transducer 44 to form a fluid passage through the transducer 44. The tube 43 can take the form of a column. The tube 43 can extend through the colinear longitudinal axis of the driver elements 46. The proximal mass 41 can be disposed adjacent to the proximal side of the driver element 46 disposed on the proximal side.

[0038] It is further contemplated that transducer 44 may alternatively include a plurality of magnetostrictive elements.

[0039] The trumpet 40 can be at least partially arranged in the gap defined by the ultrasound head 12. The trumpet 40 can be connected to the distal end of the transducer 44. The trumpet 40 can be made of a rigid steel alloy, titanium or similar material. In operation, when the transducer 44 expands and contracts, the trumpet 40 will oscillate. The trumpet 40 can be detachably connected to the transducer 44. For example, the proximal end of the trumpet 40 can include a male threaded connector, and the distal end of the transducer 44 can include a corresponding female threaded connector. Alternatively, the transducer 44 and the trumpet 40 can be permanently connected via welding, adhesives or similar bonding processes. The trumpet 40 can be configured to define a second conduit 42, which is fluidically connected to the lumen 45 defined by the tube 43 of the transducer 44. Together, the lumen 45 through the transducer 44 and the second conduit 42 through the flare 40 form a portion of a continuous fluid passage extending from the distal end of the ultrasound handpiece 12 to the proximal end of the ultrasound handpiece 12. The ultrasonic surgical handpiece assembly 10 is configured such that the driver element 46 is compressed between the proximal mass 41 and the flare 40.

[0040] The fluid passage through the ultrasound handpiece 12 may be used to provide irrigation fluid and / or vacuum through the ultrasound handpiece 12. The distal end of the flared portion 40 may further include a threaded coupler 38 configured to removably couple the ultrasonic tip 20 to the ultrasound handpiece 12 via the flared portion 40. Although the threaded coupler 38 on the distal end of the flared portion 40 may include threads configured to engage with corresponding threads on the ultrasonic tip 20, it is also contemplated that other coupling methods may be utilized. For example, the distal end of the flared portion 40 may include features that allow for snap-fit ​​engagement with the ultrasonic tip 20.

[0041] The console 13 of the ultrasonic surgical handpiece assembly 10 can be configured to provide a drive signal via a cable 30 connected to the ultrasonic handpiece 12. In many, but not all forms of ultrasonic surgical handpiece assemblies 10, the ultrasonic handpiece 12 and the cable 30 are assembled as a single unit. The drive signal is applied to the piezoelectric crystal 46. At any given moment, the same drive signal is applied to each of the plurality of piezoelectric crystals 46. The application of the drive signal causes the piezoelectric crystals 46 to expand and contract simultaneously and periodically. The length of the stack of piezoelectric crystals 46 is typically between 1 and 5 cm. The distance and amplitude of the movement of the piezoelectric crystal 46 in a single expansion / contraction cycle can be between 1 and 10 microns. The flared portion 40 can be configured to amplify the movement. Therefore, when moving from a fully retracted position to a fully extended position, the distal end of the flared portion 40, and by extension the ultrasonic tip 20, typically moves a maximum of 1000 microns, and more often moves 500 microns or less. Some ultrasonic tips 20 are also designed so that longitudinal extension / contraction of the ultrasonic tip 20 may also induce torsional motion in the cutting feature 34. When the ultrasonic handpiece 12 is actuated to induce cyclic motion of the ultrasonic tip 20, the cutting feature 34 is considered to be vibrating.

[0042] The console 13 may also include a vacuum pump and controller, and an irrigation pump and controller. The vacuum pump may be coupled to the ultrasonic surgical handpiece assembly 10 via a suction line 27. The irrigation pump may be coupled to the ultrasonic handpiece assembly 10 via an irrigation line 29.

[0043] The console 13 may have any of the features described in U.S. Patent Publication Nos. 2017 / 0071621 and 2018 / 0056328, the entire contents of which are incorporated herein by reference.

[0044] The ultrasound handpiece 12 may also include a tube 58 that is at least partially disposed within the ultrasound handpiece 12 and is configured to define a lumen 59 through the ultrasound handpiece 12 for irrigation and / or evacuation. The tube 58 defines an additional lumen 59 that passes through the ultrasound handpiece 12 to a passage defined by the lumen 45 of the transducer 44 and the second conduit 42 of the flared portion 40. For example, the tube 58 may define an irrigation lumen 59 through the ultrasound handpiece 12, and the lumen 45 through the transducer 44 and the second conduit 42 through the flared portion 40 may define an aspiration lumen 45 through the ultrasound handpiece 12. Alternatively, the tube 58 may define an aspiration passage 59 through the ultrasound handpiece 12, and the lumen 45 through the transducer 44 and the second conduit 42 through the flared portion 40 may define an irrigation passage through the ultrasound handpiece 12.

[0045] As described above, the irrigation and / or aspiration channels are mostly disposed within the ultrasonic handpiece 12, providing ergonomic advantages by eliminating one or more lines that are typically attached to the outside of the ultrasonic handpiece. It should be understood that, while those lines that define the aspiration channel and / or irrigation channel from the proximal end of the ultrasonic surgical handpiece assembly 10 to the distal end of the channel may be exposed, i.e., visible to the user during operation, the user does not need to attach any irrigation lines or aspiration lines to the sides of the ultrasonic surgical handpiece assembly 10 during use. Instead, in some embodiments, the irrigation line 29 and the aspiration line 27 are only attached to the proximal end of the ultrasonic handpiece 12, or even behind the proximal end of the ultrasonic handpiece 12. In addition, in some embodiments, during the setup of the ultrasonic surgical handpiece assembly 10, all aspiration and irrigation connections included in the sleeve originate directly from the ultrasonic handpiece 12. In other words, no irrigation or aspiration lines are coupled to one side of the sleeve 18. Therefore, the ultrasonic handpiece 12 may include connections for both irrigation and aspiration.

[0046] Reference Figure 4 , a cross-sectional view of a portion of the ultrasound handpiece 12 is shown. As described above, the transducer 44 may include a distal end and a proximal end disposed within the void of the ultrasound handpiece 12. The transducer 44 may be configured to expand and contract along a longitudinal axis of the transducer 44. The lumen 45 passing through the transducer 44 includes a distal portion and a proximal portion. The flared portion 40 may also be at least partially disposed within the ultrasound handpiece 12.

[0047] The ultrasound handpiece 12 may further include a barrier member 49 positioned within the void defined by the ultrasound handpiece 12 and configured to define a cavity. The transducer 44 may be encapsulated within the barrier member 49 so that the barrier member 49 may be configured to help mount and isolate the transducer 44 within the ultrasound handpiece 12. The barrier member 49 may not occupy the entire void defined within the ultrasound handpiece 12. Therefore, the ultrasound handpiece 12 may further include a potting element 47 or material disposed within the void defined by the ultrasound handpiece 12. The potting element 47 may be disposed within the void defined by the ultrasound handpiece 12 and outside the barrier member 49 so that the potting element 47 may occupy or fill the portion of the void within the handpiece 12 that is not occupied by the barrier member 49 or blocked by the barrier member 49. The potting element 47 may be configured to fix the position of the barrier member 49 within the void defined by the ultrasound handpiece 12. Packaging element 47 may also function as an insulator or damper configured to prevent thermal energy (ie, heat) and mechanical energy (ie, vibration) from being transferred from transducer 44 to a user's hand.

[0048] The barrier member 49 may further define a channel 53 extending in a generally proximal direction from the proximal end of the barrier member 49. The channel 53 forms a passage between the proximal end of the ultrasound handpiece 12 and the tube 43 defining the lumen 45 passing through the transducer 44. The channel 53 may further include a coupling portion 54, such as a hose barb or similar fitting configured to establish a friction fit, extending proximally from the proximal end of the ultrasound handpiece 12 and configured to couple the channel 53 to the aspiration line 27 of the console 13.

[0049] Transducer 44 may be partially mounted in the cavity defined by barrier member 49 by a rear seal 48 positioned between the proximal end of transducer 44 and the inner surface of barrier member 49. Rear seal 48 may be configured to abut the proximal end of transducer 44 and define a first aperture that is in fluid communication with lumen 45 passing through transducer 44. Rear seal 48 is positioned to help prevent moisture from entering the volume surrounding transducer 44 between barrier member 49 and the exterior of transducer 44. Rear seal 48 also functions to prevent moisture from entering between the outer surface of tube 43 and the inner surface of transducer 44. Rear seal 48 may be formed of an elastomeric material that resists thermal and vibration degradation, including those materials that can withstand the temperatures of an autoclave process.

[0050] The ultrasound handpiece 12 may further include a front seal 52 radially arranged around the outer surface of the flare 40 to prevent moisture from entering between the inner surface of the distal housing portion 16 and the flare 40. This is because the outer surface of the flare 40 is exposed to liquid during operation of the ultrasound handpiece 12. The front seal 52 may further include a plurality of protrusions or ridges configured to promote engagement between the flare 40 and the distal housing portion 16 and prevent moisture from entering the gap between the flare 40 and the distal housing portion 16 of the ultrasound handpiece 12.

[0051] The ultrasound handpiece 12 may further include a packaging seal 50 positioned between and engaged with the distal end of the barrier member 49 and the proximal end of the flared portion 40. The packaging seal 50 may also be configured to contact an inner surface of the distal housing portion 16 of the ultrasound handpiece 12, which is adjacent to the barrier member 49 and the proximal end of the flared portion 40. The packaging seal 50 may be configured to abut the distal end of the barrier member 49 and define a second hole for receiving a coupling feature of the flared portion 40. The packaging seal 50 may be configured to prevent the packaging element 47 from entering the barrier member 49 and contacting the transducer 44 during the packaging process. Once the packaging element 47 is in place, the packaging element 47 combines with the packaging seal 50 to help prevent moisture from entering between the barrier member 49 and the flared portion 40.

[0052] Reference Figure 5 and 6, shows an exemplary configuration of the distal housing portion 16. The distal housing portion 16 may include a coupling feature 60 configured to removably couple the distal housing portion 16 to a distal portion of a barrier member 49 disposed within the proximal housing portion 14. The coupling feature 60 may include a pair of tabs configured to form a snap and / or friction fit with corresponding coupling features of the barrier member 49. However, alternative coupling features, such as hooks or protrusions, are also contemplated. The coupling feature 60 may help mount and / or position the barrier member 49 within a gap defined by the distal housing portion 16 and the proximal housing portion 14.

[0053] The distal housing portion 16 of the ultrasound handpiece 12 may further include a flexible circuit 62 that may be molded into the distal housing portion 16. The flexible circuit 62 may be constructed of a conductive material configured to transmit electrical signals between a distal region and a proximal region of the flexible circuit 62. The flexible circuit 62 may include an attachment portion 64 positioned at the proximal region of the flexible circuit 62 and configured to be coupled to a processor disposed within the ultrasound handpiece 12 that is configured to communicate with the console 13. Alternatively, the attachment portion 64 of the flexible circuit 62 may be configured to be coupled to a wire, cable, or similar conductor that may be coupled to the console 13 via the cable 30. The processor or wire may be configured to transmit electrical signals between the flexible circuit 62 and the console 13 that may control the power, irrigation, and / or suction functions of the ultrasound handpiece 12. The flexible circuit 62 may also include a transceiver 66 positioned at the distal region of the flexible circuit 62. As described below, the location of the transceiver 66 in the ultrasound handpiece 12 should be carefully controlled to ensure that the corresponding coil of the sleeve 18 can always be read when the sleeve 18 is coupled to the ultrasound handpiece 12.

[0054] exist Figure 51 and 14. Also shown is a tube 58 defining the aforementioned lumen 59, which is at least partially disposed within the ultrasonic handpiece 12. The tube 58 may be at least partially disposed within the distal housing portion 16 and the proximal housing portion 14. The tube 58 may further include a coupling feature 56, such as a hose barb or similar fitting configured to establish a friction fit, which is positioned at the proximal end of the tube 58 and is configured to couple the tube 58 to an irrigation line 29 extending from the console 13 to the ultrasonic surgical handpiece assembly 10. The irrigation line 29 from the console 13 may be coupled to the ultrasonic handpiece 12 via the hose barb 56 to facilitate the flow of irrigation fluid through the tube 58 within the ultrasonic handpiece 12 to the sleeve 18 and / or the ultrasonic tip 20. In the above configuration, the irrigation fluid may flow from the proximal end to the distal end of the ultrasonic handpiece 12 within the ultrasonic handpiece 12 or the sleeve 18, thereby eliminating the need for a bulky irrigation line coupled to the side of the ultrasonic handpiece 12 or the side of the sleeve 18. This configuration is enabled by the irrigation line extending through the handpiece 12. Thus, neither the sleeve nor the ultrasonic handpiece includes irrigation coupling parts along the sides. Alternatively, in other configurations, the tube 58 can be coupled to the aspiration line 27 via the coupling feature 56. The aspiration line 27 can be used to draw a vacuum through the tube 58. The tube 58 can be in communication with the sleeve 18 and / or the ultrasonic tip 20 to remove biological material and / or fluid from the surgical site.

[0055] refer to Figure 6, an exploded view of the distal housing portion 16 of the ultrasound handpiece 12 is shown. The distal housing portion 16 may include a first half 68 and a second half 70, which are configured to be coupled together to form a portion of the distal housing portion 16. Each of the first half 68 and the second half 70 may be injection molded from injection molded plastic or a similar lightweight and durable material. In addition, each of the first half 68 and the second half 70 may be molded to include a groove 74 or a recessed portion that forms a passage in the distal housing portion 16 when the first half 68 and the second half 70 are coupled together. It is also contemplated that the groove 74 may be formed in only one of the first half 68 or the second half 70. The groove 74 may be configured to receive at least a portion of the flexible circuit 62. The groove 74 may further include a cavity 72 at a distal end of the groove 74, wherein the cavity 72 is configured to receive the transceiver 66 at a distal region of the flexible circuit 62. The cavity 72 may include a larger size than the groove 74 to accommodate the size of the transceiver 66 relative to the flexible circuit 62, and the cavity 72 and the groove 74 may be continuous. Although the cavity 72 is shown as being positioned near the distal end of the distal housing portion 16, it is contemplated that the first half 68 and the second half 70 may be configured to position the flexible circuit 62 and the transceiver 66 at alternative locations. For example, the cavity 72 may be positioned closer to the proximal end of the distal housing portion 16. In yet another configuration, the first half 68 and the second half 70 may be configured to separate along a horizontal axis rather than along a vertical axis, so that the first half 68 is positioned higher than the second half 70. In this configuration, the groove 74 and the cavity 72 may be formed in the interface of the first half 68 and the second half 70 so that the flexible circuit 62 and the transceiver 66 may be positioned on the right or left side of the distal housing portion 16.

[0056] The position of cavity 72 should be carefully controlled so that the transceiver 66 and the RFID tag 88 (see Figure 8 ) can communicate between the distal housing portion 16. For example, the cavity 72 can be positioned within the distal housing portion 16 to reduce the distance between the transceiver 66 and the corresponding RFID tag 88 of the sleeve 18 when the sleeve 18 and the ultrasound handpiece 12 are coupled together. The cavity 72 is positioned to ensure that the plane defined by the transceiver 66 is positioned approximately parallel to the plane defined by the RFID tag 88 of the sleeve 18.

[0057] As described above, the flexible circuit 62 may include a transceiver 66 positioned at the distal end of the flexible circuit 62. The transceiver 66 may include an antenna configured to send a signal to a corresponding RFID tag associated with the sleeve 18 and receive a response. When the first half 68 and the second half 70 are coupled together, the flexible circuit 62 may be at least partially disposed within the groove 74 of the distal housing portion 16. The flexible circuit 62 may generally be formed as a thin strip of tape including internal copper elements (such as wiring). The configuration and structure of the flexible circuit 62 may cause the flexible circuit 62 to be fragile or easily damaged. This may make the flexible circuit difficult to work with and / or difficult to install the flexible circuit into the distal housing portion 16. For example, it is necessary to handle the flexible circuit in a manner to prevent squeezing or breaking. It is also desirable to be very careful to avoid operations that may cause delamination of the layers of the flexible circuit 62. Therefore, the groove 74 formed in the distal housing portion 16 should avoid sharp bends or turns and attempt to provide a smooth transition along the length of the groove 74. During assembly, prior to coupling the first and second halves 68, 70 of the distal housing portion 16, the flexible circuit 62 is positioned within the groove 74 and the transceiver 66 is positioned within the cavity 72 so that the position of the transceiver 66 within the distal housing portion 16 can be fixed. It should be understood that the transducer need not always be at the distal end of the flexible circuit.

[0058] Once the first and second halves 68, 70 of the distal housing portion 16 have been mechanically assembled together so that the position of the transceiver 66 is fixed, the distal housing portion 16 may be overmolded with an autoclavable plastic to form a housing such as Figure 5 . Overmolding the flexible circuit 62 and transceiver 66 within the distal housing portion 16 of the ultrasound handpiece 12 with an autoclavable plastic serves to protect the flexible circuit 62 from heat damage during the autoclave process used to sterilize the ultrasound handpiece 12. In addition, the use of an autoclavable plastic rather than a plastic having a melting point below 150 degrees Celsius allows the distal housing portion 16 to be repeatedly autoclaved without significant degradation. Finally, by positioning the flexible circuit 62 within the recess 74 of the first and second halves 68, 70 prior to overmolding with the autoclavable plastic, the flexible circuit 62 is sufficiently isolated from the thermal energy of the melted autoclavable plastic by the first and second halves 68, 70 such that the flexible circuit 62 does not delaminate during the overmolding process. The result of the above process can be shown in Figure 5 and 8 In the device shown. Autoclavable plastics are to be understood as polymers having a melting point of more than 150 degrees Celsius.

[0059] Although the process of positioning the flexible circuit 62 is described with respect to the two halves 68, 70 of the distal housing portion 16, it should be understood that a similar process can be used with any suitable medical device housing in which accurately positioning a portion of the flexible circuit 62 is important, including those medical device housings that do not include two distinct halves.

[0060] Although not shown, the ultrasound handpiece 12 also includes a memory. The memory may contain data describing the characteristics of the ultrasound handpiece 12. The memory may be in the form of an EPROM, an EEPROM, or included in the above-mentioned RFID tag 88. In addition to data that can be read, the memory can also store data written to the memory after the ultrasound handpiece 12 is manufactured. Auxiliary components not shown are mounted on the handpiece to facilitate reading data from the memory and writing data to the memory. These components are composed of one or more of the following: a conductor; an exposed contact / stylus; a coil / antenna; or an isolation circuit.

[0061] Reference Figure 7-9 , illustrating an exemplary configuration of an interface between the distal housing portion 16 and the sleeve 18 and / or the ultrasonic tip 20 . Figure 7 A front view of an exemplary configuration of the distal end of the distal housing portion 16 described above is shown. This may also be referred to as the distal end of the ultrasound handpiece 12. The distal end of the ultrasound handpiece 12 may include an attachment area 69 configured to serve as an interface between the ultrasound handpiece 12 and the sleeve 18 and the ultrasound tip 20. The attachment area 69 may include a recess 71 defined by a proximal surface 78 and a distal surface 79, the proximal surface 78 and the distal surface 79 being connected by a plurality of walls 77 extending perpendicular to the proximal surface 78 and the distal surface 79. The proximal surface 78 may include a hole 73 that includes a coupling feature 75 at the periphery of the hole 73 (see Fig. 9 ). The coupling feature 75 may include a tab, a lip, or a similar snap-fit ​​coupling mechanism.

[0062] The distal end of the flared portion 40 can be configured to extend partially through a hole 73 defined in a proximal surface 78, wherein at least a portion of the flared portion 40 and the threaded coupler 38 are disposed within a recess 71 at the distal end of the ultrasound handpiece 12. The second conduit 42 extending through the flared portion 40 can similarly open into the recess 71.

[0063] The proximal surface 78 may further include an irrigation coupler 76 positioned at the distal end of the tube 58 defining the lumen 59 through the ultrasound handpiece 12. The irrigation coupler 76 may include a nipple, a hose barb, or a similar coupling member for coupling the distal end of the tube 58 to a corresponding irrigation line 29 of the sleeve 18. The irrigation coupler 76 may be configured to be in fluid communication with the lumen 59 disposed within the ultrasound handpiece 12 to provide irrigation fluid to the sleeve 18. The irrigation coupler 76 may be used as an inlet or an outlet to transfer material and / or fluid between the ultrasound handpiece 12 and the sleeve 18.

[0064] Reference Figure 8 , a partially exploded view of the interface between the distal end of the ultrasound handpiece 12 and the sleeve 18 is shown. The sleeve 18 may include a hub 21 positioned at the proximal end of the sleeve 18 and a sleeve body 19 extending distally from the hub 21. The sleeve 18 may include an inner cavity 98 defined by the hub 21 and the sleeve body 19, which extends the length of the sleeve 18 and is configured to surround at least a portion of the ultrasound tip 20 when coupled to the ultrasound handpiece 12. The hub 21 may include a protrusion 80 extending proximally from a distal surface 84 of the hub 21 and terminating at a proximal surface 82. The proximal surface 82 of the protrusion 80 may be oriented to be substantially parallel to the distal surface 84. The shape of the protrusion 80 may be defined by a plurality of peripheral surfaces 81 or wall members extending between the distal surface 84 and the proximal surface 82 and configured to define the outer perimeter of the protrusion 80. The peripheral surface 81 may be oriented generally perpendicular to the proximal surface 82 and / or the distal surface 84. It will be appreciated that the shape of the protrusion 80 is positioned to fit tightly within the recess 71 such that the peripheral surface 81 of the protrusion 80 engages the wall 77 of the recess 71.

[0065] However, although not shown in the drawings, it is also contemplated that the outer peripheral surface 81 of the protrusion 80 may be oriented at an angle other than 90 degrees relative to the proximal surface 82 and / or the distal surface 84 to form a tapered protrusion 80. For example, the area defined by the outer peripheral surface 81 of the protrusion 80 near the distal surface 84 may be greater than the area of ​​the proximal surface 82.

[0066] The hub 21 may further include a connector 94 extending from the proximal surface 82 of the protrusion 80. The connector 94 may be configured to be coupled to a corresponding connector 76 of the ultrasound handpiece 12. The connector 94 of the sleeve 18 and the corresponding connector 76 of the ultrasound handpiece 12 may be configured to facilitate fluid exchange between the sleeve 18 and the ultrasound handpiece 12. In particular, the connector 76 is sized to fit within the connector 94 when the sleeve 18 is coupled to the ultrasound handpiece 12. For example, irrigation fluid from the ultrasound handpiece 12 may be transferred to the sleeve 18 through the connection of the connector 94 to the connector 76. This eliminates the need to connect the sleeve to an irrigation line that is separate from the ultrasound handpiece 12, such as, for example, an irrigation line that is connected to one side of the sleeve 18. Alternatively, a vacuum may be applied to the ultrasound handpiece 12, configured to draw material from the sleeve 18 through the connectors 94 and 76 when coupled in an alternative configuration.

[0067] The sleeve 18 may further include a conduit 96 formed in the sleeve body 19 and extending adjacent to the lumen 98 of the sleeve 18. The connector 94 may be coupled to the proximal end of the conduit 96. The conduit 96 may be configured to direct an irrigation fluid through the sleeve 18 separately from the lumen 98 of the sleeve 18. The conduit 96 may extend through the sleeve 18 in a variety of ways.

[0068] The hub 21 may also include a cavity 86 in the protrusion 80, the cavity including an opening in the proximal surface 82 of the protrusion 80. The cavity 86 may be configured to at least partially enclose a tag 88, an antenna, a transceiver, or a similar wireless communication device configured to communicate with the transceiver 66 disposed in the distal housing portion 16 of the ultrasound handpiece 12. For example, the tag 88 may include an RFID tag 88, which may be inserted and / or disposed in the cavity 86. Although the figures show the cavity 86 and the RFID tag 88 as being generally positioned near the proximal end of the sleeve 18, it should be understood that the cavity 86 and the RFID tag 88 may be positioned at other locations on or within the sleeve 18. For example, the RFID tag 88 may be positioned in one of the other peripheral surfaces 81A, 81B, or 81D of the protrusion 80. Alternatively, the cavity 86 and the RFID tag 88 may be positioned in the distal surface 84 of the hub 21. The RFID tag 88 may include a storage unit that stores data and / or information about one or more properties or characteristics related to the sleeve 18 and the ultrasonic tip 20. For example, the RFID tag 88 may include information identifying the type of cutting feature 34 disposed on the distal end of the ultrasonic tip 20. The RFID tag 88 may also include information identifying the type of sleeve 18. This information may be transmitted to the ultrasound handpiece 12 and subsequently transmitted to the console 13 so that the console 13 may modify power settings, irrigation settings, aspiration settings, and / or other settings intended to optimize the efficiency of the cutting feature 34 of the ultrasonic tip 20. This may include control parameters that are not specific to power and prompts for compatibility settings for the ultrasound handpiece 12. The RFID tag 88 may also be used to prevent customers from reusing their ultrasonic tip 20 and / or sleeve 18 as part of a sterilization standard or procedure. For example, the ultrasonic tip 20 and sleeve 18 may be configured as a single-use component that is not intended to be sterilized and reused. The RFID tag 88 also includes a coil 89. The shapes of the protrusion 80 and the recess 71 are arranged so that the plane defined by the coil 89 of the RFID tag 88 is generally parallel to the plane defined by the transceiver 66 .

[0069] The RFID tag 88 in the sleeve 18 can be understood as a tip memory. The ultrasonic tip 20 and the sleeve 18 are usually packaged together in the form of a kit. The data contained in the RFID tag 88 can be used to control the actuation of the ultrasonic tip 20. The coil 89 embedded in the sleeve 18 is coupled to the storage unit of the RFID tag 88. As described above, the RFID tag 88 can be used to prevent customers from reusing the ultrasonic tip 20 and / or the sleeve 18. In combination with the storage unit, the RFID tag 88 can be further configured to track and / or count the number of times used and limit the number of times the tip is used. For example, the RFID tag 88 can be configured to store the number of times and / or the amount of time that the ultrasonic tip 20 and the sleeve 18 are operated on the storage unit. The RFID tag 88 and the storage unit can be configured to prevent the tip from being actuated beyond a defined number of times used. The defined number of times used can be passed on to the wear and effectiveness of the ultrasonic tip 20 and / or the sleeve 18 to prevent or predict failure.

[0070] like Fig. 9 As shown, the tag 88 can be fixed in the cavity 86 by a pin 89. The pin 89 may include a plastic or alloy material and is configured to establish a friction fit within the opening of the cavity 86 to fix the RFID tag 88 in the cavity 86 and protect it from damage. Alternatively, the pin 89 may include a seal such as an elastomeric O-ring. In another configuration, the pin 89 may include an epoxy resin, glue, sealant or similar compound, configured to fix the tag 88 in the cavity 86 and protect the tag from damage. It is further contemplated that the RFID tag 88 can be injection molded or hot-melt embedded in the sleeve 18. RFID may also use other forms of tags.

[0071] The protrusion 80 can be configured to have a shape that is complementary to the shape defined by the recess 71 at the distal end of the ultrasound handpiece 12, wherein the protrusion 80 is configured to be disposed within the recess 71 when the sleeve 18 is coupled to the ultrasound handpiece 12. In addition, the shapes of the recess 71 and the protrusion 80 can be configured to align the sleeve 18 relative to the ultrasound handpiece 12 and prevent rotational movement of the sleeve 18 relative to the ultrasound handpiece 12. For example, Figure 8 As shown, the recess 71 of the ultrasound handpiece 12 includes a plurality of walls 77 defining the periphery of the recess 71. Figure 7-8In the example configuration of the recess 71 shown, the walls 77A, 77B, 77C and 77D define a doghouse-like shape, wherein there are two opposing walls 77A, 77B that are substantially parallel to each other. The two opposing walls 77A, 77B are connected by a third wall 77C that is substantially perpendicular to the two opposing walls 77A, 77B. The fourth wall 77D that is opposite to the third wall 77C and connects the two opposing walls 77A, 77B can have a substantially arcuate shape. Thus, the plurality of peripheral surfaces 81A, 81B, 81C and 81D that define the outer periphery of the protrusion 80 are configured to define a doghouse-like shape corresponding to the shape of the recess 71. Although not shown in the figures, it is contemplated that the walls 77A, 77B, 77C and 77D of the recess 71 and the corresponding peripheral surfaces 81A, 81B, 81C and 81D of the protrusion 80 can be configured to define an alternative shape. For example, the wall 77 and the peripheral surface 81 may define a rectangle, a star, an ellipse, a triangle, or other similar shapes. Although the protrusion 80 and the recess 71 shown in the figure include complementary shapes, it is also contemplated that the protrusion 80 and the recess 71 may have slightly different shapes as long as the protrusion 80 can be disposed within the recess 71. For example, the protrusion 80 on the sleeve 18 may be configured to include several more peripheral surfaces 81 by forming chamfers between 81C and 81A and / or 81B, and the protrusion will still be inserted into and function in the ultrasound handpiece 12.

[0072] The shapes of the protrusion 80 and the recess 71 can be further configured to orient the tag 88 disposed in the cavity 86 of the hub 21 relative to the transceiver 66 disposed in the distal housing portion 16 of the ultrasound handpiece 12. Utilizing the shapes of the protrusion 80 and the recess 71 to orient the tag 88 relative to the transceiver 66 can improve reliable establishment of communication between the tag 88 and the transceiver 66. For example, Fig. 9 As shown, the tag 88 and the transceiver 66 are positioned so that the tag 88 and the transceiver 66 at least partially overlap in the axial direction when the sleeve 18 is coupled to the ultrasound handpiece 12. In addition, the cavity 86 in the hub 21 and the cavity 72 in the distal housing portion 16 of the ultrasound handpiece 12 can be oriented so that the first longitudinal axis of the tag 88 and the second longitudinal axis of the transceiver 66 are substantially parallel to each other. The protrusion 80 and the distal housing portion 16 can be further configured to reduce the distance between the cavity 86 in the hub 21 and the cavity 72 in the distal housing portion 16 to further improve the communication between the tag 88 and the transceiver 66.

[0073] The hub 21 may further include a plurality of retaining fingers 90 extending distally from the proximal surface 82 of the protrusion 80. The plurality of retaining fingers 90 may be spaced around the perimeter of the lumen 98 defined in the proximal surface 82. The plurality of retaining fingers 90 may further include tabs 92, bumps or projections configured to engage the coupling features 75 at the perimeter of the holes 73 in the proximal surface 78 of the recess 71 in the ultrasound handpiece 12. The tabs 92 of each of the plurality of retaining fingers 90 may engage the coupling features 75 of the recess 71 to establish a snap fit and / or friction fit to removably couple the sleeve 18 to the ultrasound handpiece 12. The plurality of retaining fingers 92 may include a highly compliant material, such as silicone rubber, or a metallic material, such as a leaf spring. Although not shown in the drawings, it is contemplated that the sleeve 18 may be coupled to the ultrasound handpiece 12 in a variety of other ways. For example, the hub 21 can be configured without the retaining fingers 90 so that the irrigation coupling 76 of the ultrasound handpiece 12 can cooperate with the irrigation fitting 94 of the sleeve 18 to form the primary retaining mechanism. In yet another configuration, the protrusion 80 can include a compliant material containing an RFID tag 88 disposed within a slit in the material, and the protrusion 80 can establish an interference fit with the cavity 71.

[0074] refer to Fig. 9 , a cross-sectional view showing an exemplary configuration of the interface between the distal housing portion 16 of the ultrasound handpiece 12 and the sleeve 18 and the ultrasound tip 20. Fig. 9 As shown, when the sleeve 18 is coupled to the ultrasound handpiece 12, the distal surface 79 of the distal housing portion 16 may abut the distal surface 84 of the protrusion 80. This can help form a stable connection between the sleeve 18 and the ultrasound handpiece 12. Similarly, when the protrusion 80 is disposed within the recess 71 to couple the sleeve 18 to the ultrasound handpiece 12, the proximal surface 78 of the distal housing portion 16 may abut the proximal surface 82 of the protrusion 80. However, when the distal surface 79 of the distal housing portion 16 abuts the distal surface 84 of the protrusion 80, there may also be a gap between the proximal surface 78 of the distal housing portion 16 and the proximal surface 82 of the protrusion 80.

[0075] In operation, a method of coupling the sleeve 18 to the ultrasound handpiece 12 may include providing the ultrasound handpiece 12 described above, wherein the ultrasound handpiece 12 includes an irrigation tube 58 configured to deliver an irrigation fluid through the ultrasound handpiece 12. The ultrasound handpiece 12 may also include an attachment portion 69 positioned near the distal end of the ultrasound handpiece 12. The attachment portion 69 may include the recess 71 described above, wherein the recess is defined by a plurality of side walls 77 configured to define a void, such as an asymmetric void. The attachment area 69 may also include a hole or similar attachment element.

[0076] The method of coupling the sleeve 18 to the ultrasound handpiece 12 may further include providing the sleeve 18 described above, wherein the sleeve 18 includes a hub 21, the hub 21 including a proximal surface 82 and a distal surface 84. The proximal surface 82 may optionally include one or more retaining fingers 90 and is configured to define an asymmetric protrusion 80 extending proximally from the distal surface 84. The protrusion 80 may be sized to be inserted into the recess 71 of the ultrasound handpiece 12.

[0077] The method of coupling the sleeve 18 to the ultrasound handpiece 12 may further include coupling the ultrasound handpiece 12 to the sleeve 18 by inserting the asymmetric protrusion 80 into the asymmetric void defined by the attachment portion 69 such that the one or more retaining fingers 90 engage the perimeter of the hole in the distal housing portion 16 to form an interference fit between the sleeve 18 and the ultrasound handpiece. As the asymmetric protrusion 80 is inserted into the asymmetric void defined by the attachment portion 69, the irrigation coupler 76 of the ultrasound handpiece 12 may cooperate with the irrigation connector 94 of the sleeve 18 to form an irrigation passage between the ultrasound handpiece 12 and the sleeve 18 without separately connecting an irrigation line to the irrigation sleeve 18. Thus, with a single step of inserting the protrusion of the sleeve into the recess of the ultrasound handpiece, irrigation and aspiration lines may be coupled to the sleeve and the sleeve may be coupled to the ultrasound handpiece.

[0078] The method of coupling the sleeve 18 to the ultrasound handpiece 12 may further include the step of providing the ultrasonic tip 20 described above, wherein the ultrasonic tip 20 includes a threaded coupler 104 at a distal end of the ultrasonic tip 20 configured to removably secure the ultrasonic tip 20 to the threaded connector 38 of the ultrasound handpiece 12. The ultrasonic tip 20 may further include a cutting feature 34 at the distal end of the ultrasonic tip 20. Next, the method may include coupling the ultrasonic tip 20 to the ultrasound handpiece 12 before the step of coupling the ultrasound handpiece 12 to the irrigation sleeve 18.

[0079] The method of connecting the sleeve 18 to the ultrasound handpiece 12 may also include the following steps: when the asymmetric protrusion 80 is inserted into the asymmetric gap defined in the attachment portion 69, the first irrigation connector 76 on the distal end of the irrigation conduit or tube 58 of the ultrasound handpiece 12 is inserted into the corresponding irrigation connector 94 on the irrigation sleeve 18, wherein the irrigation connector 94 is fluidically connected to the conduit 96 of the sleeve 18 and is configured to provide irrigation fluid to the ultrasonic tip 20.

[0080] Reference Fig.10 , Fig.11A and Fig. 11B , shows an example configuration of an ultrasonic tip 20 disposed within a sleeve 18. Fig. 11B, shows a cross-sectional view of the ultrasonic tip 20 disposed within the sleeve 18. As described above, the sleeve 18 may include a conduit 96 formed in the sleeve body 19, which extends adjacent to the lumen 98 of the sleeve 18. The distal end of the conduit 96 may terminate in an aperture 108 or nozzle positioned on the inner surface of the lumen 98. The aperture 108 may be configured to direct the fluid radially inward toward the center of the lumen 98. The fluid may then be applied to the outer surface of the ultrasonic tip 20 and / or directed toward the distal end of the sleeve 18, where the fluid may exit the lumen 98 and be applied to the surgical site.

[0081] The sleeve 18 can further include a seal 100, such as an O-ring, disposed within the lumen 98 and configured to contact a portion of the ultrasonic tip 20 when the sleeve 18 is coupled to the ultrasonic handpiece 12 and the ultrasonic tip 20 is coupled to the ultrasonic handpiece 12. The seal 100 can be configured to create a fluid seal between the inner surface of the lumen 98 and the outer surface of the ultrasonic tip 20. For example, the seal 100 can be configured to prevent fluid distal to the seal 100, between the inner surface of the lumen 98 and the outer surface of the ultrasonic tip 20, from flowing to the proximal side of the seal 100.

[0082] The ultrasonic tip 20 may include a distal end and a proximal end. The ultrasonic tip 20 may include a cutting feature 34 at the distal end of the ultrasonic tip 20 and a coupling feature 104 at the proximal end. The coupling feature 104 may be configured to engage the threaded coupler 38 of the flared portion 40 to removably couple the ultrasonic tip 20 to the ultrasonic handpiece 12. It should be understood that the coupling feature 104 of the ultrasonic tip 20 should be configured to engage the threaded coupler 38 of the flared portion 40. Therefore, if a coupling device other than complementary threads is used, the coupling features 104, 38 of the ultrasonic tip 20 and the flared portion 40 are adapted to engage with each other.

[0083] The ultrasonic tip 20 can be configured to define a lumen 102 extending from a proximal end to a distal end of the ultrasonic tip 20. The lumen 102 can be configured to be in fluid communication with a fluid passageway through the ultrasonic handpiece 12 defined by the conduit 42 of the flared portion 40 and the lumen 45 of the transducer 44 when the ultrasonic tip 20 is coupled to the ultrasonic handpiece 12. The lumen 102 can be configured to provide irrigation and / or evacuation at a surgical site based on a system coupled to the fluid passageway through the ultrasonic handpiece 12 defined by the conduit 42 of the flared portion 40 and the lumen 45 of the transducer 44. For example, if an irrigation system is coupled to the fluid passageway through the ultrasonic handpiece 12 defined by the conduit 42 of the flared portion 40 and the lumen 45 of the transducer 44, the lumen 102 can be configured to provide irrigation fluid to a surgical site near the cutting member 34. Alternatively, if the aspiration system is coupled to the fluid passageway through the ultrasonic handpiece 12 defined by the conduit 42 of the flared portion 40 and the lumen 45 of the transducer 44 , the lumen 102 may be configured to remove fluid and / or material from a surgical site proximate the cutting feature 34 .

[0084] The ultrasonic tip 20 may further include a hole 106 configured to be in fluid communication with the lumen 102. The hole 106 may be positioned between the proximal and distal ends of the ultrasonic tip 20 such that when the ultrasonic tip 20 is disposed within the lumen 98 of the sleeve 18, the hole 106 is located distally of the seal 100 of the sleeve 18. Additionally, the hole 106 may be positioned on the ultrasonic tip 20 such that when the ultrasonic tip 20 is disposed within the lumen 98 of the sleeve 18, the hole 106 is surrounded by the sleeve 18. For example, the hole 106 may be positioned on the ultrasonic tip 20 such that when the ultrasonic tip 20 is disposed within the lumen 98 of the sleeve 18, the hole 106 is located proximal to the distal end of the sleeve 18.

[0085] The ultrasonic tip 20 may also include a resonator 105 positioned between the proximal and distal ends of the ultrasonic tip 20. The resonator 105 may be configured to convert the longitudinal vibration transmitted from the transducer 44 to the ultrasonic tip 20 via the mechanical connection established by the horn 40 into the longitudinal and torsional motion of the ultrasonic tip 20 distal to the resonator 105. For example, when the transducer 44 expands and contracts, vibrations are generated, which are transmitted to the ultrasonic tip 20 via the horn 40. The portion of the ultrasonic tip 20 near the resonator 105 undergoes longitudinal motion. Then, the resonator 105 can convert the longitudinal motion of the transducer 44 and the horn 40 into the longitudinal and torsional motion of the portion of the ultrasonic tip 20 distal to the resonator 105. The resonator 105 may include a non-uniform cross-sectional area formed by grooves in the outer surface of the ultrasonic tip 20. The grooves on the outer surface of the ultrasonic tip 20 may be oriented in a generally helical and spiral configuration. This can be achieved by cutting a helical or spiral pattern of grooves on the outer surface of the ultrasonic tip 20. Alternatively, this helical or spiral pattern of grooves may be achieved by cutting straight grooves on the outer surface of the ultrasonic tip 20, wherein the grooves are generally parallel to the longitudinal axis of the ultrasonic tip 20, and then the ultrasonic tip 20 may be twisted to establish the helical or spiral pattern of grooves.

[0086] Reference Figure 12-16 , shows an example configuration of a tubing connector 22 for use with an ultrasound handpiece 12 as part of an ultrasonic surgical handpiece assembly 10. The tubing connector 22 may include a base 24 including a distal end and a proximal end. The base 24 may be constructed of a rigid material such as plastic. Alternatively, the base 24 may be constructed of a flexible or elastic material such as an elastomer.

[0087] The base 24 can be configured to define one or two lumens 112, 114 extending through the base 24. The lumens 112, 114 can define a fluid passage through the base 24 of the tubing connector 22, and can be configured to be in fluid communication with one or more conduits or lumens passing through the ultrasound handpiece 12. For example, the first lumen 112 can be configured to be in fluid communication with the passage formed by the conduit 42 of the flared portion 40 and the lumen 45 of the transducer 44 when the tubing connector 22 is coupled to the ultrasound handpiece 12. In addition, the second lumen 114 can be configured to be in fluid communication with the lumen 59 disposed within the ultrasound handpiece 12 when the tubing connector 22 is coupled to the ultrasound handpiece 12.

[0088] The base 24 may further define a groove 110 in the periphery of the base 24 extending between the distal end and the proximal end of the base 24. The groove 110 may be configured to receive a cable 30, a wiring harness, or the like extending proximally from the proximal end of the ultrasound handpiece 12. For example, Figure 1As shown, the groove 110 of the pipe connector can be configured to receive and partially surround the cable 30. The groove 110 can be shaped and / or configured to removably couple the base 24 of the pipe connector 22 to the cable 30 by a friction fit or an interference fit. For example, the groove 110 can include a U-shape or a crescent shape, wherein the width of the opening of the groove 110 at the surface of the base 24 is less than the maximum width of the cable 30.

[0089] The tubing connector 22 may further include a resilient member 26 extending proximally from the base 24 and configured to receive a suction line 27. The resilient member 26 and the base 24 may be formed as an integral component, wherein the resilient member 26 defines a portion of the lumen 112 passing through the base 24. The resilient member 26 may be configured such that the suction line 27 may be inserted into the lumen 112 at the proximal end of the resilient member 26. The suction line 27 may be used to friction fit in the lumen of the resilient member. Alternatively, the suction line 27 may be coupled to the resilient member 26 using glue, epoxy, or a similar adhesive configured to produce a chemical bond.

[0090] Although not shown, it is also contemplated that the resilient member 26 may be removably coupled to the base 24. For example, the distal end of the resilient member 26 may be configured to create friction with the base 24 when inserted into the lumen 112.

[0091] Although the drawings show the suction line 27 and / or the irrigation line 29 being inserted directly into the lumens 112, 114 defined in the base 24 of the tubing connector 22, if further considered, the suction line 27 and / or the irrigation line 29 may also be coupled to the base 24 via a hose barb or similar fitting. For example, the proximal end of the hose barb may be inserted into the opening of the suction line 27 and / or the irrigation line 29. The proximal end of the hose barb may then be inserted into the corresponding lumens 112, 114 defined in the base 24. The hose barb may be coupled to the base 24 via a friction fit within the lumens 112, 114, or the hose barb may be coupled to the base 24 using epoxy, glue, sealant, or a similar adhesive.

[0092] The base 24 can be configured to be detachably coupled to the proximal end of the ultrasound handpiece 12 via an interference fit. An interference fit can be established between the coupling feature 56 of the irrigation tube 58 and the coupling portion 54 of the passage 53 and the corresponding lumens 112, 114. For example, the coupling feature 56 and the coupling portion 54 can each include a hose barb or a similar fitting that is configured to be inserted into the corresponding lumens 112, 114 to create a friction fit that detachably secures the tubing connector 22 to the proximal end of the ultrasound handpiece 12.

[0093] Alternatively, although not shown in the figures, it is contemplated that the distal end of the base 24 may include a retaining feature, such as a tab or finger, configured to form a snap fit with the proximal end of the ultrasound handpiece 12. For example, the retaining feature may include a tab or protrusion that surrounds the perimeter of the distal end of the base 24 and is configured to engage the proximal end of the ultrasound handpiece 12 to removably couple the tubing connector 22 to the ultrasound handpiece 12 via a bayonet fit.

[0094] The tubing connector 22 can be used as a member for quickly attaching and detaching both the irrigation line 29 and the suction line 27 to the proximal end of the ultrasound handpiece 12. In addition, the tubing connector 22 can detachably fix the irrigation line and / or the suction line 29, 27 to the ultrasound handpiece 12 in a manner that reduces stress on the lines near the ultrasound handpiece 12. The tubing connector 22 can reduce bending and / or kinking of the lines near the ultrasound handpiece 12. For example, the elastic member can include an elastic material configured to support the suction line 17 and / or prevent bending or kinking of the suction line 17. In addition, the proximal offset generated by the elastic member extending proximally from the base 24 offsets the position at which the suction line 27 and the irrigation line 29 are connected to the base 24. This can prevent the lines from getting tangled together when the proximal end of the tubing connector 22 is suspended. This serves to provide support to the tubing 27 , 29 against bending of the tubing 27 , 29 proximate the ultrasound handpiece 12 to reduce the occurrence of sharp bends in the tubing 27 , 29 that would restrict flow through the tubing 27 , 29 .

[0095] Terms:

[0096] i. A method of assembling an ultrasonic surgical handpiece without using a separate irrigation connection to a tip sleeve, the method comprising:

[0097] providing a housing including an irrigation conduit configured to communicate an irrigation fluid through an ultrasonic surgical handpiece and an attachment area in the form of a recess in a distal end of the housing;

[0098] providing an irrigation sleeve including a hub, the hub including a proximal portion and a distal portion, the proximal portion defining a protrusion extending proximally from the distal portion and sized to be inserted into the recess of the housing; and

[0099] The housing is coupled to the flushing sleeve without the need to separately connect a flushing line to the flushing sleeve by inserting the protrusion into the recess to provide flushing fluid to the flushing sleeve.

[0100] ii. A sleeve for use with an ultrasonic handpiece including a coupling housing having a handpiece transceiver and configured to enclose a portion of an ultrasonic tip including a cutting feature, the sleeve comprising:

[0101] a hub comprising a proximal portion, a distal portion, and a first lumen extending through the hub;

[0102] a tubular body including a distal end and a proximal end, the tubular body extending from the distal portion of the hub and configured to define a second lumen in fluid communication with the first lumen of the hub, the second lumen being configured to surround the portion of the ultrasonic tip;

[0103] an aperture in the inner surface of the second lumen, the aperture being positioned at a midpoint along the second lumen between the proximal and distal ends of the body and facing inwardly toward the second lumen;

[0104] an irrigation conduit adjacent to the second lumen, the irrigation conduit being configured to extend from the proximal end of the body to the orifice;

[0105] an irrigation hole and a tip hole on the first face, the tip hole being configured to communicate with the first lumen;

[0106] a flushing connector positioned within the flushing aperture of the first face of the hub and in fluid communication with the flushing tube;

[0107] a cavity defined in the proximal portion of the hub, the cavity comprising an opening in the first surface; and

[0108] A sleeve transceiver is positioned within the cavity and is configured to communicate with a corresponding handpiece transceiver.

[0109] iii. An ultrasonic handpiece assembly for use with an elongated cutting instrument / element, the assembly comprising:

[0110] An ultrasound handpiece, comprising:

[0111] a housing including a proximal end and an opposite distal end, the housing defining a volume, the distal end having a distal side;

[0112] a transducer configured to define a first conduit, the transducer being disposed at least partially within the volume defined by the housing;

[0113] a flared portion including a first end and an opposite second end, the flared portion being configured to be disposed at least partially within the volume defined by the housing;

[0114] a second conduit in the flared portion configured to extend between the first end and the second end of the flared portion;

[0115] an irrigation outlet fitting extending from the distal end of the housing and configured to discharge irrigation fluid from the housing;

[0116] a coupler on the second end of the flared portion configured to engage an elongated cutting instrument;

[0117] a recess in the distal end of the housing; and

[0118] a handpiece transceiver including a handpiece coil;

[0119] A flushing sleeve comprising:

[0120] a hub including a proximal portion and a distal portion, the proximal portion being configured to define a protrusion sized to be inserted into the recess of the housing;

[0121] an abutment portion configured to contact the distal surface of the ultrasound handpiece when the protrusion is inserted into the recess of the housing;

[0122] a sleeve transceiver comprising a sleeve coil and a storage unit for storing information related to optimal drive parameters of the elongated cutting instrument; and

[0123] Wherein, the sleeve transceiver is disposed in a cavity defined in the hub such that the second axis of the sleeve coil is aligned with the handpiece coil.

[0124] iv. A method of manufacturing a surgical handpiece having a flexible circuit with an antenna, the method comprising:

[0125] providing an internal flex circuit having an antenna at a distal end of the internal flex circuit;

[0126] providing a first housing component and a second housing component, wherein the first and second housing components are injection molded such that one of the first and second housing components defines a void and one of the first and second housing components includes an irrigation conduit configured to communicate an irrigation fluid through the surgical handpiece;

[0127] positioning an internal flexible circuit within the void of one of the first housing member and the second housing member;

[0128] securing the first housing member to the second housing member to secure the internal flexible circuit in place; and

[0129] The first housing component, the second housing component and a portion of the internal flexible circuit are overmolded with an autoclavable plastic to secure the position of the antenna of the internal flexible circuit in the first and second housing components.

[0130] v. The method of clause iv, further comprising an initial step of injection molding the first housing component and the second housing component.

[0131] vi. The method described in clause v, wherein the first shell component and the second shell component are injection molded to include corresponding passages extending longitudinally along the length of each of the first shell component and the second shell component, wherein the corresponding passages define the gap when the first shell component and the second shell component are fixed together.

[0132] vii. The method of clause vi, wherein the step of positioning the internal flexible circuit within the void includes inserting a portion of the internal flexible circuit into a passageway of the first housing component or the second housing component prior to securing the first housing component to the second housing component.

[0133] viii. The method of any of clauses iv-vii, further comprising the step of coupling the proximal end of the flexible circuit to a processor, wherein the processor is configured to communicate with an antenna at the distal end of the flexible circuit.

[0134] ix. A method of manufacturing a surgical handpiece having a flexible circuit with an antenna, the method comprising:

[0135] providing an internal flexible circuit having a sensor;

[0136] providing a first housing component and a second housing component, wherein the first housing component and the second housing component are injection molded such that one of the first and second housing components defines a void and one of the first and second housing components includes an irrigation conduit configured to communicate an irrigation fluid through the surgical handpiece;

[0137] positioning an internal flexible circuit within the void of one of the first housing member and the second housing member;

[0138] securing the first housing member to the second housing member to secure the internal flexible circuit in place; and

[0139] The first housing component, the second housing component and a portion of the internal flexible circuit are overmolded with an autoclavable plastic to secure the position of the sensor of the internal flexible circuit in the first and second housing components.

[0140] Several embodiments have been discussed in the foregoing description. However, the embodiments discussed herein are not intended to be exhaustive or to limit the invention to any particular form. For example, although the example construction describes the surgical instrument as an ultrasonic handpiece, it is also conceivable that the features and concepts described with respect to the ultrasonic handpiece can be applied to other medical or surgical instruments. This is similarly applicable to the ultrasonic tip 20, which may also include a blade, a drill, a rotary file, a window-type scraper, etc. The terms used are intended to be descriptive, rather than restrictive. In view of the above teachings, many modifications and variations are possible, and the invention may be practiced in a manner different from that specifically described.

Claims

1. A sleeve for use with an ultrasonic handpiece including a coupling housing having a handpiece transceiver and configured to enclose a portion of an ultrasonic tip including a cutting feature, the sleeve comprising: a hub comprising a proximal portion, a distal portion, and a first lumen extending through the hub, the proximal portion having a first face configured to abut an ultrasound handpiece and a second face positioned distal to the first face; a tubular body including a distal end and a proximal end, the tubular body extending from the distal portion of the hub and configured to define a second lumen in fluid communication with the first lumen of the hub, the second lumen being configured to surround the portion of the ultrasonic tip; an aperture in the inner surface of the second lumen, the aperture being positioned at a midpoint along the second lumen between the proximal and distal ends of the body and facing inwardly toward the second lumen; an irrigation conduit adjacent to the second lumen, the irrigation conduit being configured to extend from the proximal end of the body to the orifice; an irrigation hole and a tip hole on the first face, the tip hole being configured to communicate with the first lumen; an irrigation connector positioned within the irrigation aperture of the first face of the hub and in fluid communication with the irrigation conduit; at least one retention finger protruding proximally from the first face, the retention finger configured to engage a coupling housing of an ultrasound handpiece; a cavity defined in the proximal portion of the hub, the cavity comprising an opening in the first surface; as well as A sleeve transceiver is positioned within the cavity and is configured to communicate with a corresponding handpiece transceiver.

2. The sleeve according to claim 1, wherein The proximal portion includes an asymmetrical shape and is configured to be inserted into a coupling housing of an ultrasound handpiece.

3. The sleeve according to claim 2, wherein: The proximal portion comprises: a first wall and a third wall oriented parallel to each other; a second wall extending between the first wall and the third wall, the second wall being oriented generally perpendicular to the first wall and the third wall; a fourth wall extending between the first wall and the third wall opposite the second wall, the fourth wall comprising a generally arcuate shape; Wherein, the first wall, the second wall, the third wall and the fourth wall define the asymmetric shape of the proximal portion.

4. The sleeve according to any one of claims 1 to 3, wherein: The first face and the second face are oriented in the same direction.

5. The sleeve according to any one of claims 1 to 4, wherein: The first face and the second face are oriented parallel to each other.

6. The sleeve according to any one of claims 1 to 5, wherein: The irrigation connector defines a third lumen configured to receive a corresponding barb of an ultrasound handpiece to provide irrigation fluid to the sleeve.

7. The sleeve of any one of claims 1-6, further comprising a seal positioned within the opening of the cavity, the seal configured to secure the sleeve transceiver within the cavity.

8. The sleeve according to any one of claims 1 to 7, wherein: The quill transceiver includes a first axis, and the quill transceiver is positioned within the cavity such that the first axis is substantially perpendicular to a second axis defined by the first face.

9. The sleeve according to any one of claims 1 to 8, wherein: The sleeve transceiver also includes a memory configured to store data related to one or more characteristics associated with the ultrasonic tip.

10. An ultrasonic surgical handpiece for use with an ultrasonic tip assembly, the ultrasonic tip assembly comprising a sleeve having at least one retaining member, the ultrasonic surgical handpiece comprising: a housing including a proximal end and an opposite distal end, the housing being configured to define a volume; a transducer disposed at least partially within the volume defined by the housing; a flare including a first end and an opposite second end and configured to be disposed at least partially within the volume defined by the housing, the first end of the flare being operatively coupled to the transducer; wherein the transducer is configured to cause the horn to vibrate / oscillate when operated; an attachment area formed in the distal end of the housing, the attachment area defining a recess including a face and a plurality of side walls configured to receive a sleeve; an attachment element in the face of the recess, the attachment element configured to receive the at least one retaining member of the sleeve to removably couple the sleeve to the ultrasonic surgical handpiece; a first connector extending from the face of the recess and configured to removably couple with the sleeve to provide flushing to the sleeve; and Wherein, the second end of the flared portion is configured to protrude from the surface.

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