Ultrasonic tip having projects defining top

Abstract

An ultrasonic tip for use with a surgical handpiece to produce longitudinal and torsional motion. The ultrasound tip includes a shaft having a longitudinal axis extending between a proximal end and a distal end, the proximal end and the distal end having respective first and second diameters, where the first diameter is greater than the second diameter. The ultrasound tip also includes a cutting feature coupled to the distal end of the shaft. The shaft defines a suction lumen extending along a longitudinal axis of the shaft. A protrusion on the shaft is positioned between the distal end and the proximal end of the shaft. A portion of the protrusion has a third diameter that is less than the first diameter and greater than the second diameter. An aperture is defined by the protrusion and in fluid communication with the suction lumen, wherein the protrusion reinforces an area around the aperture.

Description

[0001] This application is a divisional application of the invention patent application with application date of September 23, 2019, application number 201980060538.2, and invention name “Ultrasonic tip with a protrusion that defines a top suction hole”.

[0002] Related Applications

[0003] This patent application claims priority to and all benefits of U.S. Provisional Patent Application No. 62 / 735,440, filed on September 24, 2018, the entire contents of which are incorporated herein by reference. Background Art

[0004] As medical professionals strive to reduce the size of incisions and the recovery time required after surgical procedures, the size of medical instruments used in these surgeries has become increasingly smaller. The medical instruments used in performing these surgical procedures may include the use of cutting attachments, such as ultrasonic tips. When performing cutting, shaving, or shaping operations, the cutting attachments will be exposed to forces of varying magnitudes, creating stresses within the cutting attachments. The cutting attachments may also be used in conjunction with irrigation or suction (i.e., aspiration) to reduce heat and / or remove debris from the surgical site. Irrigation may also be used as a cutting medium. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Advantages of the present disclosure will become better understood by referring to the following detailed description when considered in conjunction with the accompanying drawings, so that it will be readily appreciated.

[0006] Figure 1 is a top view of an ultrasonic surgical handpiece assembly.

[0007] Figure 2 yes Figure 1 A cross-sectional view of the ultrasonic surgical handpiece assembly along the direction of section line arrow 2.

[0008] Figure 3 is a top view of the ultrasonic tip and the irrigation sleeve, wherein the ultrasonic tip is located within the irrigation sleeve.

[0009] Figure 4 yes Figure 3 A cross-sectional view of the ultrasonic tip and the irrigation sleeve along the direction of the section line arrow 4.

[0010] Figure 5 is a perspective view of the distal portion of the ultrasonic tip, including the protrusions and cutting features.

[0011] Fig. 6A is a side view of a first configuration of an ultrasonic tip including a protrusion and a cutting feature.

[0012] Figure 6B The ultrasound tip moves along Fig. 6A6B line is a cross-sectional view in the direction of the section line arrow 6B.

[0013] Figure 6C The ultrasound tip moves along Fig. 6A A cross-sectional view taken along line 6C in the direction of section line arrow 6C.

[0014] Fig.6D The ultrasound tip moves along Fig. 6A The 6D line shown in FIG. 6 is a cross-sectional view in the direction of the section line arrow 6D.

[0015] Fig. 6E The ultrasound tip moves along Fig. 6A The 6E line shown in FIG. 6 is a cross-sectional view in the direction of the section line arrow 6E.

[0016] Fig. 6F The ultrasound tip moves along Fig. 6A The 6F line shown in FIG. 6 is a cross-sectional view in the direction of the section line arrow 6F.

[0017] Figure 7 yes Fig. 6A Cross-sectional view of the ultrasonic tip in the direction of the section line arrow 7.

[0018] Figure 8 yes Figure 5 A cross-sectional view of the distal portion of the ultrasonic tip including protrusions and cutting features in the direction of the section line arrow 8.

[0019] Fig. 9 yes Figure 4 FIG. 9 is an enlarged cross-sectional view of the distal portion of the ultrasonic tip and the irrigation sleeve of the portion in the oval 9.

[0020] Fig. 10A is a bottom view of a first configuration of an ultrasonic tip including a protrusion and a cutting feature.

[0021] Fig. 10B is Fig. 10A A perspective view of a first configuration of a cutting feature at a distal region of an ultrasonic tip.

[0022] Fig. 10C is Fig. 10A A perspective view of a second configuration of a cutting feature at a distal region of an ultrasonic tip.

[0023] Fig. 10D is Fig. 10A A perspective view of a third configuration of a cutting feature at a distal region of an ultrasonic tip.

[0024] Fig. 10E is Fig. 10A A perspective view of a fourth configuration of a cutting feature at a distal region of an ultrasonic tip.

[0025] Fig.11 yes Figure 1 Side view of an ultrasonic surgical handpiece assembly. DETAILED DESCRIPTION

[0026] An example of a surgical instrument that can use an irrigation and / or aspiration system is an ultrasonic surgical handpiece. Typically, one or more lines can be coupled to the ultrasonic surgical handpiece to supply irrigation and / or aspiration. The ultrasonic surgical handpiece can also include a sleeve that includes one or more lumens that can be used to direct fluid from an irrigation source to a surgical site and / or a cutting attachment, i.e., an ultrasonic tip.

[0027] The ultrasonic tip is used for use with a surgical handpiece to generate longitudinal and torsional motion, the handpiece including an ultrasonic transducer disposed within a housing. The ultrasonic tip includes a shaft, a cutting feature, and a protrusion. The shaft has a longitudinal axis extending between a proximal end and a distal end of the shaft. The proximal end has a first diameter. The distal end has a second diameter. The first diameter is greater than the second diameter. The shaft includes a vibration conversion mechanism for converting vibration energy transmitted from the ultrasonic transducer into a composite vibration consisting of a longitudinal vibration and a torsional vibration along the longitudinal axis. The cutting feature is coupled to the distal end of the shaft. The suction lumen is defined by the shaft. The suction lumen is configured to extend along the longitudinal axis of the shaft. The suction lumen is configured to be placed in fluid communication with the handpiece. The protrusion is on the shaft and is positioned between the distal end and the proximal end. The protrusion is positioned distal to the vibration conversion mechanism along the longitudinal axis. A portion of the protrusion has a third diameter. The third diameter is less than the first diameter, and the third diameter is greater than the second diameter. The aperture is defined by the protrusion. The aperture is in fluid communication with the suction lumen. The protrusion strengthens the area around the aperture.

[0028] The proximal end of the shaft may include a coupling feature configured to removably couple the shaft to a transducer of the handpiece.

[0029] The coupling feature may include a plurality of threads configured for coupling to the transducer of the handpiece.

[0030] The vibration conversion mechanism may include one or more spiral groove portions formed on the outer surface of the shaft.

[0031] The axis of the aperture may be transverse to the longitudinal axis of the ultrasonic tip.

[0032] The cutting feature may include a cutting surface facing in a direction that is equal to or less than 90 degrees from the longitudinal axis.

[0033] The cutting feature may have a cutting face disposed radially outward from the longitudinal axis. The cutting face may include one or more teeth.

[0034] The projection may include a first tapered region, an intermediate region, and a second tapered region. The outer surface of the intermediate region may be substantially parallel to the longitudinal axis. The intermediate region may be disposed between the first tapered region and the second tapered region. The first tapered region may be proximal to the intermediate region and have a positive slope. The second tapered region may be distal to the intermediate region and have a negative slope.

[0035] The suction lumen may be open at the distal and proximal ends of the shaft.

[0036] An ultrasonic sleeve assembly is used for use with a surgical handpiece including an ultrasonic transducer. The ultrasonic sleeve assembly includes a cutting tip and an irrigation sleeve. The cutting tip includes a shaft, a vibration conversion mechanism, a cutting feature, and a protrusion. The shaft extends between a proximal end and a distal end. The proximal end includes a coupling feature configured to removably couple the shaft to the handpiece. The proximal end includes a first diameter, and the distal end includes a second diameter. The first diameter is greater than the second diameter. The vibration conversion mechanism is used to convert the vibration energy transmitted from the ultrasonic transducer into a composite vibration consisting of a longitudinal vibration and a torsional vibration along a longitudinal axis. The cutting feature is coupled to the distal end of the shaft. The suction lumen is defined by the shaft and is configured to extend along the longitudinal axis of the shaft. The suction lumen is configured to be in fluid communication with the surgical handpiece when the shaft is coupled to the surgical handpiece. The protrusion is on the shaft and is positioned distal to the vibration conversion mechanism. A portion of the protrusion has a third diameter. The third diameter is less than the first diameter. The third diameter is greater than the second diameter. The protrusion is configured to reinforce the shaft. The aperture is defined by the projection and is in fluid communication with the suction lumen. The flushing sleeve is configured to surround a portion of the shaft when the flushing sleeve and the cutting tip are coupled to the handpiece. The flushing sleeve defines a lumen including a proximal end and a distal end. The proximal end of the lumen includes a coupling mechanism configured to be removably coupled to the handpiece. The flushing sleeve also defines a flushing channel separated from the lumen. The flushing channel has a distal end and a proximal end. The proximal end of the flushing channel is configured to be releasably coupled to a flushing source. The flushing channel is configured to deliver fluid to the lumen through a flushing port. The flushing port is in fluid communication with the flushing channel and the lumen.

[0037] The coupling feature may include a plurality of threads configured for coupling to the transducer of the handpiece.

[0038] The vibration conversion mechanism may include one or more spiral groove portions formed on the outer surface of the shaft.

[0039] The cutting feature may include a cutting face facing in a direction perpendicular to the longitudinal axis.

[0040] The apertures may be positioned in a direction radially opposite to the cutting surface.

[0041] The cutting feature may have a cutting face disposed radially outward from the longitudinal axis. The cutting face may include one or more teeth.

[0042] The projection may include a first tapered region, an intermediate region, and a second tapered region. The outer surface of the intermediate region may be substantially parallel to the longitudinal axis. The intermediate region may be disposed between the first tapered region and the second tapered region. The first tapered region may be proximal to the intermediate region and may have a positive slope. The second tapered region may be distal to the intermediate region and may have a negative slope.

[0043] The suction lumen may be open at the distal and proximal ends of the shaft.

[0044] An ultrasonic cutting system for generating longitudinal and torsional motion includes a handpiece, a cutting tip and an irrigation sleeve. The handpiece includes a transducer arranged in a housing. The cutting tip is coupled to the handpiece and includes a shaft and a cutting feature. The shaft includes a distal end and a proximal end. The proximal end includes a coupling feature configured to removably couple the shaft to the handpiece. The cutting feature is coupled to the distal end of the shaft. A suction lumen is defined by the shaft. The suction lumen is configured to extend along the longitudinal axis of the shaft. The suction lumen is in fluid communication with the handpiece. The pore is in fluid communication with the suction lumen and is located between the proximal and distal ends of the shaft. The pore has a proximal end and a distal end. An irrigation sleeve is coupled to the handpiece. The irrigation sleeve surrounds a portion of the shaft and has a proximal end and a distal end. The irrigation sleeve defines an inner cavity. The proximal end of the irrigation sleeve has a coupling mechanism configured to removably couple the irrigation sleeve to the handpiece. The irrigation sleeve further defines an irrigation channel including a distal end and a proximal end. The proximal end of the irrigation channel is configured to receive irrigation fluid from an irrigation source. The irrigation port is in fluid communication with the distal end of the irrigation channel. The irrigation port is configured to distribute irrigation fluid toward the shaft. The distal end of the irrigation sleeve is positioned proximal to the distal end of the shaft. The irrigation port is positioned proximal relative to the aperture along the longitudinal axis. The distal end of the irrigation sleeve is distal to the distal end of the aperture so that the irrigation sleeve surrounds the entire aperture.

[0045] The distal end of the irrigation sleeve may extend in a distal direction along the longitudinal axis beyond the distal end of the aperture.

[0046] The coupling feature may include a plurality of threads configured for coupling to the transducer of the handpiece.

[0047] The shaft may include a vibration conversion mechanism for converting vibration energy transmitted from the transducer into a composite vibration consisting of a longitudinal vibration along the longitudinal axis and a torsional vibration.

[0048] The vibration conversion mechanism may include one or more spiral groove portions formed on the outer surface of the shaft.

[0049] The cutting feature may include a cutting face facing in a direction perpendicular to the longitudinal axis.

[0050] The apertures may be positioned in a direction radially opposite to the cutting surface.

[0051] The cutting feature may have a cutting face disposed radially outward from the longitudinal axis, and wherein the cutting face includes one or more teeth.

[0052] The suction lumen may be open at the distal and proximal ends of the shaft.

[0053] The ultrasonic tip is used for use with a surgical handpiece to generate longitudinal and torsional motion, the surgical handpiece including an ultrasonic transducer. The ultrasonic tip includes a shaft, a cutting feature and a protrusion. The shaft extends between a proximal end and a distal end. The proximal end has a first cross-sectional area and a second cross-sectional area. The first cross-sectional area is greater than the second cross-sectional area. The shaft includes a vibration conversion mechanism for converting vibration energy transmitted from the ultrasonic transducer into a composite vibration consisting of a longitudinal vibration and a torsional vibration along a longitudinal axis. The cutting feature is coupled to the distal end of the shaft. The suction lumen is defined by the shaft. The suction lumen is configured to extend along the longitudinal axis of the shaft. The suction lumen is configured to be placed in fluid communication with the handpiece. The protrusion is on the shaft and is located between the distal end and the proximal end. The protrusion is positioned distal to the vibration conversion mechanism along the longitudinal axis. A portion of the protrusion has a third cross-sectional area. The third cross-sectional area is less than the first cross-sectional area. The third cross-sectional area is greater than the second cross-sectional area. The pore is defined by the protrusion and is in fluid communication with the suction lumen. The protrusion strengthens the area around the pore.

[0054] The ultrasonic tip is used with a surgical handpiece, which includes an ultrasonic transducer arranged in a housing. The ultrasonic tip includes a shaft, a cutting feature and a protrusion. The shaft includes a distal region, a middle region and a proximal region. The middle region has a first diameter. The distal region has a second diameter. The first diameter is greater than the second diameter. The shaft includes a vibration conversion mechanism for converting vibration energy transmitted from the ultrasonic transducer into a composite vibration consisting of longitudinal vibration and torsional vibration along the longitudinal axis. The cutting feature is coupled to the distal region of the shaft. The first lumen is defined by the shaft. The first lumen is configured to extend along the longitudinal axis of the shaft. The first lumen is configured to be placed in fluid communication with the handpiece. The protrusion is on the shaft and is positioned between the middle region and the distal region. The middle region is positioned between the protrusion and the vibration conversion mechanism. A portion of the protrusion has a third diameter. The third diameter is less than the first diameter, and the third diameter is greater than the second diameter. A pore is defined by the protrusion. The pore is in fluid communication with the first lumen. The protrusion strengthens the area around the pore.

[0055] The ultrasonic tip is used for use with a surgical handpiece to generate longitudinal and torsional motion, the handpiece including an ultrasonic transducer. The ultrasonic tip includes a shaft, a cutting feature, and a protrusion. The shaft extends between a proximal end and a distal end. The proximal end has a first cross-sectional area. The distal end has a second cross-sectional area. The first cross-sectional area is greater than the second cross-sectional area. The cutting feature is coupled to the distal end of the shaft. A suction lumen is defined by the shaft. The suction lumen is configured to extend along the longitudinal axis of the shaft. The suction lumen is configured to be placed in fluid communication with the handpiece. The protrusion is on the shaft and is positioned between the distal end and the proximal end. A portion of the protrusion has a third cross-sectional area. The third cross-sectional area is less than the first cross-sectional area. The third cross-sectional area is greater than the second cross-sectional area. An aperture is defined by the protrusion and is in fluid communication with the suction lumen. The protrusion strengthens the area around the aperture.

[0056] The ultrasonic tip is used to produce longitudinal and torsional motion with a surgical handpiece, the handpiece including an ultrasonic transducer disposed within a housing. The ultrasonic tip includes a shaft, a cutting feature, and a protrusion. The shaft has a longitudinal axis extending between a proximal end and a distal end. The proximal end has a first diameter and the distal end has a second diameter. The first diameter is greater than the second diameter. The cutting feature is coupled to the distal end of the shaft. A suction lumen is defined by the shaft. The suction lumen is configured to extend along the longitudinal axis of the shaft. The suction lumen is configured to be placed in fluid communication with the handpiece. The protrusion is on the shaft and is positioned between the distal end and the proximal end. A portion of the protrusion has a third diameter. The third diameter is less than the first diameter. The third diameter is greater than the second diameter. An aperture is defined by the protrusion and is in fluid communication with the suction lumen. The protrusion strengthens an area around the aperture.

[0057] Figure 1 and Figure 2 An exemplary configuration of an ultrasonic surgical handpiece assembly 10 is shown, which may include a portion of an ultrasonic cutting system 12 that may be used by a medical professional to remove biological material from a patient. The ultrasonic surgical handpiece assembly 10 may include an ultrasonic handpiece 11 that includes a proximal housing portion 22 and a distal housing portion 20. An irrigation sleeve 24 may be removably coupled to the distal housing portion 20 of the ultrasonic surgical handpiece 11. The irrigation sleeve 24 and the ultrasonic tip 26 (also referred to herein alternatively as the cutting tip 26) may be configured such that the irrigation sleeve 24 surrounds at least a portion of the ultrasonic tip 26 along its length when both are coupled to the ultrasonic handpiece 11. The irrigation sleeve 24 and the ultrasonic tip 26 may at least partially comprise the ultrasonic sleeve assembly 14.

[0058] Figure 2 Shows Figure 1 A cross-sectional view of an ultrasonic surgical handpiece assembly 10 is shown. Figure 2As shown, the ultrasound handpiece 11 may include a transducer 32, which may be an ultrasound transducer 32, disposed within a space defined by the distal housing portion 20 and the proximal housing portion 22 of the ultrasound handpiece 11. The transducer 32 may include a piezoelectric element or a magnetostrictive element configured to generate mechanical energy.

[0059] The ultrasound handpiece 11 may further include a flared portion 30, which may be at least partially disposed within a gap defined by the distal housing portion 20 and the proximal housing portion 22 of the ultrasound handpiece 11. The flared portion 30 may include a distal end and a proximal end. The proximal end of the flared portion 30 may be coupled to the distal end of a transducer 32. The transducer 32 may be configured to provide mechanical energy generated by a piezoelectric element or a magnetostrictive element to the flared portion 30. The flared portion 30 may also be configured to define a flared portion lumen 31 extending from the distal end of the flared portion 30 to the proximal end to be fluidically connected to a mouth 28 at the proximal end 16 of the proximal housing portion 22. The mouth 28 may be used to connect the handpiece 11 to a vacuum source (not shown). The flared portion lumen 31 may define a portion of a channel extending through the ultrasound handpiece 11 to provide suction to the ultrasound tip 26.

[0060] The ultrasound handpiece 11 may also include an irrigation line 33 disposed within a void defined by the distal housing portion 20 and the proximal housing portion 22 of the ultrasound handpiece 11. The irrigation line 33 may be configured to extend from the proximal end 16 to the distal end of the ultrasound handpiece 11. The irrigation line 33 may be used to direct water from an irrigation system coupled to the ultrasound handpiece 11 through the ultrasound handpiece 11 to the irrigation sleeve 24. It should be understood that the irrigation line 33 may be directed directly from an irrigation source (not shown) to the ultrasound sleeve (i.e., the irrigation line need not necessarily extend through the handpiece).

[0061] The ultrasonic tip 26 may include a shaft 48 including a distal region 50 (also referred to herein alternatively as the distal end 50), a middle region 37, and a proximal region 36 (also referred to herein alternatively as the proximal region 36). The shaft also has a distal end and a proximal end, wherein the proximal region is adjacent to the proximal end and the distal region is adjacent to the distal end. The ultrasonic tip may also include a coupling feature 34 positioned at the proximal region 36 of the shaft 48 and configured to couple the proximal region 36 of the ultrasonic tip 26 to the distal end of the flare 30 to allow the flare 30 to be mechanically connected to the ultrasonic tip 26. The coupling feature 34 may be a threaded coupler configured to engage with a corresponding threaded coupler 35 on the distal end of the flare 30. The ultrasonic tip 26 may be screwed into the flare 30 and tightened to a predetermined torque specification to removably secure the ultrasonic tip 26 to the ultrasound handpiece 11. Although not shown in the drawings, it is contemplated that the coupling feature 34 can be configured as a quick connection, a quarter-turn adapter connection, or a similar coupling mechanism. It is further contemplated that the coupling feature 34 can be configured to permanently attach the ultrasonic tip 26 to the handpiece 11. For example, the ultrasonic tip 26 can be coupled to the ultrasonic handpiece 11 by welding, epoxy, or a similar coupling method. Alternatively, it is also contemplated that the ultrasonic tip 26 and the horn 30 can be formed as an integral component.

[0062] The shaft 48 of the ultrasonic tip 26 can also be configured to define a suction lumen 52 extending from the proximal region 36 of the ultrasonic tip 26 through the intermediate region 37 to the distal region 50. The suction lumen 52 can be oriented to be substantially parallel to the longitudinal axis and can extend along the longitudinal axis. The suction lumen 52 of the ultrasonic tip 26 can be configured to form a fluid channel with the lumen 31 of the horn 30 when the ultrasonic tip 26 is coupled to the horn 30. Unless otherwise stated, the suction lumen 52 can be configured to be placed in fluid communication with the lumen 31 of the handpiece 11, especially the horn 30. The suction lumen 52 is open at the distal region 50 of the shaft 48. The suction lumen 52 of the ultrasonic tip 26 can be configured to provide suction away from the surgical site. For example, the suction lumen 52 can be used to draw fluid and biological tissue away from the distal end 50 of the ultrasonic tip 26. The suction lumen 52 can be in fluid communication with the lumen defined by the cutting feature 62.

[0063] Figure 3A top view of an exemplary configuration of an irrigation sleeve 24 is shown, the irrigation sleeve 24 having a distal end 94 and a proximal end. The irrigation sleeve 24 may include an irrigation sleeve coupling mechanism 38 on the proximal end of the irrigation sleeve 24. The irrigation sleeve coupling mechanism 38 may include one or more fingers 42 extending proximally from the proximal end of the irrigation sleeve 24. Each of the one or more fingers 42 may include a tab 44 extending in a radially outward direction relative to a longitudinal axis 46 of the irrigation sleeve 24. The finger 42 serves as a male fitting that is configured to couple with a female fitting (not shown) on the handpiece 11 to establish a snap fit 40 or an interference fit. It is contemplated that other types of irrigation sleeve coupling mechanisms 38 may be used to couple the irrigation sleeve 24 to the ultrasound handpiece 11. For example, the irrigation sleeve coupling mechanism 38 may be configured as a threaded connection.

[0064] Reference Figure 4 , shows a cross-sectional view of an ultrasonic tip 26, which is at least partially arranged in the inner cavity 70 defined by the irrigation sleeve 24. The irrigation sleeve 24 may include an irrigation channel 88 having a proximal end and a distal end. The proximal end of the irrigation channel 88 may be configured to be connected to the distal end or irrigation source of the irrigation line 33 of the ultrasound handpiece 11. The irrigation channel 88 may be configured to extend adjacent to the inner cavity 70 defined by the irrigation sleeve 24 and terminate at a port 92 disposed on the surface of the inner cavity 70 to provide irrigation fluid from the ultrasound handpiece 11 to the ultrasonic tip 26 and the surgical site. The location of the port 92 may be different. For example, the port 92 may be adjacent to the proximal end of the sleeve 24. Alternatively, the location of the port may be adjacent to the distal end of the sleeve.

[0065] Reference Figure 5, showing a portion of the distal region of the ultrasonic tip 26. The shaft 48 of the ultrasonic tip 26 may include a protrusion 68 at an intermediate point on the shaft 48 between the proximal region 36 and the distal region 50 of the ultrasonic tip 26. The protrusion 68 may be configured to extend radially around the shaft 48 of the ultrasonic tip 26. The protrusion 68 may include a first tapered region 76, an intermediate region 80, and a second tapered region 78. The intermediate region 80 is positioned between the first tapered region 76 and the second tapered region 78. In an exemplary configuration, the first tapered region 76 may have a positive slope proximal to the protrusion 68, and the second tapered region 78 may have a negative slope distal to the protrusion 68 relative to the longitudinal axis of the lumen of the shaft. The intermediate region 80 may have no slope and may be parallel relative to the longitudinal axis 46. In another configuration, the protrusion 68 may include a generally circular or hemispherical geometry at the transition from the first tapered region 76 to the intermediate region 80 and then the second tapered region 78. The diameter and cross-sectional area of ​​the first tapered region 76 and the second tapered region 78 are smaller than the diameter and cross-sectional area of ​​the middle region 80. In another configuration, the protrusion 68 may include other multi-faceted shapes, not shown in the figure. The protrusion 68 may be configured to have a gradual transition from the first tapered region 76 to the middle region 80, and then from the middle region 80 to the second tapered region 78. The gradual transition of the protrusion 68 can reduce the possibility of generating additional stress points in the shaft 48, which may have a higher probability of failure during ultrasonic vibration. In addition, when the fluid moves from the irrigation port 92 between the irrigation sleeve 24 and the ultrasonic tip 26 to the distal side 50 relative to the ultrasonic tip 26, this gradual transition prevents the disturbance of the fluid flow distribution around the ultrasonic tip 26. The gradual transition also allows the ultrasonic tip 26 to be used at high power, but will not be subjected to high stress to the extent that may cause damage to the ultrasonic tip 26. The gradual transition can also improve the performance of the shaft 48 to allow the ultrasonic tip 26 to operate at an optimal frequency.

[0066] The shaft 48 may not have any abrupt steps from the length associated with the diameter D4 to the length associated with the diameter D5 and / or from the length associated with the diameter D3 to the length associated with the diameter D5. The absence of any abrupt steps means that the angle of inclination of each transition region relative to the outer surface of the shaft 48 is less than 10 degrees or 5 degrees.

[0067] The ultrasonic tip 26 may further include an aperture 66 on the shaft 48. The protrusion 68 generally defines the aperture 66 in a middle region 80 of the protrusion 68. The aperture 66 is in fluid communication with the aspiration lumen 52. The axis of the aperture 66 may be transverse to the longitudinal axis 46 of the ultrasonic tip 26. In one configuration, the axis of the aperture 66 may be perpendicular to the longitudinal axis 46. The diameter of the aperture 66 is smaller than the diameter of the aspiration lumen 52.

[0068] The protrusion 68 strengthens the area of ​​the shaft 48 near the aperture 66. Because the aperture 66 would otherwise weaken the strength of the shaft 48 through the aperture 66, the thicker third diameter D3 of the shaft 48 at the protrusion 68 can help increase the structural integrity of the ultrasonic tip 26 when the ultrasonic tip 26 is subjected to ultrasonic movement in torsional and longitudinal directions during use.

[0069] The cutting feature 62 and the suction lumen opening 72 may be positioned at the distal end of the shaft 48 . Figure 8 and 9 A suction lumen opening 72 is shown opening on the distal region 50 of the shaft 48 and / or the cutting feature 62. The suction lumen opening 72 may be used to remove excess fluid and / or biological debris from the surgical site.

[0070] In certain configurations, the size of the protrusion 68 is configured based on the size of the aperture 66. For example, the axial length of the intermediate region 80 can be 200-1000% greater than the diameter of the aperture 66. In other configurations, the axial length of the intermediate region 80 can be 500-800% greater than the diameter of the aperture 66. Similarly, the lengths of the first and second tapered regions (76, 78) can also be related to the diameter of the aperture 66. For example, the combined axial length of the first tapered region 76, the intermediate region 80, and the second tapered region 78 can be between 15,000% and 24,000% greater than the diameter of the aperture 66. These dimensions ensure that the tip achieves a precise balance of stress reduction and cutting performance.

[0071] For example, the length of the protrusion 68 (ie, Fig. 6A The distance between the lines at 6E and 6F in the figure) can be about 2 mm, and can be between 1 mm and 6 mm in other configurations. The axial length (length from D4 to D5) and radial thickness of the protrusion 68 can be related to the amount of material removed to create the aperture. For example, if the aperture 66 has a larger diameter, the diameter and thickness of the protrusion 68 will be larger. Conversely, if the aperture 66 has a smaller diameter, the thickness and length of the protrusion 68 will be smaller.

[0072] Figure 7 and Figure 8 The ultrasonic tip 26 is shown, which includes a shaft 48 and a protrusion 68 positioned on the shaft 48 between the distal region 50 and the proximal region 36. Fig. 6A As shown, protrusion 68 is positioned distally of vibration conversion mechanism 60 along longitudinal axis 46. Shaft 48 may have a third diameter D3 at protrusion 68 that is less than first diameter D1 at intermediate region 37 and greater than second diameter D2 at distal region 50.

[0073] like Figure 6A-7As shown, the diameter of the ultrasonic tip 26 varies from the proximal region 36, through the middle region 37, to the distal region 50 of the shaft 48. The shaft 48 includes a first diameter D1 and includes a second diameter D2, wherein the first diameter D1 is greater than the second diameter D2. The diameter D1 is located in the middle region 37 of the shaft 48, and the diameter D2 is located in the distal region 50 of the shaft.

[0074] The shaft 48 can generally taper along the longitudinal axis 46 from the proximal region 36, through the intermediate region 37, to the distal region 50. For example, the diameter of the shaft 48 can decrease distally along the shaft 48 from the proximal region 36 to the distal region 50. One of the many advantages provided by the tapered shaft 48 is that it can reduce the size of the tip and improve the user's line of sight when using the ultrasonic tip 26.

[0075] Depending on the application, the shaft 48 can be made of a metallic material such as titanium alloy, stainless steel, etc., or a non-metallic material such as a composite material. In one example of the shaft 48, the ultrasonic tip 26 can be integral, monolithic, and one-piece. In another example, the distal end 50 of the ultrasonic tip 26 can be attached to the shaft 48 by a suitable mechanism such as a thread (not shown). It should be understood that metals are known in the art for high-power ultrasonic components. It should also be understood that the diameter of the distal region 50 of the shaft 48 and the ultrasonic tip 26 has a relatively small diameter, such as less than one centimeter (1 cm), so as to work in a small opening of the patient. It should be further understood that the shaft 48 and the ultrasonic tip 26 can be scaled up or down according to the application.

[0076] Reference Fig. 6A , the ultrasonic tip 26 also includes a vibration conversion mechanism 60, which is used to convert the vibration energy transmitted from the ultrasonic transducer 32 into a composite vibration consisting of a longitudinal vibration and a torsional vibration along the longitudinal axis 46. The middle area 37 is on the far side of the vibration conversion mechanism 60. The vibration conversion mechanism 60 may include one or more spiral groove portions 71 on the surface of the shaft 48. As shown in the figure, these one or more groove portions 71 may extend around the circumferential surface of the shaft 48. The vibration conversion mechanism 60 is used to convert the longitudinal vibration transmitted from the transducer 32 into a composite vibration through the horn-shaped portion 30, which is composed of a longitudinal vibration in the direction of the longitudinal axis 46 of the ultrasonic tip 26 and a torsional vibration with the longitudinal axis 46 of the ultrasonic tip 26 serving as a fulcrum. It should be understood that the vibration conversion mechanism may alternatively adopt other forms suitable for converting longitudinal motion into composite motion. These alternative forms may be asymmetric in the cross-sectional shape of the shaft 48. Details regarding vibration conversion mechanisms may be found in U.S. Patent Nos. 6,497,715, 6,955,680, and 6,984,220, the entire contents of which are incorporated herein by reference.

[0077] Fig. 6A The ultrasonic tip 26 is also shown to include a shaft 48 and a cutting feature 62 coupled to the distal region 50 of the shaft 48. The cutting feature 62 may be that portion of the ultrasonic tip 26 that dissects or cuts the biological tissue of the patient. A series of different cutting features 62 may be coupled to the distal end 50 of the shaft 48. In one example, the cutting feature 62 may have a cutting face 64 facing a direction that is equal to or less than 90 degrees relative to the longitudinal axis 46. The terms "cutting face" and "cutting surface" may be used interchangeably herein. The cutting face 64 may be positioned in such a manner that the center of the cutting face 64 is located on the opposite side of the shaft 48 relative to the aperture 66. The cutting feature may be configured to cut with a twisting motion.

[0078] like Figure 6B-6F As shown, the cross-sectional area of ​​the shaft 48 at the intermediate region 37 at the location D1 may be larger than the cross-sectional area at the location D2 . Figure 6B The cross-sectional area of ​​the shaft 48 at the position D1 is shown. Figure 6C The cross-sectional area of ​​the shaft 48 at D2 is shown. In addition, Fig.6D The cross-sectional area of ​​shaft 48 at position D3 is shown, and aperture 66 is also shown. Fig. 6E As shown, the cross-sectional area of ​​D4 is smaller than the cross-sectional area of ​​D3. Fig. 6F The cross-sectional area at position D5 is shown. Figure 6B-6F When viewed together, this indicates that the cross-sectional area at location D3 near the protrusion 68 is greater than the cross-sectional area at locations D4 and D5 adjacent to the protrusion at its proximal and distal sides, respectively. The different cross-sectional areas of the shaft 48 provide different strengths for the shaft 48 at different locations along its length. In general, the greater the cross-sectional area of ​​the shaft 48 at a given location, the greater the wall thickness, and thus the greater the strength.

[0079] As described above, the aperture 66 weakens the strength of the shaft 48. The larger cross-sectional area at the protrusion 68 overcomes the weak point created by the aperture 66, allowing the ultrasonic tip 26 to be used at higher power settings and not fail due to increased stress. The cross-sectional area of ​​the protrusion 68 can be configured to have the minimum amount of area necessary to avoid inefficiency and maintain line of sight while maintaining the necessary stress characteristics to prevent failure.

[0080] like Figure 8As shown, the shaft 48 of the ultrasonic tip 26 has a varying thickness. Assuming that the suction lumen 52 has a constant diameter from the distal region 50, through the middle region 37, to the proximal region 36, the thickness of the shaft 48 at the aperture 66 is greater than the thickness of the shaft 48 in the region immediately adjacent to the aperture. In other words, the thickness of the shaft 48 at the middle region 80 is greater than the thickness of the shaft 48 at the first tapered region 76 and the second tapered region 78. The increased thickness of the shaft 48 at the middle region 80 where the aperture 66 is provided can improve the strength of the shaft 48.

[0081] like Figure 4 As shown, the irrigation sleeve 24 is configured to surround a portion of the shaft 48 when the irrigation sleeve 24 and the ultrasonic tip 26 are coupled to the handpiece 11. The irrigation sleeve 24 includes an inner cavity 70. The irrigation sleeve 24 has a proximal end 36 and a distal end 94. The proximal end 36 of the sleeve 24 includes a coupling mechanism 38 configured to be removably coupled to the handpiece 11. The irrigation sleeve defines an irrigation channel 88 and is separated from the inner cavity 70. The irrigation channel 88 has a distal end and a proximal end, and the proximal end of the irrigation channel 88 is configured to be releasably coupled to an irrigation source (not shown). The irrigation channel 88 can deliver fluid to the inner cavity 70 through an irrigation port 92. The irrigation port 92 can be in fluid communication with the irrigation channel 88 and the inner cavity 70.

[0082] In certain configurations, fluid may flow from an irrigation source (not shown) through the irrigation channel 88 to the irrigation port 92. The irrigation port 92 supplies fluid to the lumen 70 of the irrigation sleeve 24. The fluid in the lumen 70 of the irrigation sleeve 24 may flow distally toward the cutting tip 26. As the fluid flows toward the cutting tip 26, some of the fluid may enter the suction lumen 52 through the aperture 66 on the projection 68. The fluid flowing through the aperture 66 helps to reduce the temperature of the cutting tip 26 and may improve the performance of the surgical handpiece assembly 10. In addition, it may alternatively help to reduce the temperature of the sleeve 24, thereby preventing tissue in contact with the outer surface of the sleeve from being inadvertently heated.

[0083] The irrigation sleeve 24 may be made of any polymer, such as thermoplastics. The distal end 94 of the irrigation sleeve 24 may have a frangible portion that can be cut or sheared to change the length of the irrigation sleeve 24.

[0084] The irrigation channel 88 can be in fluid communication with the handpiece 11 and / or an irrigation source (not shown). The combination of the aperture 66 on the shaft 48, the irrigation channel 88, the position of the distal end 94 of the sleeve 24 relative to the aperture 66, the irrigation port 92, and the suction lumen 52 improves the cooling capability of the ultrasonic tip 26. In addition, the above combination improves the cooling of the ultrasonic tip 26 to prevent the irrigation sleeve 24 from deforming or melting due to excessive heat generated by the longitudinal and torsional movement of the ultrasonic tip 26.

[0085] like Fig. 9 As shown, the irrigation sleeve 24 surrounds a portion of the ultrasonic tip 26 along its length. The distal end 94 of the irrigation sleeve 24 extends along the longitudinal axis 46 toward the distal region 50 of the ultrasonic tip 26. The distal end 94 of the irrigation sleeve 24 can extend beyond the aperture 66. The aperture 66 can have a proximal end and a distal end, and the distal end 94 of the irrigation sleeve 24 extends beyond the proximal end and the distal end of the aperture 66. In other words, when the ultrasonic tip and sleeve 24 are coupled to the handpiece 11, the aperture 66 is completely covered by the sleeve 24. The fluid in the lumen 70 helps to cool the ultrasonic tip 26 and the sleeve 24.

[0086] The ultrasonic tip 26 allows effective bone removal through torsional or longitudinal motion of the instrument tip. The cutting feature 62 may include a cutting surface 64A to aid in this removal. However, it should be understood that the ultrasonic tip 26 may also be used with a transducer that vibrates longitudinally, torsionally, or a combination of longitudinal and torsion motions. In addition, in some examples, the ultrasonic tip has no vibration conversion mechanism.

[0087] The torsional dissecting tip is effective in removing bone, bony prominences, calcified excrescences, cartilage, cartilaginous material, intervertebral discs, and other pathological components when in contact with the resection feature. The device is particularly useful in the following surgical procedures: neurosurgery, especially bone dissection from the inside out after the superficial cortex has been removed, spinal surgery, orthopedic surgery, plastic / reconstructive surgery, and ear, nose and throat surgery, as well as other surgeries where the above tissues are encountered.

[0088] It should be appreciated that the cutting feature 62 of the ultrasonic tip 26 may have a variety of configurations. Figures 10A-10E , various exemplary configurations of the cutting feature 62 of the ultrasonic tip 26 are shown. The cutting feature 62 may include a cutting face 64, wherein the cutting face 64 includes one or more teeth 65. The teeth 65 of the cutting face 64 may be arranged wherein the teeth 65 are oriented radially outward from the longitudinal axis 46 of the ultrasonic tip 26. For certain configurations, the plane of the cutting feature is generally parallel to, but offset from, the central axis of the distal end 50 of the instrument, but the position of the cutting face 64 may be varied in a virtually infinite manner.

[0089] Reference Fig. 10B , a first configuration of the cutting feature 62 is shown. The first configuration of the cutting feature 62 includes a cutting surface 64B that includes a plurality of teeth 65 radially disposed about the distal end 50 of the shaft 48. For example, the teeth 65 may be configured to point outward from the longitudinal axis 46 of the ultrasonic tip 26, and the teeth 65 are arranged around the entire circumference of the distal end of the shaft 48. At least some of the teeth extend distally.

[0090] Alternatively, Fig. 10CA second configuration of the cutting feature 62 is shown. The second configuration of the cutting feature 62 includes a cutting surface 64C having an arcuate or semi-cylindrical shape including a plurality of teeth 65 pointing outwardly from the longitudinal axis of the ultrasonic tip 26.

[0091] Fig. 10D A third configuration of the cutting feature 62 is shown. The third configuration of the cutting feature 62 includes a cutting surface 64D having an arcuate or semi-cylindrical shape including a plurality of teeth 65 directed outwardly from the longitudinal axis of the ultrasonic tip 26. The cutting surface 64D is generally offset from the axis 48 of the ultrasonic tip 26 and oriented perpendicular to the longitudinal axis 46 of the ultrasonic tip 26.

[0092] Fig. 10E A fourth configuration of the cutting feature 62 is shown. The fourth configuration of the cutting feature 62 includes a cutting surface 64E having an arcuate or semi-cylindrical shape including a plurality of teeth 65 directed outwardly from the longitudinal axis of the ultrasonic tip 26. The cutting surface 64E is generally offset from the axis of the ultrasonic tip 26 and oriented perpendicular to the longitudinal axis 46 of the ultrasonic tip 26. Other suitable cutting features are also contemplated, including those described in U.S. Pat. No. 8,512,340 and U.S. 2018 / 0103976, the entire contents of which are incorporated herein by reference.

[0093] Several examples have been discussed in the foregoing description. However, the examples discussed herein are not intended to be exclusive 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 applies similarly to ultrasonic tips, which may include blades, drills, burs, shavers, and the like. The terms that have been used are intended to have the nature of descriptive terms, 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. An ultrasonic tip for use with a surgical handpiece to produce longitudinal and torsional motion, the handpiece comprising an ultrasonic transducer disposed within a housing, the ultrasonic tip comprising: a shaft having a longitudinal axis extending between a proximal end and a distal end, the proximal end having a first diameter and the distal end having a second diameter, wherein the first diameter is greater than the second diameter, wherein the shaft includes a vibration conversion mechanism for converting vibration energy transmitted from the ultrasonic transducer into a composite vibration consisting of a longitudinal vibration along a longitudinal axis and a torsional vibration; a cutting feature coupled to the distal end of the shaft; a suction lumen defined by the shaft, the suction lumen being configured to extend along the longitudinal axis of the shaft, the suction lumen being configured to be placed in fluid communication with the handpiece; a protrusion on the shaft and positioned between the distal end and the proximal end, wherein the protrusion is positioned distally of the vibration conversion mechanism along the longitudinal axis, a portion of the protrusion having a third diameter, wherein the third diameter is less than the first diameter and the third diameter is greater than the second diameter; as well as An aperture defined by the projection is in fluid communication with the suction lumen, wherein the projection reinforces an area surrounding the aperture.

2. The ultrasonic tip according to claim 1, wherein: The proximal end of the shaft includes a coupling feature configured for removably coupling the shaft to a transducer of a handpiece.

3. The ultrasonic tip according to claim 2, wherein: The coupling feature includes a plurality of threads configured for coupling to a transducer of the handpiece.

4. The ultrasonic tip according to claim 1, wherein: The vibration conversion mechanism includes one or more spiral groove portions formed on an outer surface of the shaft.

5. The ultrasonic tip according to claim 4, wherein: The axis of the aperture is transverse to the longitudinal axis of the ultrasonic tip.

6. The ultrasonic tip according to claim 1, wherein: The cutting feature includes a cutting face that faces in a direction that makes an angle equal to or less than 90 degrees with the longitudinal axis.

7. The ultrasonic tip according to claim 1, wherein: The cutting feature has a cutting face disposed radially outward from the longitudinal axis, wherein the cutting face includes one or more teeth.

8. The ultrasonic tip according to claim 1, wherein: The protrusion includes a first tapered region, a middle region, and a second tapered region, wherein the outer surface of the middle region is substantially parallel to the longitudinal axis and the middle region is disposed between the first tapered region and the second tapered region, the first tapered region is proximal to the middle region and has a positive slope, and the second tapered region is distal to the middle region and has a negative slope.

9. The ultrasonic tip according to claim 1, wherein: The suction lumen opens at the distal end and the proximal end of the shaft.

10. An ultrasonic sleeve assembly for use with a surgical handpiece including an ultrasonic transducer, the ultrasonic sleeve assembly comprising: A cutting tip, the cutting tip comprising: a shaft extending between a proximal end and a distal end, the proximal end comprising a coupling feature configured to removably couple the shaft to a handpiece, the proximal end comprising a first diameter and the distal end comprising a second diameter, wherein the first diameter is greater than the second diameter; wherein the shaft includes a vibration conversion mechanism for converting the vibration energy transmitted from the ultrasonic transducer into a composite vibration consisting of a longitudinal vibration along the longitudinal axis and a torsional vibration; a cutting feature coupled to the distal end of the shaft; a suction lumen defined by the shaft and configured to extend along the longitudinal axis of the shaft, the suction lumen being configured to be in fluid communication with a surgical handpiece when the shaft is coupled to the surgical handpiece; a protrusion on the shaft positioned distal to the vibration conversion mechanism, wherein a portion of the protrusion has a third diameter, wherein the third diameter is less than the first diameter and the third diameter is greater than the second diameter, wherein the protrusion is configured to reinforce the shaft; and an aperture defined by the projection and in fluid communication with the aspiration lumen; and an irrigation sleeve configured to surround a portion of the shaft when the irrigation sleeve and the cutting tip are coupled to a handpiece, the irrigation sleeve defining a lumen including a proximal end and a distal end, the proximal end of the lumen including a coupling mechanism configured to be removably coupled to a handpiece; The flushing sleeve further defines a flushing channel separated from the inner cavity, the flushing channel having a distal end and a proximal end, the proximal end of the flushing channel being configured to be releasably connected to a flushing source, the flushing channel being configured to deliver fluid to the inner cavity through a flushing port, the flushing port being in fluid communication with the flushing channel and the inner cavity.

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