Powered surgical handpieces, surgical tools and hand switches

Abstract

A hand switch (50) for a power surgical handpiece (54) includes a mounting base (62), a lever (70), a spring, a safety switch (68), and a lever extension. The mounting base defines a pivot axis. The elongated lever defines a lever axis substantially perpendicular to the direction of the pivot axis. The lever includes a proximal end pivotally connected to the mounting base at the pivot axis and a distal end opposite the proximal end. A first track is on an interior side of the lever. A second track is on an exterior side of the lever opposite the interior side, both tracks being substantially parallel to the lever axis. A spring is between the base and the lever and biases the lever about the pivot axis. The safety switch is slidably disposed on the first track. The lever extension is slidably disposed on the second track.

Description

[Technical field]

[0001] [Related Applications] This application claims priority to and the entire benefit of both U.S. Provisional Patent Application No. 62 / 832,983, filed April 12, 2019, and U.S. Provisional Patent Application No. 62 / 884,765, filed August 9, 2019, the entire contents of each of which are incorporated herein by reference. [Background technology]

[0002] A hand switch for a powered surgical handpiece that is easier to install and offers improved convenience of operation is desired. Summary of the Invention [Problem to be solved by the invention]

[0003] The prior art does not address the need to provide an ergonomically optimized handswitch for a powered surgical handpiece. [Means for solving the problem]

[0004] A hand switch for a powered surgical handpiece includes a mounting base, a lever, a spring, a run-safe switch, and a lever extension. The mounting base defines a pivot axis. The elongated lever defines a lever axis substantially perpendicular to the direction of the pivot axis. The lever includes a proximal end pivotally connected to the mounting base at the pivot axis and a distal end opposite the proximal end. A first track is on an interior side of the lever. A second track is on an exterior side of the lever opposite the interior side, both tracks being substantially parallel to the lever axis. A spring is between the base and the lever and biases the lever about the pivot axis. A safety switch is slidably disposed on the first track. The lever extension is slidably disposed on the second track.

[0005] The handswitch and its features may include additional features and modifications as described below, such features and modifications included separately or in combination with one another, such combinations being limited only by mutual exclusivity.

[0006] At least one of the first track and the second track of the hand switch can be one of a T-slot and a T-track.

[0007] The first track and the second track of the hand switch can both be T tracks.

[0008] The lever of the handswitch can have first and second sides connecting the inner and outer sides, and the safety switch of the handswitch can have at least one outboard side extending laterally beyond at least one of the sides of the lever.

[0009] The outboard face of the handswitch lever may be defined by an indicator arm.

[0010] The lever of the hand switch may have a slot therein that receives at least one of a magnet and a magnet retainer secured to the safety switch.

[0011] The slot in the lever of the hand switch may be shorter in length than the length of the lever. The slot may define a range of travel for the safety switch.

[0012] A detent may be disposed on the hand switch between the safety switch and the lever.

[0013] A detent of the hand switch between the safety switch and the lever may include a safety switch plunger, a first notch associated with an actuated position of the safety switch, and a second notch associated with a non-actuated position of the safety switch.

[0014] The hand switch may have a safety switch plunger disposed on the lever and a notch disposed on the switch.

[0015] The hand switch may have a detent disposed between the lever and the lever extension.

[0016] A detent of the hand switch between the lever and the lever extension may include an extension plunger and first, second, third and fourth notches associated with the first, second, third and fourth positions of the extension, respectively.

[0017] The extension plunger of the detent in the hand switch between the lever and the lever extension can be located on the lever and the notch can be located on the lever extension.

[0018] The mounting base of the handswitch can include an annular collar defining a mounting axis substantially perpendicular to at least the direction of the pivot axis, The collar can be sized for slidable placement on the proximal end of the handpiece.

[0019] The annular collar of the handswitch can define a positioning tab extending axially in a distal direction, the tab including an angled wedge surface. The annular collar can further include one of a detent plunger and a detent notch defining a bias surface on an inner diameter thereof.

[0020] The annular collar of the handswitch can include at least a second positioning tab. The second positioning tab can also extend axially in the distal direction and can include an angled wedge surface.

[0021] The detent plunger of the mounting base detent of the hand switch may be disposed in the collar.

[0022] The surgical tool includes a powered surgical handpiece and a hand switch. The powered surgical handpiece includes a longitudinally extending handpiece and a magnetic field sensor. The longitudinally extending handpiece housing extends along a housing axis. The magnetic field sensor is disposed within the housing. The hand switch includes a mounting base, an elongated lever, a spring, a safety switch, and a lever extension. The mounting base defines a pivot axis having a direction substantially perpendicular to the housing axis and a mounting surface extending in a first direction. The elongated lever defines a lever axis substantially perpendicular to the direction of the pivot axis. The lever includes a proximal end, a distal end, a first track, and a second track. The proximal end is pivotally connected to the mounting base at the pivot axis. The distal end is opposite the proximal end. The first track is substantially on an inner side facing the housing axis. The second track is on an outer side opposite the inner side, both tracks being substantially parallel to the lever axis. A spring is between the base and the lever and biases the lever about the pivot axis. A safety switch is slidably disposed on the first track and has a magnet secured thereto. A lever extension is slidably disposed on the second track.

[0023] The surgical tools and features thereof may include additional features and modifications as described below, such features and modifications included separately or in combination with one another, such combinations being limited only by mutual exclusivity.

[0024] At least one of the first track and the second track of the hand switch can be one of a T-slot and a T-track.

[0025] The first track and the second track of the hand switch can both be T tracks.

[0026] The lever of the handswitch may have first and second sides connecting the inboard and outboard sides. The safety switch of the handswitch may have at least one outboard face extending laterally beyond at least one of the sides of the lever.

[0027] The outboard face of the handswitch lever may be defined by an indicator arm.

[0028] The lever of the hand switch may have a slot therein that receives at least one of a magnet and a magnet retainer secured to the safety switch.

[0029] The slot in the lever of the hand switch may be shorter in length than the length of the lever. The slot may define a range of travel for the safety switch.

[0030] The detent may be located on the hand switch between the safety switch and the lever.

[0031] A detent of the hand switch between the safety switch and the lever may include a safety switch plunger, a first notch associated with an actuated position of the safety switch, and a second notch associated with a non-actuated position of the safety switch.

[0032] The hand switch may have a safety switch plunger disposed on the lever and a notch disposed on the switch.

[0033] The hand switch may have a detent disposed between the lever and the lever extension.

[0034] A detent of the hand switch between the lever and the lever extension may include an extension plunger and first, second, third and fourth notches associated with the first, second, third and fourth positions of the extension, respectively.

[0035] The extension plunger of the detent in the hand switch between the lever and the lever extension can be located on the lever and the notch can be located on the lever extension.

[0036] The mounting base of the handswitch can include an annular collar defining a mounting axis substantially perpendicular to at least the direction of the pivot axis, The collar can be sized for slidable placement on the proximal end of the handpiece.

[0037] The annular collar of the handswitch can define a positioning tab extending axially in a distal direction, the tab including an angled wedge surface. The annular collar can further include one of a detent plunger and a detent notch defining a bias surface on an inner diameter thereof.

[0038] The annular collar of the handswitch can include at least a second positioning tab. The second positioning tab can also extend axially in the distal direction and can include an angled wedge surface.

[0039] A detent plunger of a mounting base detent of the handswitch may be disposed within the collar.

[0040] The hand switch for a powered surgical handpiece includes a mounting base, an elongated lever, a spring, a safety switch, and a mounting base. The mounting base includes an annular collar defining a pivot axis and defining a mounting axis substantially perpendicular to at least a direction of the pivot axis. The collar is sized for slidable placement on a proximal end of the handpiece in a direction of the mounting axis. The elongated lever is pivotally connected to the mounting base at a proximal end of the lever. A spring is between the base and the lever and biases the lever about the pivot axis. The safety switch is slidably disposed on the lever. The mounting base further includes a collar first positioning tab and a second positioning tab. Each tab extends axially distally from a main portion of the collar. Each tab includes an angled wedge surface. An inner diameter of the annular collar has disposed thereon one of a detent notch and a detent plunger defining a bias surface.

[0041] The handswitch and its features may include additional features and modifications as described below, such features and modifications included separately or in combination with one another, such combinations being limited only by mutual exclusivity.

[0042] Each tab of the handswitch may include an angled wedge surface.

[0043] Each tab of the handswitch can have a tab centerline about which the tab is substantially symmetrical. Each tab can have two angled wedge surfaces.

[0044] Both tab centerlines of the handswitch may be a predetermined distance below the mounting axis and opposite the pivot axis of the mounting axis.

[0045] The collar of the handswitch may have a detent plunger disposed within the collar.

[0046] A safety switch of the hand switch may be slidably disposed inside the lever.

[0047] The hand switch may have a lever extension slidably disposed outside the lever.

[0048] The surgical tool includes a powered surgical handpiece and a hand switch. The powered surgical handpiece includes a longitudinally extending handpiece housing and a magnetic field sensor. The longitudinally extending handpiece housing can extend along a housing axis. The magnetic field sensor can be disposed within the housing. The hand switch includes a mounting base, an elongated lever, a spring, and a safety switch. The mounting base defines a pivot axis and includes an annular collar. The annular collar defines a mounting axis that is substantially perpendicular to a direction of at least the pivot axis. The annular collar is sized for slidable placement on a proximal end of the handpiece in a direction of the mounting axis. The elongated lever is pivotally connected to the mounting base at a proximal end of the lever. The spring is between the bases. The spring biases the lever about the pivot axis. The safety switch is slidably disposed on the lever. The mounting base further includes a first positioning tab and a second positioning tab on the collar. Each tab extends axially distally from a main portion of the collar. Each tab includes an angled wedge surface. The mounting base further includes one of a detent notch and a detent plunger disposed on an inner diameter of the annular collar, the detent notch defining a bias surface.

[0049] The surgical tools and features thereof may include additional features and modifications as described below, such features and modifications included separately or in combination with one another, such combinations being limited only by mutual exclusivity.

[0050] The handswitch may have each tab including an angled wedge surface.

[0051] Each tab of the handswitch can have a tab centerline about which the tab is substantially symmetrical. Each tab can have two angled wedge surfaces.

[0052] Both tab centerlines of the handswitch may be a predetermined distance below the mounting axis and opposite the pivot axis of the mounting axis.

[0053] The collar of the handswitch may have a detent plunger disposed within the collar.

[0054] A safety switch of the hand switch may be slidably disposed inside the lever.

[0055] The hand switch may have a lever extension slidably disposed outside the lever.

[0056] The surgical tool may further include two receiving channels and a plurality of contact points. The housing may include two receiving channels. The channels may be formed at a proximal end of the housing. The receiving channels may be defined, at least in part, by a peripheral wall, the channels extending axially away from the proximal end of the housing toward the distal end of the housing. A first side of each channel may define its first channel contact point. A second side of each channel defines its second channel contact point. Each positioning tab may extend a second predetermined length in a distal direction. Each tab may include a first side defining its first tab contact point and a second side defining its second tab contact point. When the collar is engaged with the housing, each first tab contact point is in contact with a first channel contact point of a respective channel and each second tab contact point is in contact with a second channel contact point of a respective channel. One of the detent plunger and the angled groove defining the bias surface may be disposed on an inner diameter of the collar.

[0057] The surgical tools and features thereof may include additional features and modifications as described below, such features and modifications included separately or in combination with one another, such combinations being limited only by mutual exclusivity.

[0058] The surgical tool may include a notch in the housing defining the bias surface, and the detent plunger may be disposed on an inner diameter of the collar.

[0059] The surgical tool may include a partially distally facing bias surface that may be engaged by the plunger when the respective contact points of the tab and channel are engaged.

[0060] An electrical connector for a surgical tool, the connector comprising an axially extending cable end receiver and an outer sleeve. The axially extending cable end receiver in turn comprises an inner sleeve and a pin holder. The inner sleeve includes a resilient clip including a first retaining wedge. The pin holder is secured to the inner sleeve and includes a core and a plurality of pins secured to the core. The outer sleeve slidably receives substantially the entire cable end receiver. The outer sleeve includes a first window that receives the retaining wedge. The outer sleeve has a slidable range relative to the receiver. The slidable range extends from a latched position in which the wedge is substantially axially aligned with the window to a released position in which the wedge is axially offset from alignment with the window.

[0061] An electrical cable assembly for use with a surgical tool includes a cable and a connector. The cable includes a plurality of conductors. The connector includes an axially extending cable end receiver and an outer sleeve. The axially extending cable end receiver includes an inner sleeve and a pin holder. The inner sleeve includes a resilient clip including a first retaining wedge. The pin holder includes a core and a plurality of pins secured to the core. The pin holder is secured to the inner sleeve and disposed completely therein. The outer sleeve slidably receives substantially the entirety of the cable end receiver. The outer sleeve includes a first window that receives the retaining wedge. The outer sleeve has a range of slideability relative to the receiver, the range extending from a latched position in which the wedge is substantially axially aligned with the window to a released position in which the wedge is axially offset from alignment with the window. The plurality of conductors are electrically connected to the plurality of pins.

[0062] The surgical system includes a handpiece and a cable assembly. The handpiece includes a housing and an electric drive motor disposed therein. The cable assembly includes a cable and a connector. The cable includes a plurality of conductors. The connector includes an axially extending cable end receiver and an outer sleeve. The axially extending cable end receiver includes an inner sleeve and a pin holder. The inner sleeve includes a resilient clip including a first retaining wedge. The pin holder includes a core and a plurality of pins secured to the core. The pin holder is secured to the inner sleeve and disposed completely therein. The outer sleeve slidably receives substantially the entirety of the cable end receiver. The outer sleeve includes a first window that receives the retaining wedge. The outer sleeve has a range of slideability relative to the receiver, the range extending from a latched position in which the wedge is substantially axially aligned with the window to a released position in which the wedge is axially offset from alignment with the window. The plurality of conductors are electrically connected to the plurality of pins.

[0063] Each of the above referenced electrical connectors, electrical cable assemblies, and surgical systems may be improved or modified as described below. Such improvements or modifications are not limited to the extent that they are mutually exclusive and may be combined with any of the others.

[0064] The cable end receiver may further include a bushing disposed between the pin holder and the inner sleeve.

[0065] The bushing may include cable engagement feet extending radially inwardly for engagement of the cable.

[0066] The bushing may be disposed completely within the inner sleeve.

[0067] The release position of the outer sleeve relative to the cable end receiver may be proximal to the latched position of the outer sleeve.

[0068] In the released position, a ramp surface of the wedge may engage the second surface of the window and a stop surface of the wedge may be spaced from the first surface of the window.

[0069] The cable end receiver may further include a retaining nut disposed over the inner sleeve and threadably secured thereto.

[0070] The outer sleeve may have a raised alignment surface.

[0071] The resilient clip may further include a beam secured at both ends to the inner sleeve, and the wedge may be secured to the beam between the ends.

[0072] The inner sleeve may further include a second wedge and the outer sleeve may include a second window.

[0073] Relative orientations and directions (e.g., distal, proximal, upper, lower, bottom, rear, forward, back, dorsal, outboard, inboard, medial, lateral, lateral, left, right) are shown in this description without limitation, but for the convenience of the reader in depicting at least one embodiment of the described structures. Such exemplary orientations may be from a user's perspective.

[0074] The depicted elements may take many different forms and may include multiple and / or alternative components and facilities. The example components shown are not intended to be limiting. In fact, additional or alternative components and / or implementations may be used. Additionally, the depicted elements are not necessarily drawn to scale unless expressly stated as such. [Brief description of the drawings]

[0075] [Figure 1]FIG. 2 is a perspective view of a handswitch disposed on a handpiece, the handpiece and the handswitch engaged by a connector. [Diagram 2] FIG. 2 is an exploded view of the handswitch, handpiece, and connector of FIG. 1. [Figure 3A] FIG. 3 is a perspective view of the lever of the handswitch of FIG. 2 with the lever extension fully extended. [Figure 3B] FIG. 3 is a second perspective view of the handswitch of FIG. 2 with the lever extension fully retracted. [Figure 4] FIG. 3 is an exploded view of the hand switch of FIG. 2. [Figure 5A] FIG. 5 is a first perspective view of the collar of the handswitch of FIG. 4. [Figure 5B] FIG. 5B is a second perspective view of the collar of FIG. 5A. [Figure 5C] FIG. 5B is a top view of the collar of FIG. 5A. [Figure 5D] FIG. 5B is a right side view of the collar of FIG. 5A. [Figure 5E] FIG. 5B is a front view of the collar of FIG. 5A. [Figure 5F] FIG. 5B is a bottom top view of the collar of FIG. 5A. [Figure 5G] 5G is a cross-sectional view of the collar of FIG. 5A taken in the direction of arrow 5G of FIG. 5E. [Figure 6A] FIG. 3 is a perspective view of the handpiece housing of FIG. 2. [Figure 6B] FIG. 6B is a right side view of a portion of the handpiece housing of FIG. 6A. [Figure 6C] FIG. 6B is a left side view of a portion of the handpiece housing of FIG. 6A. [Figure 6D] FIG. 6C is an enlarged cross-sectional view of a portion of the housing within circle 6D of FIG. 6B. [Figure 7] 7 is a cross-sectional view of the lever and housing of FIG. 1 through plane 7 taken in the direction of arrow 7A. [Figure 8A] FIG. 5 is a perspective view of a lever of the hand switch of FIG. 4. [Figure 8B] FIG. 8B is a top view of the lever of FIG. 8A. [Figure 8C]FIG. 8B is a bottom view of the lever of FIG. 8A. [Figure 8D] FIG. 8B is a right side view of the lever of FIG. 8A. [Figure 8E] 8E is a cross-sectional view of the lever of FIG. 8A taken in the direction of arrow 8E of FIG. 8B. [Figure 8F] FIG. 8B is a front view of the lever of FIG. 8A. [Figure 9A] FIG. 5 is a perspective view of a lever extension of the handswitch of FIG. [Figure 9B] FIG. 9B is a top view of the lever extension of FIG. 9A. [Figure 9C] FIG. 9B is a right side view of the lever extension of FIG. 9A. [Figure 9D] FIG. 9B is a bottom view of the lever extension of FIG. 9A. [Figure 9E] 9E is a cross-sectional view of the lever extension of FIG. 9A taken in the direction of arrow 9E of FIG. 9D. [Figure 9F] FIG. 9B is a rear view of the lever extension of FIG. 9A. [Figure 10A] FIG. 5 is a perspective view of the switch of the hand switch of FIG. 4. [Figure 10B] FIG. 10B is a top view of the switch of FIG. 10A. [Figure 10C] 10C is a cross-sectional view of the switch of FIG. 10A taken in the direction of arrow 10C of FIG. 10B. [Figure 10D] 10D is a cross-sectional view of the switch of FIG. 10A taken in the direction of arrow 10D of FIG. 10B. [Figure 11] FIG. 1 is an exploded view of a first alternative interface between a handpiece and a handswitch. [Figure 12A] FIG. 13 is a perspective view of the handpiece housing showing a housing portion of a second alternative interface between the handpiece and the handswitch. [Figure 12B] FIG. 12B is a perspective view of the handpiece housing of FIG. 12A with a handswitch installed illustrating a second alternative interface between the handpiece and the handswitch. [Figure 13A]11 is a perspective view of a handpiece and handpiece housing showing a housing portion of a third alternative interface between the handpiece and the handswitch. FIG. [Figure 13B] FIG. 13B is a perspective view of the handpiece and handpiece housing of FIG. 13A with a handswitch installed illustrating a third alternative interface between the handpiece and the handswitch. [Figure 14A] FIG. 13 is a perspective view of an alternative hand switch. [Figure 14B] FIG. 14B is an exploded perspective view of the hand switch of FIG. 14A. [Figure 14C] FIG. 14B is a cross-sectional side view of the handswitch of FIG. 14A. [Figure 15A] FIG. 14B is an upper right front perspective view of the lever of the handswitch of FIG. 14A. [Figure 15B] FIG. 14B is a lower left front perspective view of the lever of the handswitch of FIG. 14A. [Figure 16] FIG. 14B is a bottom left front perspective view of the lever extension of the handswitch of FIG. 14A. [Figure 17] FIG. 14B is a bottom left rear perspective view of the switch of the handswitch of FIG. 14A. [Figure 18A] FIG. 2 is a perspective view of the handpiece and connector in the connected position. [Figure 18B] FIG. 18B is a perspective view of the handpiece and connector of FIG. 18A in a released position. [Figure 19] FIG. 18C is an exploded view of the connector of FIG. 18B. [Figure 20A] 18B is a cross-sectional side view of the handpiece and connector of FIG. 18A in a first position passing through plane 20 as viewed in the direction of arrow 20A, with plane 20 passing through the central axis of the connector. [Figure 20B] 20B is an exploded view of a portion of the connector shown in box 20B of FIG. 20A, with the connector in a second position. [Figure 20C] 18C is a cross-sectional side view of the connector of 18B in a first position passing through plane 20' as viewed in the direction of arrow 20C, with plane 20' passing through the central axis of the connector. [Figure 21]FIG. 20D is a cross-sectional side view of the connector of FIG. 20C with a cable installed in the connector. [Figure 22] FIG. 18C is a perspective view of a cable assembly including the connector of FIG. 18B. [Diagram 23] FIG. 18B is a perspective view of a surgical system including the connector and handpiece of FIG. 18A. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0076] As shown in FIGS. 1-23, the exemplary surgical tool 50 includes an exemplary hand switch 52, an exemplary powered surgical handpiece 54, and an exemplary electrical connector 56. The exemplary hand switch 52 may be selectively attached to an exemplary longitudinally extending handpiece housing 58 of the exemplary powered surgical handpiece 54. An exemplary connector 56, selectively connectable to a proximal end 60 of the handpiece 54, may aid in retaining the hand switch 52 on the housing 58. When connected to the handpiece 54, the connector 56 may electrically connect the handpiece 54 to a console 53 via an electrical cable 51 (shown in dotted lines in FIG. 1) to communicate control signals and power therebetween.

[0077] The cable 51 and housing 58 may include a signal conductor 55, such as, for example, a wire, and a power conductor 57. The signal conductor 55 may be electrically connected to a magnetic field sensor 59 disposed within the housing 58, and a controller 63, which may be disposed within the console 53. The power conductor 57 may be connected to a drive motor 61 disposed within the housing. The drive motor 61 may be powered by any conventional means, e.g., electrical power, air pressure. The power conductor 57 may be a wire or a pneumatic hose, by way of example and not limitation. Each of the conductors 55, 57 may be comprised of an internal housing portion and an internal cable portion that may be connected at the proximal end of the connector 56 or at the proximal end 60 of the handpiece 54. The controller 63 may be programmed to control power to the electric drive motor 61 in response to a signal from a sensor, e.g., the magnetic field sensor 59. The controller 63 may also be electrically connected to other sensors (not shown), potentially including a switch, e.g., a user-controlled foot switch (not shown). Alternatively, the handpiece 54 may include a battery as a power source and may communicate signals wirelessly with the console 53. Further alternatively, the connector 56 may be a wireless connector and may include one or both of a battery and a wireless communication device, such as a dongle.

[0078] The hand switch 52 includes an exemplary mounting base 62, an exemplary lever 64 pivotally connected to the mounting base 62, an exemplary switch spring 66 disposed between the mounting base 62 and the lever 64 for biasing the lever 64 away from the handpiece housing 58, a safety switch 68, i.e., an unlock-lock switch 68 slidably disposed on the lever 64, and a lever extension 70 also slidably disposed on the lever 64.

[0079] The base 62 and the handpiece housing 58 cooperatively define an exemplary alignment interface 72. The safety switch 68 and the lever 64 cooperatively define an exemplary safety switch interface 74. The lever extension 70 and the lever 64 cooperatively define an exemplary extension interface 76. Each of the lever 64, lever extension 70, switch 68, base 62, and housing 58 include features that define interfaces 72, 74, 76, such features being described in more detail below. The exemplary interfaces 72, 74, 76 can define one or more relative positions between the respective components, as described in more detail below.

[0080] The mounting base 62 may include a first ear 78A and a second ear 78B. The ears 78A, 78B define a receiving pocket 80. A proximal tab 82 may be provided at a distal end of the mounting base 62, which may serve as a visual alignment cue to a user when aligning the connector 56 with the handpiece 54, and a closure may be defined at a proximal end of the pocket 80.

[0081] The ears 78A, 78B may be pierced by a first ear opening 84A and a second ear opening 84B, respectively, which are aligned with one another on a pivot axis 86 defined by the openings 84A, 84B.

[0082] The mounting base 62 may also include, as part of the alignment interface 72, an exemplary annular collar 88 that defines a mounting axis 90. The collar 88 may have an inner diameter D1 that defines an annular mounting surface 91 centered about the axis 90. The collar 88 may be sized for removable and slidable reception by the proximal end 60 of the housing 58. An exemplary nominal value for D1 may be about 20 mm (0.80 inches). The pivot axis 86 and the mounting axis 90 do not intersect, but may be perpendicular to one another when viewed from a direction perpendicular to both axes 86, 90, as shown, for example, in FIG. 5C.

[0083] The exemplary first positioning tab 92A, i.e., first collar tab 92A, and the exemplary second positioning tab 92B, i.e., second collar tab 92B, have an axial length L1 extending from a main distal edge 94, i.e., annular portion 95 of the collar 88, in a direction parallel to the mounting axis 90 to a tip 96A, 96B of each tab 92A, 92B. An exemplary nominal value of L1 may be about 15 mm (0.60 inches). The tabs 92A, 92B may each have a substantially trapezoidal shape when the collar 88 is viewed from the side. The tabs 92A, 92B are arcuately shaped and aligned with a diameter D1 of a portion of the collar 88 when viewed from the distal end of the collar 88, as in FIG. 5E.

[0084] Each of the tabs 92A, 92B may be substantially symmetrical about a centerline 98A, 98B of each of the tabs 92A and 92B. For example, the first tab 92A may have exemplary tapered sides, e.g., a first, or upper, wedge surface 100A1 and a second, or lower, wedge surface 100A2, separated by a tab wedge angle α1, with each of the wedge surfaces 100A1 and 100A2 separated from the centerline 98A at an angle of α1 / 2. An exemplary nominal value of α1 may be about 32°, and α1 / 2 is about 16°. Thus, both of the wedge surfaces 100A1 and 100A2 are angled with respect to the centerline 98A. The tip distance from the distal edge 94 to the tip 96A, i.e., the axial length of the tab 92A, as described above, is the length L1. Tabs 92A, 92B may maintain an inner diameter D1 over their length.

[0085] The second tab 92B may be similarly formed and disposed on the collar 88 and may include upper and lower wedge surfaces 100B1 and 100B2, respectively. Both centerlines 98A, 98B may be disposed a parallel distance B1 below the mounting axis 90, as best shown in FIGS. 5D and 5G. An exemplary nominal value for B1 may be about 2.5 mm (0.10 inches). The wedge surfaces 100A1, 100A2, 100B1, 100B2 are angled in that each is disposed at an angle relative to the mounting axis 90.

[0086] The tabs 92A, 92B may also partially define nominal tab contact points 101A1, 101A2, 101B1, 101B2, one on each of the wedge surfaces 100A1, 100A2, 100B1, 100B2. The role of the nominal tab contact points 101A1, 101A2, 101B1, 101B2 will be explained in more detail below.

[0087] The mounting base 62 may further include a plunger receiving opening 102 for receiving an exemplary spring-loaded ball-based detent plunger 104, i.e., a collar detent plunger 104, best shown in FIG. 7, which comprises a portion of the alignment interface 72. The receiving opening 102 may include a counterbore 106.

[0088] The detent plunger 104 may be purchased commercially. The following description of the detent plunger 104 is exemplary and may be applicable to the ball plunger referenced later. The exemplary plunger 104 may include a substantially constant diameter sleeve 108 formed of steel with a closed end 110 and an open end 112. The closed end 110 may include a vent opening. A durable plunger ball 114 (e.g., steel, ceramic) may be disposed within the sleeve 108 with a compression coil plunger spring 116 disposed within the sleeve 108 between the ball 114 and the closed end 110 that may extend or protrude from the open end 112. The open end 112 may be formed to provide an inner lip 118 that traps the ball 114 and the spring 116 therein and to provide an outer lip 120 thereto. The outer lip 120 may be used to limit the movement of the sleeve 108 into the receiving opening 102. The counterbore 106 may be of a depth and diameter to accommodate the outer lip 120, allowing the plunger 104 to be substantially flush with the mounting surface 91 of the collar 88, while the ball 114 may extend beyond the mounting surface 91 and through the inner diameter D1 of the collar 88. Although the plunger 104 has been described as including a sleeve, a coil spring, and a ball, the described structure is merely exemplary and alternative plungers may be used. For example, the plunger may use a bullet-shaped plunger projectile instead of a ball-shaped plunger projectile. Or, instead of a ball, a double-ended cylinder with an arc at one or both ends may be used. Alternatively, the plunger may use a spring type other than a coil spring, for example, a leaf spring, to displace the projectile. Still alternatively, the plunger may comprise an arched leaf spring that functions primarily as both the spring and the projectile received by the recess when aligned therewith. The arched leaf spring may be curved or cantilevered. The plunger may further alternatively include a dome spring instead of a separate spring and projectile.The dome spring may be in the form of a resilient thin-walled partial hemisphere that is resiliently and substantially resiliently deflected at its apex when compressed to invert the apex portion of the dome and self-restore to its partial hemispherical shape, i.e., the dome shape when placed over the detent notch. The plunger may further alternatively rely on magnetic or electromagnetic properties of components to bias the projectile in a desired direction to engage the detent notch.

[0089] To facilitate the formation of the receiving aperture 102 and counterbore 106, an access hole 122 may be formed in a bottom 124 of the collar 88 that aligns opposite the receiving aperture 102 and counterbore 106 to receive and seat the detent plunger 104 in the aperture 102. The plunger 104 is retained in the receiving aperture 102 by an interference fit, or press fit, relationship therebetween. A portion of the receiving aperture 102 may be larger than the outer diameter of the plunger 104 to facilitate aligned reception of the plunger 104 by the receiving aperture 102. The access hole 122 may include a chamfer (not shown) to facilitate passage of the plunger 104. The plunger 104 is shown in the aperture 102 in FIG. 7.

[0090] The alignment interface 72 may include the collar 88, including the annular portion 95 and the tabs 92A, 92B, and the plunger 104, and complementary features on the handpiece housing 58, best shown in Figures 6A-6D. Such complementary features may include first and second tab receiving channels 128A, 128B for receiving the first and second tabs 92A, 92B, respectively, and a biasing surface 130 provided by a detent notch 132 that defines a biasing surface 130 for engagement by the plunger 104. The tab receiving channels 128A, 128B are disposed on the housing 58 for receiving in alignment with the collar tabs 92A, 92B.

[0091] The handpiece housing 58 includes both a grip surface 134 and a relatively recessed engagement surface 136. The recessed engagement surface 136 is disposed proximal to the grip surface 134. A peripheral wall 138 defines a boundary between and connects the two surfaces 134 and 136. The grip surface 134 may have a first surface diameter D2. An exemplary nominal value for D2 may be about 22 mm (0.90 inches). The engagement surface 136 may have a smaller second surface diameter D3. An exemplary nominal value for D3 may be about 20 mm (0.80 inches). Both diameters D2 and D3 may be centered about a housing axis 140 along which the housing 58 extends. Given the exemplary values ​​for D2 and D3, an exemplary height H1 of the peripheral wall 138 may be about 1 mm (0.04 inches).

[0092] The diameter D3 of the engagement surface 136 is smaller than the inner diameter D1 of the collar 88 such that the surface 136, and thus the collar 88, are sized to allow the collar 88 to be slidably disposed on the proximal end of the housing 58 of the handpiece 54 when the housing axis 140 is substantially aligned with the mounting axis 90. When the hand switch 52 is coupled to the housing 58, the housing axis 140 may coincide with the mounting axis 90. As shown in FIG. 5C, the mounting axis 90 is perpendicular to the direction of the pivot axis 86. Thus, the housing axis 140 may also be perpendicular to the direction of the pivot axis 86 when the hand switch 52 is coupled to the housing 58. The peripheral wall 138 may extend radially outward relative to the mounting axis 90 to connect the engagement surface 136 with the grip surface 134. The peripheral wall 138 can define a first tab receiving channel 128A, i.e., first channel 128A, and a second tab receiving channel 128B, i.e., second channel 128B.

[0093] The first channel 128A may have an axial length L2. More specifically, a channel end 142A similar to the tip 96A is spaced a length L2 from a proximal edge 144 of the peripheral wall 138. The second channel 128B may similarly have a length L2, with the channel end 142B similar to the tip 96B being spaced a length L2 from a proximal edge 144 of the peripheral wall 138. An exemplary nominal value for L2 may be about 15 mm (0.60 inches). The axial length L2 of the channels 128A, 128B may be substantially equal to the axial length L1 of the tabs 92A, 92B. The first channel 128A has upper and lower wedge surfaces 146A1, 146A2. The second channel 128B has corresponding upper and lower wedge surfaces 146B1, 146B2. The upper and lower wedge faces of both channels have an included angle α2 therebetween. Angle α2 may be substantially equal to angle α1. An exemplary nominal value for α2 may be about 34°.

[0094] The channels 128A may be substantially symmetrical about a channel centerline 147A of the tab receiving channel 128A. For example, the first channel 128A may have its upper wedge surface 146A1 and its lower wedge surface 146A2 each separated from the centerline 147A by an angle of α2 / 2. Similarly, the second channel 128B may have its upper wedge surface 146B1 and its lower wedge surface 146B2 separated from its channel centerline 147B by an angle of α2 / 2. As noted above, an exemplary nominal value for α2 may be 34°, and α2 / 2 is approximately 17°. Thus, the wedge surfaces 146A1 and 146A2 are angled with respect to the centerline 147A, and thus, the wedge surfaces 146B1 and 146B2 are angled with respect to the centerline 147B. The channel centerline 147A may be disposed a distance B2 below the mounting axis 90, as best shown in Figures 6B and 6C. The value of B2 may be substantially equal to the value of B1, with an exemplary nominal value for B2 being approximately 2.5 mm (0.10 inches).

[0095] Channel wedge surfaces 146A1 and 146A2, along with tab wedge surfaces 100A1, 100A2, define nominal channel contact points 148A1, 148A2 on channel wedge surfaces 146A1, 146A2 and tab contact points 101A1 and 101A2 on tab wedge surfaces 100A1, 100A2. In an engaged position of handswitch 52 on housing 58, wedge surfaces 100A1, 100A2 engage channel wedge surfaces 146A1, 146A2 at channel contact points 148A1, 148A2, respectively, which are in contact with tab contact points 101A1, 101A2. Channel contact points 148B1, 148B2 on wedge surfaces 146B1, 146B2 of second channel 128B are similarly defined by engagement of wedge surfaces 146B1, 146B2 with tab contact points 101B1, 101B2 of second tab 92B. Such engagement occurs either before tips 96A, 96B engage end 142A of first channel 128A or end 142B of second channel 128B, and before proximal edge 144 engages distal edge 94 of collar 88.

[0096] The housing 58 may have a diamond-like carbon ("DLC") coating, which may beneficially provide a coated surface with wear resistance and a lower coefficient of friction.

[0097] The collar detent plunger 104 and the detent notch 132 cooperatively define a mounting base detent 149. The detent 149 may function to retain the hand switch 52 on the housing 58 and to bias the tab wedge faces 100A1, 100A2, 100B1, 100B2 against the first channel wedge faces 146A1, 146A2 and the second channel wedge faces 146B1, 146B2. The detent notch 132 may be formed as a recess in the engagement face 136 and may be symmetrical about a notch centerline 151. The notch 132 need not be symmetrical, but may be if formed with a rotary tool, such as a mill. The biasing face 130 of the notch 132 is disposed at an engagement angle α3 relative to the mounting axis 90. An exemplary nominal value of α3 relative to the housing axis 140 may be approximately 19°. With the mounting base 62 installed in the housing 58, the plunger ball 114 is partially received by the notch 132, as shown in Figure 7. The bias of the plunger spring 116 within the sleeve 108 and against the ball 114 urges the ball 114 against the biasing surface 130 which in turn urges the tab wedge surfaces 100A1, 100A2, 100B1, 100B2 into engagement with the first channel wedge surfaces 146A1, 146A2 and the second channel wedge surfaces 146B1, 146B2 at their respective contact points.

[0098] The biasing surface 130 is at the proximal end of the detent notch 132 that is engaged by the plunger 104. The notch may also include a retention edge 150 that may be at 90 degrees relative to the housing axis 140, or may be arcuate, or may be at an angle greater than angle α3 but less than 90 degrees. The retention edge 150 may advantageously increase the axial force required to remove the hand switch 52 from the housing 58. The edge 150 causes the ball 114 to suddenly displace against the plunger spring 116. The increased displacement results in an increased force against the ball 114, which translates into an increased force in the axial direction, i.e., parallel to the housing axis 140, resisting what may be an unintentional removal of the hand switch 52 from the housing 58.

[0099] The tabs 92A, 92B and channels 128A, 128B facilitate proper alignment of the handswitch 52 with the housing 58 and, in turn, installation of the handswitch 52 into the housing 58. The combination of the detents 149, tabs 92A, 92B, and channels 128A, 128B allows the handswitch 52 to be properly aligned with the housing 58 to hold the handswitch 52 on the housing 58 prior to installing the handswitch 52 thereon and connecting the connector 56 to the housing 58. An exemplary force required to remove the handswitch 52 from the housing 58 against the detents 149 can be in the range of 27 to 36 Newtons (6 to 8 pounds) of force.

[0100] As described above, the elongated lever 64 is pivotally connected to the mounting base 62. The lever 64 defines a lever axis 152 that is substantially perpendicular to at least the direction of the pivot axis 86, as best shown in FIG. 8C. The lever 64 includes a proximal end 154 pivotally connected to the mounting base 62 at the pivot axis 86 and a distal end 156 opposite the proximal end 154. A pivot pin 155 centered about the pivot axis 86 can be used to pivotally connect the lever 64 to the base 62. The lever 64 can have an exemplary nominal overall length L3 from the distal end 156 to the proximal end 154 of approximately 92 mm (3.6 inches). A first track 158, i.e., the switch track, is on an inner side 160 of the lever. The inner side 160 of the lever 64 can face substantially the housing axis 140 when installed in the handpiece housing 58. A second track 162, or extension track, is on the inner side 160 of the lever 64 and the opposite outer side 164, and both tracks 158, 162 are substantially parallel to the lever axis 152. The first track 158 is positioned such that in the installed position it is always closer to the lever axis 152 than the second track 162.

[0101] The lever 64 may have a width W1 between opposing first and second sides 165A, 165B. An exemplary value for width W1 may be about 10 mm (0.40 inches). The sides 165A, 165B are disposed between and connect the inner side 160 and the outer side 164. The lever 64 is biased about the pivot axis 86 relative to the base 62 by a spring 66. The safety switch 68 is slidably disposed on the first track 158. The lever extension 70 is slidably disposed on the second track 162. The lever 64, as well as the housing 58, may include a DLC coating.

[0102] The lever 64 presents its outer side 164 and second track 162 in FIG. 8B and has opposed first and second position indicator wings 166A, 166B, respectively, near the distal end 156. The wings 166A, 166B are arranged to align with an indicator line 168 on the switch 68, as described in more detail below. The wings 166A, 166B may be labeled with icons 167A, 167B indicating the associated switch position. For example, a locked icon 167A in the form of a schematic diagram of a locked, i.e., closed, padlock may indicate a secure, i.e., not running, state, and an icon 167B in the form of a schematic diagram of an unlocked, i.e., open, padlock may indicate a running state. Other markings may be used instead of the padlock icons 167A and 167B. For example, the words "RUN" and "SAFE" may be used as icons. The unlocked icon 167B may be located closer to the pivot axis 86 than the locked icon 167A.

[0103] A lever extension detent plunger 172, i.e., an extension plunger opening 170 for receiving the extension plunger 172, may be formed in the lever 64 on the outer side 164. The plunger 172 may include a portion of a lever extension multi-position detent. The extension plunger 172 may be spring loaded and may be formed like the switch plunger 198.

[0104] A pin opening 176 for an extension travel limiting pin 178, shown in FIGS. 8B and 8C, can be located proximate the distal end 156 to maximize the extension of the extension 70 relative to the lever 64. The pin opening 176 can extend through the lever 64. The proximal end 180 can extend a distance L4 from the proximal end 154 of the lever to an end wall 182 of the proximal end 180. An exemplary value for the distance, or length, L4, can be about 18 mm (0.70 inches). The proximal end 180 can accommodate a hinge pocket 184 therebelow and can further define a flush outer surface 186 of the proximal end 180 that aligns with an outer surface, or contact surface 188, of the lever extension 70 when the extension 70 is installed on the lever 64, best shown in FIGS. 8C and 8E. The end wall 182 can define a distal end of the flush outer surface 186.

[0105] In FIG. 8C, the lever 64 presents its inner side 160 and the first track 158. The unlabeled side of the wings 166A, 166B is shown. At the proximal end 154, the hinge pocket 184 can be seen. At the distal end 192, at the distal end 156, a tapered end face 194 is provided. As shown in FIGS. 8D and 8E, the end face 194 when viewed from the side can extend in a downward proximal direction at an angle α4. The angle α4 can be about 45°. A switch plunger opening 196 for receiving a switch detent plunger 198, i.e., a safety switch plunger 198, or alternatively referred to as a switch plunger 198, can be formed in the lever 64 on the inner side 160. The switch plunger 198 can include a portion of a multi-position switch detent, can be spring loaded, and can be formed like the collar detent plunger 104. The switch plunger 198 may be shorter than the collar detent plunger 104 .

[0106] An aperture 176 for an extended travel limiting pin 178 is also shown, the through aperture 176 facilitating installation of the pin 178. Alternatively, the aperture 176 may be a blind hole that does not extend all the way through the lever 64 to the inside 160.

[0107] The inner side 160 of the distal end 192 may also include a switch travel slot 202 that receives a magnet retainer, i.e., a magnet housing 204 that in turn receives a switch magnet 206, both of which are mounted to the switch 68 and extend upwardly therefrom. An exemplary length L5 of the slot 202 may be about 15 mm (0.60 inches). An exemplary width W2 of the slot 202 may be about 5 mm (0.20 inches). An exemplary depth H2 of the slot 202 may be about 3 mm (0.12 inches). The switch 68, switch magnet 206, and magnet housing 204 are shown in FIG. 4. The range of travel of the switch 68 relative to the lever 64 may be defined by the length L5 of the slot 202.

[0108] The side view of FIG. 8D and the cross-sectional side view of FIG. 8E show that the distal end 192 of the lever 64 can have a distal end thickness H3 that is greater than a central portion thickness H4 of the central portion 207 of the lever 64. An exemplary value for the thickness H3 of the distal end 192 can be about 5 mm (0.20 inches) and an exemplary value for the central portion thickness H4 can be about 3 mm (0.12 inches). As indicated by the thickness H3, the distal end 192 can extend a length L6 in a proximal direction from the distal end 156 of the lever 64. An exemplary nominal value for L6 can be about 40 mm (1.6 inches).

[0109] Both tracks 158 and 162 can be seen in both Figures 8D and 8F, the second track 162 can be seen in Figure 8B, and the first track 158 can be seen in Figure 8C.

[0110] The first track 158, i.e., switch track 158, can be seen in each of FIGS. 8D and 8F. The first track 158 is included in the distal end 192 of the inner side 160. The first track 158 can be in the shape of a T-shaped track, i.e., a T-track. Alternatively, the track 158 can have a different profile, presenting, for example, a dovetail, a T-slot, a rectangular or circular track or slot, or any other suitable shape. The length L7 of the first track 158 (an exemplary length is about 38 mm (1.5 inches)) can be shorter than the length L6 of the distal end 192 having a track end 208, which can function as a switch travel stop for the safety switch 68 in the unlocked position, i.e., the run or actuated position. Alternatively, a switch travel stop for the safety switch 68 in the unlocked position may be provided by the proximal end 210 of the slot 202, whereby travel of the switch 68 relative to the lever 64 terminates when the magnet housing 204 engages the proximal end 210 of the slot 202. Similarly, a switch travel stop for the locked, i.e., safe or unactuated, position of the switch 68 may be provided by the distal end 212 of the slot 202, whereby travel of the switch 68 relative to the lever 64 terminates when the magnet housing 204 engages the distal end 212 of the slot 202.

[0111] The second track 162, i.e., the extended track 162, can be seen in each of Figs. 8B, 8D and 8F. The second track 162 can extend a length L8 from the distal end 156 of the lever to an end wall 182 of the proximal end 180 of the outer side 164. An exemplary value of the length L8 can be about 75 mm (3.0 inches). The second track 162 can also be in the shape of a T-shaped track, i.e., a T-track. Similar to the first track 158, the second track 162 can instead have a different profile, for example, presenting a dovetail, a T-slot, or a circular track or slot, or any other suitable shape. The end wall 182 can function as a travel stop for the extension 70 in the retracted position. Alternatively, the extended travel stop for the retracted position can be provided by the distal end 210 of the pin slot 216 of the extension 70. Thus, movement of the extension 70 to the retracted position can be terminated by either engagement of the proximal end 218 of the extension 70 with the end wall 182 or engagement of the distal end 210 of the pin slot 216 by the extension travel limiting pin 178. Similarly, an extension travel stop for the extension 70 in the fully extended position can be provided by the proximal end 218 of the slot 216, with movement of the extension 70 relative to the lever 64 terminating when the extension travel limiting pin 178 engages the proximal end 218 of the slot 216. Alternatively, the pin 178 can be located on the extension 70 and the slot 216 can be located on the lever 64.

[0112] The hinge pocket 184 includes opposed first and second side members 220A, 220B having aligned coaxial first and second openings 222A, 222B, respectively, that define or at least are aligned with the pivot axis 86 when assembled to the base 62. Alternatively, the proximal end 180 may not have a pocket 184 and may be formed as a solid mass with a single opening that passes over the pivot axis 86. The openings 222A, 222B may have either a clearance fit or a press fit relationship with respect to the pivot pin 155. The pin 155 may have a first diameter D4 at the first end 224 and a second diameter D5 at the second end 226, the first diameter D4 being greater than the second diameter D5. Exemplary nominal values ​​of diameters D4 and D5 may be approximately 3.6 mm (0.14 inches) and approximately 3.5 mm (0.13 inches), respectively. Opening 84A of ear 78A of mounting base 62 may have a diameter D6, an exemplary value of which is equal to or less than diameter D4 of first end 224 of pin 155, the difference being selected to provide a press fit, if necessary, between first end 224 of pin 155 and first opening 84A of ear 78A. Opening 84B of ear 78B of mounting base 62 may have a diameter D7, an exemplary value of which is equal to or less than diameter D5 of second end 226 of pin 155, the difference being selected to provide a press fit, if necessary, between second end 226 of pin 155 and second opening 84B of ear 78B. The openings 222A, 222B in the side members 220A, 220B may both have a diameter D8 that is greater than the diameter D5 of the second end 226 of the pin 155, the difference being selected to provide a clearance fit between the second end 226 of the pin 155 and the openings 84B, 222A, 222B.

[0113] The switch 68 as shown in FIGS. 10A-10D may include a switch sliding body 228. The sliding body 228 may be substantially rectangular and may have a switch sliding axis 230. The sliding axis 230 may be coincident with or substantially parallel to the lever axis 152 when the switch 68 is disposed on the lever 64. The sliding body 228 has a sliding surface 232 that receives or is received by the first track 158. Depending on the shape of the first track 158, the sliding surface 232 may be disposed on or instead of the first track 158, as an example, inside the first track 158. The exemplary sliding surface 232 is provided by a T-slot 234 that may extend a length L9 of the sliding body 228 and may be aligned with the axis 230. An exemplary nominal value of L9 may be about 21 mm (0.80 inches). Two indicator arms 236A, 236B defining corresponding outboard faces 238A, 238B extend from opposite sides of the sliding body 228 opposite the T-slot 234. Each arm 236A, 236B may include the indicator line 168 referenced above. Each indicator line 168 may form its associated arm 236A, 236B as a recess or a protrusion. An exemplary width W4 of the switch 68 between the outboard faces 238A, 238B of the arms 236A, 236B may be about 21 mm (0.80 inches). Each arm 236A, 236B may extend laterally about 6 mm (0.24 inches) beyond the side faces 165A, 165B, respectively. The exemplary width W5 of the lever 64 between the wings 166A, 166B, which is approximately 16 mm (0.63 inches), may also be exceeded by a spread of the arms 236A, 236B of approximately 2.5 mm (0.10 inches).

[0114] At the bottom surface 240 of the T-slot 234, first and second switch detent recesses 242A, 242B, which include a portion of the switch detent, may be positioned for engagement by a ball (not shown) of the switch plunger 198. The detent recesses 242A, 242B may be hemispherical in shape. The recesses 242A, 242B may be separated axially, i.e., parallel to the axis 230, by a distance L10 substantially equal to the distance between the locked and unlocked icons 167A, 167B on the wings 166A, 166B. An exemplary nominal value of L10 may be approximately 10 mm (0.40 inches). The magnet housing opening 244 may pass through the bottom surface 240 of the T-slot 234. The first recess 242A may be engaged by the plunger 198 when the switch 68 is in the locked position, i.e., when the indicator line 168 is aligned with the locked icon 167A. The second recess 242B may be engaged by the plunger 198 when the switch 68 is in the unlocked position, ie, when the indicator line 168 is aligned with the unlocked icon 167B.

[0115] The opening 244 can receive the magnet housing 204 in a press-fit relationship. The magnet 206 can be held within the housing 58 for assembly purposes by petroleum jelly, or by adhesive, or by mechanical entrapment, e.g., a press-fit closure. The underside of the switch 68 can have an increased thickness in the area surrounding the opening 244. The exemplary magnet 206 and magnet housing 204 can be installed in the switch 68 when the switch 68 is slidably disposed on the lever 64 and the magnet housing opening 244 is aligned with the switch travel slot 202.

[0116] 9A-9F may include an extension sliding body 246. The sliding body 246 may be substantially rectangular and may have an extension sliding axis 248 that extends from a distal end 249 to a proximal end 250 of the extension 70. The extension sliding axis 248 may be coincident with or substantially parallel to the lever axis 152 when the extension 70 is disposed on the lever 64.

[0117] The sliding body 246 has a lever-extending sliding surface 252 that receives or is received by the second track 162. Depending on the shape of the second track 162, the sliding surface 232 may be disposed, for example, on or instead of the first track 162, inside the first track 162. The exemplary sliding surface 252 is provided by a T-slot 254 that may extend the length L11 of the sliding body 246 and may be aligned with the axis 248. An exemplary nominal value of L11 may be about 77 mm (3.0 inches).

[0118] The outwardly facing contact surface 188 may be substantially continuous from the distal end 249 to the proximal end 250. An engagement head 258 may be provided at the distal end 249 of the extension 70. The engagement head 258 extends upwardly from the contact surface 188 and provides an angled engagement surface 260 for engagement by the thumb or finger of a user of the tool 50. A plurality of distal engagement surfaces 262 may be provided on the contact surface 188 proximate the head 258 for engagement by the user's finger or thumb. The distal engagement surfaces 262 may be defined by recesses or alternatively by protrusions. Similarly, the lever extension 70 may have a plurality of proximal engagement surfaces 264 in the contact surface 188 proximate the proximal end 250.

[0119] In the upper surface 266 of the T-slot 254, a plurality of, for example, four, detent recesses, i.e., notches, a first detent recess 268A, a second detent recess 268B, a third detent recess 268C, and a fourth detent recess 268D, may be formed therein and positioned for engagement by a ball (not shown) of the extension plunger 172. The detent recesses 268A, 268B, 268C, 268D may be substantially hemispherical. The recesses 268A, 268B, 268C, 268D may be elongated laterally to make the lateral alignment of the recesses 268A, 268B, 268C, 268D with the plunger 172 insensitive. The recesses 268A, 268B, 268C, 268D may be uniformly spaced apart in the axial direction, i.e., parallel to the axis 248. The first detent recess 268A, which is the most proximal recess, may align with the plunger 172 when the extension 70 is in a fully retracted position, e.g., when the proximal end of the extension 70 engages the distal end of the end wall 182. The fourth detent recess 268D, which is the most distal recess, may align with the plunger 172 when the extension 70 is in a fully extended position, e.g., when the travel limiting pin 178 engages the proximal end 218 of the pin slot 216.

[0120] The pin slot 216 may be formed in the upper surface 266 and may extend axially an exemplary width W3 for at least an exemplary expected travel distance L12 of the extension 70. An exemplary nominal value of W3 may be approximately 2 mm (0.08 inches). An exemplary nominal value of L12 may be approximately 40 mm (1.6 inches). The pin 178 is received in the slot 216 after the lever extension 70 is slidably received by the lever 64. The pin slot 216 may have a depth H5 that is less than a thickness H6 of the extension. An exemplary nominal value of H5 may be approximately 1 mm (0.04 inches). An exemplary nominal value of H6 may be approximately 1.2 mm (0.05 inches). The fact that the slot 216 does not extend through the entire thickness of the extension 70 is not necessary for the extension 70 to slide in a desired manner, but may help reduce ingress of debris into the T-slot and the associated increased resistance to sliding.

[0121] The extension 70 can be assembled to the lever 64 by sliding the extension 70 onto the lever 64 and then extending the pin 178 from the inside 160 of the lever 64 through the pin opening 176 of the lever 64 and into the slot 216. As mentioned above, if the pin opening 176 is provided as a blind hole, a clearance hole (not shown) can be provided in the lever in alignment with the slot 216. After sliding the extension 70 onto the lever 64, the clearance hole can be aligned with the pin opening 176 and the pin 178 passes through the clearance hole and into the pin opening 176. The height of the installed pin 178 must fit within the available height of the slot 216. If the slot 216 extends through the extension, the pin 178 should be below the contact surface 188 for the comfort of the user of the handswitch 52.

[0122] In operation, the hand switch 52 is installed in the housing 58 by aligning the tabs 92A, 92B with the first and second channels 128A and 146A, and sliding the collar 88 axially onto the proximal end 60 of the housing 58. The offset B1 of the tab centerlines 98A, 98B relative to the mounting axis 90 and the offset B2 of the channel centerlines 147A, 147B relative to the housing axis 140 may allow for faster initial alignment and provide a visual cue to the user to help prevent mis-orientation and mis-installation of the hand switch in the housing 58. The tabs 92A, 92B are received by the first and second channels 128A and 146A, respectively. The tab wedge faces 100A1, 100A2, 100B1, 100B2 contact the first and second channel wedge faces 146A1, 146A2 and 146A, respectively. The wedge surfaces may cooperatively rotationally align the housing 58 and handswitch 52, and with continued axial movement therebetween, the handswitch 52 is in rotational alignment with the handpiece housing 58, i.e., in the aligned, engaged position. As the collar 88 approaches the fully installed position, the ball 114 of the plunger 104 passes the edge 150 of the notch 132 and drops into the notch 132. Upon entering the notch 132, the ball 114 is forced by the spring 116 against the biasing surface 130, creating a biasing force. The biasing force biases the collar 88, and therefore the entire handswitch 52, toward a seated position on the housing 58. In the seated position, the contact points 101A1, 101A2 of the first tab are in contact with the contact points 148A1, 148A2 of the first channel, and the contact points 101B1, 101B2 of the second tab are in contact with the contact points of the second channel.

[0123] With the handswitch 52 installed in the housing 58, the connector 56 may be engaged with the housing 58. The connector 56 may help retain the handswitch 52 on the housing 58.

[0124] In use, the hand switch can selectively pivot its lever 64 about pivot axis 86 toward the housing to operate the tool 50, e.g., a saw, burr, drill, etc. The hand piece 54 includes a housing 58, as previously described. The hand piece 54 can have a magnetic field sensor 59 disposed within the housing 58. When the safety switch 68 is in the unlocked position and the lever 64 is displaced downward toward and potentially relative to the housing 58, the magnetic field sensor 59 is in alignment with the switch magnet 206. The sensor 59 can be connected to the controller 63 by signal conductors 55 or wirelessly, as described above. Similarly, the motor 61 disposed within the housing 58 can be connected by power conductors 57 to the console 53 and a power source therein (not shown). Communication of power and control signals between the hand piece 54 and the console 53 can be connected by connector 56.

[0125] Operation of the tool 50 relies on the magnetic field sensor 59 detecting the magnet 206. The controller 63 can effect a change in power to the drive motor 61 in response to the strength of the detected magnetic field. Thus, as the magnet 206 approaches the sensor 59, within the sensing range of distance, the power and / or speed of the tool 50 increases. With the switch 68 in the locked position, the magnet 206 is kept outside the sensing range of distance of the sensor 59 and the motor 61 cannot be operated.

[0126] To operate the tool 50 after the hand switch 52 is installed in the housing 58, the switch 68 is placed in an unlocked position on the lever. The switch 68 is placed in the unlocked position by sliding the switch 68 proximally from the locked position. To do so, a user can engage one or both of the arms 236A, 236B with one or more fingers to load the switch 68 in a direction parallel to the switch slide axis 230 and displace the switch 68 axially proximally, i.e., toward the axis 230. Thus, the switch 68 can be moved to the unlocked position without loading the lever against the switch spring 66. A sufficient axial force must be applied to at least one of the arms 236A, 236B to overcome the detent load resulting from the switch plunger 198 engaging the recess 242A. The switch 68 can be displaced axially to the unlocked position by overcoming this load. Movement of the switch 68 toward the unlocked position may be limited by one of the engagement of the proximal end of the sliding body 228 with the track end 208 and the engagement of the magnet housing 204 with the proximal end 210 of the slot 202. Retention of the switch 68 in the unlocked position may be assisted by engagement of the plunger 198 with the recess 242B. No force perpendicular to the sliding axis 230 tending to pivot the lever about the pivot axis 86 is required to displace the switch 68 from the locked position to the unlocked position or to move the switch 68 from the unlocked position to the locked position. The lever 64 is pivoted toward the housing against the bias of the switch spring 66. As described above, the sensor 59 may provide a signal to the controller 63 when the magnet 206 in the switch 68 is within the sensing range. The controller 63 may then directly or indirectly power the drive motor 61, also in the housing 58, to initiate movement of the tool bit 280. Accidental actuation of tool 50 is prevented by sliding switch 68 to the locked position. Release of lever 64 by the user allows spring 66 to pivot lever 64 away from housing 58 to the off position.

[0127] The switch 68 can be returned to the locked position by the user by pushing the switch 68 axially in a distal direction. The action is essentially the same as moving the switch 68 to the unlocked position, but in the opposite direction. The detent load of the engagement of the plunger 198 with the recess 242B is overcome by the user. The switch 68 is slid distally by the user, and the movement of the switch 68 relative to the lever 64 is limited by the engagement of the magnet housing 204 with the distal end 212 of the slot 202. Retention of the switch 68 in the locked position can be assisted by the engagement of the plunger 198 with the recess 242A.

[0128] The hand switch 52 may be used with the extension 70 in a fully pulled position as shown in FIGS. 1, 2, 3B, a fully extended position as shown in FIG. 3A, or any position in between. There are two intermediate positions shown for the exemplary hand switch 52, but there may be more or fewer intermediate positions. The extension 70 may be held in any of four exemplary positions associated with receipt of the ball of the plunger 172 in a corresponding one of the detent recesses 268A, 268B, 268C, 268D of the extension 70. The same detent effect can be achieved by placing the plunger 172 in the extension 70 and providing a detent recess. The recesses 268A, 268B, 268C, 268D in the lever extension 70 may each be spaced a distance L13 apart, with the total distance between the recesses 268A and 268D being three times the distance L13. An exemplary nominal value for L13 may be approximately 13 mm (0.50 inches). Recesses 268A, 268B, 268C, 268D may comprise part of a lever extension multi-position detent. Extension 70 provides a user of tool 50 with a variable length lever that can be adjusted to fit the user's hand size.

[0129] When the extension 70 is in the fully extended, or stored, position, the contact surface 188 of the lever extension 70 and the flush outer surface 186 of the proximal end 180 of the lever 64 cooperatively present a substantially continuous smooth surface for engagement by a user's fingers. Retention of the extension 70 in the extended position may be assisted by engaging the extension plunger 172 with the recess 268D. A user may axially displace the extension 70, i.e., slide the extension along the axis 248, by pushing and engaging the extension 70 in a desired direction of extension movement relative to the mounting base 62. The head 258 provides what may be the most prominent engagement feature of the extension 70 for finger engagement. Complementary engagement features that facilitate grasping of the extension 70 by the fingers are provided by the distal and proximal engagement surfaces 262, 264. Such features 258, 262, 264 may resist finger slippage across the extension 70. To slide the extension 70 from the extended position toward the fully extended position, sufficient axial force must be applied to the extension 70 in the desired direction of movement to overcome the detent force associated with the engagement of the extension plunger 172 with the recess 268D.

[0130] An exemplary extended length of the combined lever 64 and extension 70 may be substantially equal to the sum of L4 and the distance between the proximal end 250 and the distal end 249 of the lever extension, such total extended length being approximately equal to 102 mm (4 inches). An exemplary fully extended length of the combined lever 64 and extension 70 may be approximately 142 mm (5.6 inches). The extension 70 may be positioned anywhere between the extended position and the fully extended position. A user may find it useful to set the extension at a particular intermediate position. The intermediate detent positions, which may be provided by the recesses 268B and 268C, may prevent the lever extension from moving along the axis 248 away from a desired intermediate position with little or no axial force. The illustrated extension 70 has two intermediate detent positions associated with the recesses 268B and 268C, although the number of intermediate positions may be fewer or greater.

[0131] Movement of the extension 70 toward the fully extended position and away from the end wall 182 is ultimately limited by engagement of the pin 178 with the proximal end 218 of the slot 216. Retention of the extension 70 in the fully extended position may be assisted by engaging the extension plunger 172 with the recess 268A. Return of the extension 70 to the extracted position may be accomplished by pulling the extension 70 axially in the proximal direction until movement is limited by one of the engagement between the proximal end 250 of the extension 70 and the end wall 182 and the engagement of the pin 178 with the distal end 214 of the slot 216. Retention of the extension 70 in the extracted position may again be assisted by engaging the extension plunger 172 with the recess 268D.

[0132] In any extended position, i.e., any position other than the withdrawn position, the extension presents a significant contact pad, including outer surface 188 and head 258, separated from proximal end 180, for engagement by a user's fingers. The contact pad may present a width of the extension, e.g., about 10 mm (0.40 inches) and a length of about 85 mm (3.3 inches). Such a large area contact region, facilitated by locating extension 70 on track 162 on exterior side 164 of lever 64, improves comfort for the user's fingers when pushing extension 70 to operate tool 50.

[0133] 11 through 13B show alternative mounting base configurations.

[0134] 11 shows a handpiece housing 58' and a mounting base 62' with a single locating tab 92'. A wedging surface 100' of the tab 92' engages a wedging surface 146' of a single receiving channel 128'. Although not shown, the base 62' and housing 58' may include detents, such as a mounting base detent 149, for retaining the handswitch 52' on the handpiece housing 58'. A contact point may also be provided between a peripheral wall 138' of the housing 58' and a distal edge 94' of the collar 88' at the bottom of the collar 88'.

[0135] 12A and 12B show a handpiece housing 58'' with a receiving channel 146'' that slidably receives a handswitch 52'' with a mounting base 62''. The mounting base 62'' has a retention tang 92'' with a barb 100''. The tang 92'' is spring biased to flare outward. As the barb 100'' passes the end of the channel 146'', the tang 92'' flare and the barb 100'' engages the proximal end 60'' of the housing 58'' on either side of the channel 146'' to retain the handswitch 52''.

[0136] 13A and 13B show a handpiece housing 58''' with a receiving channel 146''' having a dovetail profile and disposed transversely relative to the housing axis 140'''. The handswitch 52''' has a mounting base 62''' with a rail 92''' having a dovetail shape complementary to that of the channel 146'''. The channel 146''' has a detent notch 132'''' therein for engagement by a plunger (not shown) disposed on the mounting base 62'''. The rail 92'''' of the mounting base 62''' is received by the channel 146''' and is retained therein by the plunger engaging the detent notch 132''''.

[0137] A further alternative hand switch 52'''' having an alternative lever 64'''', switch spring 66'''', safety switch 68'''', and lever extension 70'''' is shown in FIGS. 14A-17. The lever 64'''' may be received by a receiving pocket 80'''' in the mounting base 62''''. A pivot pin 155'''' centered about a pivot axis 86'''' may be used to pivotally connect the lever 64'''' to the base 62''''. The mounting base 62'''' may also include an exemplary annular collar 88'''' that defines a mounting axis 90''''.

[0138] Lever extension 70'''' is slidably disposed on lever 64'''' and selectively moved by a user between a fully pulled position shown in FIG. 14A and a fully extended position, not shown, similar to the fully extended position of the lever extension of FIG. 3A. Switch 68'''' is slidably disposed on lever 64'''' and selectively moved by a user between an unlocked position and a locked position.

[0139] The lever 64'''' defines a lever axis 152'''' that is substantially perpendicular to the direction of at least the pivot axis 86''''. The lever extension 70'''' and the safety switch 68'''' may each have a respective sliding surface 252'''', 232'''' that is aligned with the lever axis 152''''.

[0140] The lever 64'''' has a first track 158'''' and a second track 162'''' that extend substantially parallel to the lever axis 152''''. The first track 158'''' is closer to the mounting axis 90'''' than the second track 162'''' in the installed position. The second track 162'''' is on the outer side 164''''. The first track 158'''' may include an interior inward facing, i.e., inner side 160'''' of the lever 64''''. Neither the inner side 160'''' nor the outer side 164'''' need to be on the exterior surface of the lever 64''''. The lever 64'''' that is hollow may have multiple inner sides, e.g., an inner side 1632'''' closest to the axis 90'''', and an outer side 163''''. The lever 64'''' may have multiple outer sides as well.

[0141] The lever 64'''' may be formed of sheet metal by stamping. The lever 64'''' includes a switch spring 66'''' formed integrally therewith as an integral part of the lever 64'''' and disposed between the remainder of the lever 64'''' and the base 62''''. The spring 66'''' may bias the lever 64'''' about the pivot axis 86''''. The lever 64'''' may include a plurality (e.g., two) mating tabs 282'''' at a first seam edge 284'''' having a first shape. Each of the tabs 282'''' is received by a mating notch 286'''' at a second seam edge 288'''' of the lever 64''''. An exemplary shape of the tabs 282'''' and notches 286'''' may be dovetail as shown.

[0142] The lever 64'''' may include a downwardly extending switch stop tab 204'''' and an upwardly extending extension stop tab 178''''. As described in more detail below, the stop tabs 204'''', 178'''' may be used to limit the travel of the switch 68'''' and lever extension 70'''', respectively.

[0143] The lever 64'''' may also include a switch plunger 198'''' and an extension plunger 172''''. The extension plunger 172'''' may be formed on the exterior 164'''' of the lever 64'''' and may be in the form of a cantilever leaf spring 290'''' with an integral protrusion 292'''' disposed at an end thereof. The switch plunger 198'''' may be formed on the exterior interior 163'''' of the lever 64''''. The switch plunger 198'''' may be in the form of a cantilever leaf spring 296'''' with an integral protrusion 298'''' disposed at an end thereof.

[0144] The lever extension 70'''' is slidably disposed on the second track 162''''. A sliding surface 252'''' of the lever extension 70'''' is capable of receiving the second track 162''''.

[0145] An extended travel slot 216'''' may be formed in the upper surface 266'''' of the sliding surface 252''''. The slot 216'''' may extend at least the exemplary expected travel distance of the extension 70''''. The extended stop tab 178'''' is received in the slot 216'''' after the lever 64'''' is slidably received by the lever extension 70''''. The tab 178'''' may be resiliently deflected upon initial receipt of the lever 64'''' by the sliding surface 252'''' of the lever extension 70''''. When the extension 70'''' is pressed a sufficient distance onto the lever 64'''', the tab 178'''' is received by the slot 216'''' and snaps back to extend into the slot 216''''.

[0146] A plurality of detent recesses or notches 268'''' may be formed in the top surface 266'''' and positioned for engagement by the protrusions 292'''' of the extension plunger 172''''. The detent recesses 268'''' may be substantially semi-cylindrical in shape and may extend laterally across substantially the entire width of the top surface 266''''. The recesses 268'''' may be uniformly spaced apart in the axial direction, i.e., in a direction parallel to the axis 152'''', or may be unequally spaced apart, as shown in FIGS. 14C and 16. The distal-most of the recesses 268'''' may be aligned with the plunger 172'''', and more specifically, the protrusions 292'''' thereof, when the extension 70'''' is in a fully retracted position. The proximal-most portion of recess 268'''' may be aligned with projection 292'''' when plunger 172'''', i.e., extension 70'''', is in a fully extended position, e.g., the fully extended position is achieved when tab 178'''' engages with proximal end 218'''' of slot 216''''.

[0147] Two detent recesses 242'''' may be formed in a bottom surface 240'''' of the sliding surface 232'''' of the switch 68''''. The recesses 242'''' may be positioned for engagement by a protrusion 298'''' of the switch plunger 198''''. The detent recesses 242 may be semi-cylindrical in shape and may extend laterally across the entire width of the switch 68'''', as shown in FIG. 17. The recesses 242'''' may be separated in an axial direction, i.e., in a direction parallel to the axis 152'''', by a distance substantially equal to the distance between the locked and unlocked positions of the switch 68''''. When the switch 68'''' is in the locked position, a more distal portion of the recesses 242'''' may be engaged by a protrusion 298''''. When the switch 68'''' is in the unlocked position, a more proximal portion of the recesses 242'''' may be engaged by a protrusion of the plunger 198''''. The magnet 206'''' may be press-fit into the magnet opening 244'''' in the switch 68''''.

[0148] The top surface 300'''' of the sliding surface 232'''' of the switch 68'''' may include a switch travel slot 202'''' formed therein. The axial length of the slot 202'''' may determine the range of travel of the switch 68'''' relative to the lever 64''''. After the switch 68'''' is slidably received by the first track 158'''' of the lever 64'''', the switch stop tab 204'''' is received in the slot 202''''. The tab 204'''' may be resiliently deflected upon initial receipt of the sliding surface 232'''' of the switch 68'''' by the first track 158'''' of the lever 64''''. When the switch 68'''' is pressed a sufficient distance into the lever 64'''', the tab 204'''' is received by the slot 202''''.

[0149] Connector 56 may be advantageously configured to facilitate engagement and disengagement with handpiece 54. FIGS. 18A-23 show an exemplary connector 56. Connector 56 may be connected to a first end of cable 51. Connector 56 and cable 51 may be included as elements of an electrical cable assembly 301. Cable assembly 301 may further include a second connector 302 secured to a second end of cable 51. Second connector 302 is shown diagrammatically and may or may not be identical to connector 56. Cable assembly 301 and handpiece may collectively comprise a surgical system 303.

[0150] The connector 56 includes an axially extending cable end receiver 304 and an outer sleeve 305. The cable end receiver 304 can be secured directly to the end of the cable 51. The outer sleeve 305 is received and positioned over substantially the entire length of the cable end receiver 304.

[0151] The cable end receiver 304 includes a pin holder 306 disposed within and secured to an inner sleeve 308. A bushing 310 may be disposed against a proximally facing side 312 of the pin holder 306 to retain or help retain the pin holder 306 inside the inner sleeve 308. A retaining nut 314 may be disposed on a proximal end 316 of the inner sleeve 308 to help retain the pin holder 306 within the inner sleeve 308. A washer 318 may be disposed coaxially between the nut 314 and the inner sleeve 308. The outer sleeve 305 extends substantially the entirety of the receiver 304, including the nut 314, if included, so that the receiver 304 cannot be grasped by a user to pull the connector 56 from the handpiece 54. The connector 56 can only be removed from the handpiece 54 by grasping the outer sleeve 305 and then pulling it away from the handpiece 54, i.e., in a proximal direction. The components are described in more detail below.

[0152] The outer sleeve 305 is substantially cylindrical and includes a gripping portion 319 and an insert portion 320. The insert portion 320 may be of a substantially constant first outer diameter and a substantially constant first inner diameter, both sized to be received by a handpiece electrical receptacle 321. The receptacle may define an annular gap between a central boss and a surrounding inner diameter surface. The insert portion 320 may also include one or more windows 322 for receiving a corresponding number of retaining wedges 330 disposed on the inner sleeve 308. The illustrated insert portion 320 shows two such windows 322. The windows 322 are shown as being disposed in opposite directions from one another across the axis 140. Each of the windows 322 may have a first surface, e.g., a proximal engagement surface 323, and a second surface, e.g., a distal engagement surface 324, for respective engagement with a distally facing ramp surface 325 of the wedge 330 and a proximally facing stop surface 326 of the wedge 330.

[0153] The gripping portion 319 of the outer sleeve 305 may include a raised alignment surface 328. The alignment surface 328 may be presented as a lobe, such as a raised surface extending radially further from the axis 140 than an oppositely disposed surface of the outer sleeve 305, which may align with the proximal tab 82 of FIG. 5C, for example, to facilitate alignment with the hand piece 54. Such alignment also results in alignment of the pin 332 of the connector 56 with a receiving socket 334 in the receptacle 321 of the hand piece 54, and alignment of the wedge 330 with an engagement recess 335 disposed on the inner diameter surface of the annular gap of the receptacle 321. The gripping portion 319 may also include a gripping surface 336, for example, a plurality of parallel recesses and V-shaped surface pockets as shown in FIG. 22, or a plurality of raised edges on its sides. The length L14 of the outer sleeve 305 is sufficient to substantially cover the assembled inner sleeve 308, pin holder 306, bushing 310, washer 318, and nut 314.

[0154] The inner sleeve 308 includes a shank portion 338 and a base portion 339. The shank portion 338 is disposed substantially entirely within the insert portion 320 of the outer sleeve 305. The wedge 330 may be attached to the shank portion 338. More specifically, each wedge 330 may be fixedly attached to an associated telescopically and elastically deflectable beam 340. Together, the wedge 330 and the beam comprise an elastic clip. Each beam 340 and the wedge 330 may be integrally formed with the shank portion as a single unitary formation. The beam 340 may be oriented longitudinally parallel to the axis 140 on opposite sides of the axis. The beam 340 may be defined by a longitudinal slit in the shank portion 338 and may have respective distal and proximal ends disposed within and secured to the shank portion 338. The beam 340 may have a thinner cross-sectional thickness than the remainder of the shank portion 338 to facilitate deflection. The base portion 339 is disposed substantially entirely within the gripping portion 319 of the outer sleeve 305. The inner sleeve 308 is permitted to move axially a limited distance within the outer sleeve 305. The inner sleeve 308 includes an internal chamber 341 capable of receiving each of the pin holder 306 and the bushing 310. Both the pin holder 306 and the bushing 310 are fixedly inserted into the internal chamber 341.

[0155] The pin holder 306 includes a pin holder core 342 and a plurality of pins 332 mounted within and secured to the pin holder core 342. A locator ring 344 may be formed as an integral unitary part of the core 342. The pin holder core 342 may be made of a non-conductive material, e.g., rubber, plastic. The pins 332 may be made of a rigid conductive material, e.g., metal.

[0156] A distal portion of the pin holder 306 is distal to the locator ring 344 and can be disposed within the shank portion 338 of the inner sleeve 308. A proximal portion of the pin holder 306 is proximal to the locator ring 344 and can be disposed within the base portion 339. A plurality of pins 332, e.g., nine, can be disposed parallel to the axis 140 within the pin holder 306, with tips of the pins 332 extending beyond the core 342 at the pin distal end 346 and a wire-receiving pocket disposed at the proximal end 348 of the pin 332. The core 342 can be hollow, e.g., have an open cavity 350 at its proximal end.

[0157] The bushing 310 may have an internal chamber extending the length of the bushing 310. The bushing 310 may have an opening at a distal end 352 sized to receive the proximal end of the pin holder 306. Movement of the bushing 310 relative to the pin holder 306 in an axial direction within the inner sleeve 308 may be limited by a locator ring 344 of the core 342. Movement of the bushing 310 may be so limited by engagement between a proximally facing side 312 of the pin holder 306, e.g., a proximal side of the locator ring 344 that functions as a pin holder core locator surface, and the distal end 352 of the bushing 310.

[0158] The locator ring 344 may include a keyway notch 354 for receiving a key tab 356 formed on the bushing 310. The alignment of the key tab 356 and the keyway notch 354 ensures alignment of the bushing 310 and the pin holder 306.

[0159] The bushing 310 may also include a number of cable engagement feet 358, each disposed at an end of a bushing leg 360. The bushing legs 360 may be defined by a corresponding number of slots 362 in a proximal end 364 of the bushing 310. The bushing legs 360 may define a rake edge 366 for engaging with a rake notch 368 on an inner diameter of the base portion 339 of the inner sleeve 308. The engagement between the rake edge 366 and the rake notch 368 helps retain each of the bushing 310 and the pin holder 306 within the inner sleeve 308. The cable engagement feet 358 are disposed at the proximal end 364 of the bushing 310 and are oriented to face radially inward. The feet 358 may engage the cable 51 when the connector 56 is secured to the cable 51.

[0160] The nut 314 includes a threaded cylindrical body 370 and a proximal end flange 372 at the proximal end of the cylindrical body 370. The nut 314 includes threads on an inner diameter of the threaded cylindrical body 370 that can threadably engage threads on an outer diameter of the proximal end 316 of the inner sleeve 308. A distal end of the nut 314 can engage a proximally facing engagement surface of the base portion 339 of the inner sleeve 308 to limit travel of the nut 314 thereover. A plurality of spanner pin openings 374, for example five, can be formed in the end flange 372. The spanner pin openings 374 can receive an engagement pin (not shown) of a spanner wrench (not shown).

[0161] A washer 318 may be disposed within the nut 314 , between the proximal end 316 of the inner sleeve 308 and the end flange 372 .

[0162] As part of the assembly process, the cable 51 may be connected to the pins 332 in the pin holder 306. The individual conductors 55 of the cable 51 may each be placed in a predefined pin pocket at the distal end 346 and secured, e.g., soldered, to the associated pins 332. After the conductors 55 of the cable 51 are connected to the pins 332, the pin holder 306 and bushing 310 may be placed or connected to a mold (not shown) that surrounds the end of the cable proximal to the bushing 310. An insulator 376 having an uncured liquid form, e.g., silicone, may be injected into the mold and thus into the connector 56 to seal the inside of the bushing 310 and the ends of the pins 332 disposed on the cable 51. The cured insulator 376, i.e., the overmold 376, is a solid. The overmold 376 may be elastically flexible, allowing the portion of the cable in which the overmold 376 is disposed to flex. The overmold 376 may protect the pins 332 at the end of the pin holder 306 of the connector 56 from contamination.

[0163] The washer 318 can be disposed inside the nut 314, between the end flange 372 and the proximal end 316 of the inner sleeve 308. The nut 314 can be threaded onto the inner sleeve 308 after forming the overmold 376. Thus, the washer 318 can be pressed against the end flange 372 by the overmold 376.

[0164] The assembled cable end receiver 304, i.e., inner sleeve 308, pin holder 306, bushing 310, nut 314, washer 318, and cable 51, may be axially and rotationally aligned with and pressed into the outer sleeve 305. The inner sleeve 308 may have a guide rail 378 received by a complementary guide slot 380 to ensure axial alignment of the wedge 330 and window 322.

[0165] When connector 56 is fully assembled, outer sleeve 305 extends substantially over the combined inner sleeve 308 and nut 314 .

[0166] In operation, the connector 56 in an uninserted state has a wedge 330 extending radially outward through the window 322 beyond the first outer diameter of the insertion portion 320. In an uninserted state, the outer sleeve 305 is in a latched position relative to the inner sleeve 308. In the latched position, the wedge 330 is substantially axially aligned with the window 322 of the outer sleeve 305 such that the beam 340 is not substantially deflected, allowing the wedge 330 to extend beyond the first outer diameter of the insertion portion 320. The connector 56 is aligned with the handpiece 54 using the alignment surface 328 to orient the connector 56 relative to the handpiece 54. The connector 56 is then pressed into engagement with the handpiece 54. During insertion, engagement of the angled surface 325 of the wedge 330 against the inner diameter of the receptacle 321 of the handpiece 54 biases the wedge 330 downward into the window 322 against the resistive force of the beam 340. The inner sleeve 308 and outer sleeve 305 remain in the latched position and the wedge 330 is aligned with the window 322. Once the window 322 is axially aligned with the engagement recess 335 of the handpiece 54, the wedge 330 is restored to the extended position by the resilient beam 340. As a result, the wedge 330 is partially disposed in the recess 335.

[0167] The wedge 330 tends to resist withdrawal of the connector 56 from the handpiece 54. However, by applying a sufficient withdrawal force to the outer sleeve 305, the resistance to withdrawal can be overcome by the action of the distal engagement surface 324 of the window 322 acting against the ramp 325. The force against the ramp 325 initially pushes the stop surface 326 of the wedge 330 against the proximal end of the recess 335, limiting the movement of the inner sleeve 308 relative to the handpiece 54. As the withdrawal force applied to the outer sleeve 305 increases, the distal engagement surface 324 of the window 322 acts against the ramp 325. The force on the outer sleeve 305 overcomes the resistance of the beam 340 and displaces the wedge 330 radially inward. Such displacement of the wedge allows the outer sleeve 305 to move axially relative to the inner sleeve 308 to a release position therebetween with the wedge 330 axially offset from alignment with the window 322. 20B, with the outer sleeve 305 in the released position relative to the inner sleeve 308, the wedge 330 is withdrawn, i.e., removed, from the recess 335. Such removal of the wedge 330 from the recess 335 allows the connector 56 to be withdrawn from the receptacle 321. Upon removal from the handpiece 54, the connector 56 may be restored to the latched position by the restoring force of the beam pressing the angled surface 325 against the distal surface 324 of the window 322, creating relative axial movement over the slidable range between the inner sleeve 308 and the outer sleeve 305.

[0168] Pulling only on cable 51 will not result in release of the connector because stop surface 326 engages the proximal end of recess 335. Accidental removal of connector 56 is therefore limited.

[0169] In the drawings, like reference numbers refer to like elements. Moreover, some or all of these elements may be modified. With respect to the media, processes, systems, methods, heuristics, etc. described herein, the steps of such processes, etc. are described as occurring according to a particular ordered sequence, and it is understood that such processes can be practiced with the described steps performed in an order other than the sequence described herein. Furthermore, it is understood that certain steps can be performed simultaneously, other steps can be added, or certain steps described herein can be omitted. In other words, the process descriptions herein are provided for the purpose of describing particular embodiments and should not be construed as limiting the scope of the claims.

[0170] Therefore, it should be understood that the above description is intended to be illustrative and not restrictive. Many embodiments and applications other than the examples provided will become apparent upon reading the above description. The scope should be determined without reference to the above description, but should instead be determined with reference to the appended claims along with the full scope of equivalents to which such claims are entitled. It is anticipated and intended that future developments will occur in the technology discussed herein, and that the disclosed systems and methods will be incorporated into such future embodiments. In summary, it should be understood that this application is capable of modification and alteration.

[0171] As used herein, the adverb "substantially" means that shapes, structures, measurements, amounts, times, etc. may deviate from the precisely described geometric shapes, distances, measurements, quantities, times, etc. due to imperfections in materials, machining, manufacturing, data transmission, computation speed, etc.

[0172] All terms used in the claims are intended to be given their ordinary meaning as understood by those familiar with the art described herein, unless an express indication to the contrary is made herein. In particular, the use of singular articles such as "a," "the," "said," etc. shall be read to describe one or more of the indicated elements, unless the claim recites an express limitation to the contrary.

[0173] The Abstract is provided to enable the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Moreover, in the foregoing Detailed Description, it will be seen that various features have been grouped together in various embodiments for the purpose of streamlining the disclosure. This method of disclosure should not be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Accordingly, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as separately claimed subject matter. The following are features described in the claims at the time of filing. [Feature 1] 1. A hand switch for a powered surgical handpiece, comprising: a mounting base defining a pivot axis; an elongated lever defining a lever axis substantially perpendicular to a direction of at least said pivot axis, the elongated lever including a proximal end pivotally connected to said mounting base at said pivot axis, a distal end opposite said proximal end, an inner first track, and an outer second track opposite said inner track, both tracks being substantially parallel to said lever axis; a spring between the base and the lever biasing the lever about the pivot axis; a safety switch slidably disposed on the first track; a lever extension slidably disposed on the second track. [Feature 2] 2. The handswitch of claim 1, wherein at least one of the first track and the second track is one of a T-slot and a T-track. [Feature 3] 3. The hand switch of feature 2, wherein the first track and the second track are both T-tracks. [Feature 4] 4. The hand switch of any one of features 1 to 3, wherein the lever has first and second sides connecting the inner and outer sides, and the safety switch has at least one outboard face extending laterally beyond at least one of the sides. [Feature 5] 5. The handswitch of claim 4, wherein the outboard surface is defined by an indicator arm. [Feature 6] 6. The hand switch of any one of features 1 to 5, wherein the lever has a slot therein for receiving at least one of a magnet and a magnet holder fixed to the safety switch. [Feature 7] 7. The hand switch of claim 6, wherein the slot has a length less than a length of the lever, the slot defining a range of travel of the safety switch. [Feature 8] 8. The hand switch of any one of features 1 to 7, wherein a detent is disposed between the safety switch and the lever. [Feature 9] 9. The hand switch of claim 8, wherein the detent includes a safety switch plunger, a first notch associated with an actuated position of the safety switch, and a second notch associated with an unactuated position of the safety switch. [Feature 10] 10. The hand switch of claim 9, wherein the safety switch plunger is disposed on the lever and the notch is disposed on the switch. [Feature 11] 11. The hand switch of any one of features 1 to 10, wherein a detent is disposed between the lever and the lever extension. [Feature 12] 12. The handswitch of claim 11, wherein the detent includes an extension plunger and first, second, third and fourth notches associated with first, second, third and fourth positions of the extension, respectively. [Feature 13] 13. The handswitch of claim 12, wherein the extension plunger is disposed on the lever, and the notch is disposed on the lever extension. [Feature 14] 14. The handswitch of any one of features 1 to 13, wherein the mounting base includes an annular collar defining a mounting axis substantially perpendicular to a direction of at least the pivot axis, the collar sized for slidable placement on a proximal end of the handpiece. [Feature 15] the annular collar defining a positioning tab extending axially in a distal direction, the tab including an angled wedge surface; 15. The handswitch of feature 14, further comprising one of a detent plunger disposed on an inner diameter of the annular collar and a detent notch defining a bias surface. [Feature 16] 16. The handswitch of feature 15, wherein the collar includes at least a second positioning tab, the second positioning tab also extending axially in the distal direction and including an angled wedge surface. [Feature 17] 17. The handswitch of claim 16, wherein the detent plunger is disposed on the collar. [Feature 18] 1. A surgical tool having a powered surgical handpiece and a hand switch, comprising: The powered surgical handpiece includes a longitudinally extending handpiece housing extending along a housing axis; a magnetic field sensor disposed within the housing; The hand switch is a mounting base defining a pivot axis having an orientation substantially perpendicular to the housing axis and a mounting surface extending in a first direction; an elongate lever defining a lever axis substantially perpendicular to the direction of said pivot axis, a proximal end pivotally connected to the mounting base at the pivot axis; a distal end opposite the proximal end; and an inner first track substantially facing the housing axis; an elongated lever including a second track on an outer side opposite the inner side, both tracks being substantially parallel to the lever axis; a spring between the base and the lever biasing the lever about the pivot axis; a safety switch slidably disposed on the first track to which a magnet is fixed; a lever extension slidably disposed on the second track. [Feature 19] 20. The surgical tool of feature 18, wherein at least one of the first track and the second track is one of a T-slot and a T-track. [Feature 20] 20. The surgical tool of feature 19, wherein the first track and the second track are both T-tracks. [Feature 21] 21. The surgical tool of any one of features 18 to 20, wherein the lever includes first and second sides connecting the inner and outer sides, and the safety switch includes at least one outboard surface extending laterally beyond at least one of the sides. [Feature 22] 22. The surgical tool of any one of features 18 to 21, wherein the lever includes a slot on the inside that receives at least one of the magnet and a magnet holder secured to the safety switch. [Feature 23] 23. The surgical tool of feature 22, wherein the slot has a length less than a length of the lever, the slot defining a range of travel of the safety switch. [Feature 24] 24. The surgical tool of any one of features 18 to 23, wherein a detent is disposed between the safety switch and the lever. [Feature 25] 25. The surgical tool of feature 24, wherein the detent includes a safety switch detent plunger, a first notch associated with an actuated position of the safety switch, and a second notch associated with an unactuated position of the safety switch. [Feature 26] 26. The surgical tool of feature 25, wherein the detent plunger is disposed on the lever and the notch is disposed on the switch. [Feature 27] 27. The surgical tool of feature 26, wherein a detent is disposed between the lever and the lever extension. [Feature 28] 28. The surgical tool of feature 27, wherein the detent includes an extended detent plunger and first, second, third and fourth notches associated with the first, second, third and fourth positions of the extension, respectively. [Feature 29] 30. The surgical tool of claim 28, wherein the extension detent plunger is disposed on the lever, and the notch is disposed on the lever extension. [Feature 30] 30. The surgical tool of any one of features 18 to 29, wherein the mounting surface is defined by an annular collar including at least a portion of the mounting base, the collar defining a mounting axis substantially perpendicular to a direction of the pivot axis, the collar being sized for slidable placement on a proximal end of the handpiece. [Feature 31] a housing including a receiving channel formed in the proximal end thereof, the receiving channel being defined at least in part by a circumferential wall, the channel extending axially away from the proximal end of the housing toward the distal end of the housing, a first side of the channel defining a first channel contact point and a second side of the channel defining a second channel contact point; an annular collar defining a positioning tab extending a second predetermined length in a distal direction, the tab including a first side defining a first tab contact point and a second side defining a second tab contact point, the first tab contact point contacting the first channel contact point and the second tab contact point contacting the second channel contact point when the collar is engaged with the housing; 31. The surgical tool of feature 30, further comprising one of a detent plunger disposed on an inner diameter of the collar and an angled groove defining a bias surface. [Feature 32] 32. The surgical tool of feature 31, wherein the collar includes at least a second positioning tab and the housing includes a second receiving channel that receives the second positioning tab when the collar is engaged with the housing. [Feature 33] 33. The surgical tool of feature 32, wherein the detent plunger is disposed in the collar. [Feature 34] 1. A hand switch for a powered surgical handpiece, comprising: a mounting base including an annular collar defining a pivot axis and defining a mounting axis substantially perpendicular to at least a direction of the pivot axis, the collar sized for slidable placement on a proximal end of the handpiece in the direction of the mounting axis; an elongated lever pivotally connected to the mounting base at a proximal end of the lever; a spring between the base and the lever biasing the lever about the pivot axis; a safety switch slidably disposed on the lever; The mounting base is a first positioning tab and a second positioning tab, each extending axially distally from a main portion of the collar, each tab including an angled wedge surface; The handswitch further includes a detent notch defining a biasing surface and one of a detent plunger disposed on an inner diameter of the annular collar. [Feature 35] 35. The handswitch of feature 34, wherein each tab includes an angled wedge surface. [Feature 36] 36. The handswitch of feature 35, wherein each tab has a tab centerline about which it is substantially symmetrical, and each tab has two angled wedge surfaces. [Feature 37] 37. The handswitch of feature 36, wherein both tab centerlines are a predetermined distance below the mounting axis on an opposite side of the mounting axis from the pivot axis. [Feature 38] 38. The handswitch of any one of features 34 to 37, wherein the detent plunger is disposed on the collar. [Feature 39] 39. The hand switch of any one of features 34 to 38, wherein the safety switch is slidably disposed inside the lever. [Feature 40] 40. The handswitch of claim 39, wherein a lever extension is slidably disposed on an exterior side of the lever. [Feature 41] 1. A surgical tool having a powered surgical handpiece and a hand switch, comprising: The electric surgical handpiece comprises: a longitudinally extending handpiece housing extending along a housing axis; a magnetic field sensor disposed within the housing; The hand switch is a mounting base including an annular collar defining a pivot axis and defining a mounting axis substantially perpendicular to at least a direction of the pivot axis, the collar sized for slidable placement on a proximal end of the handpiece in the direction of the mounting axis; an elongated lever pivotally connected to the mounting base at a proximal end of the lever; a spring between the base and the lever biasing the lever about the pivot axis; a safety switch slidably disposed on the lever; The mounting base is a first positioning tab and a second positioning tab, each extending axially distally from a main portion of the collar, each tab including an angled wedge surface; A surgical tool including a detent notch defining a bias surface and one of a detent plunger disposed on an inner diameter of the annular collar. [Feature 42] 42. The surgical tool of feature 41, wherein each tab includes an angled wedge surface. [Feature 43] 43. The surgical tool of feature 42, wherein each tab has a tab centerline about which it is substantially symmetrical, and each tab has two angled wedge surfaces. [Feature 44] 44. The surgical tool of feature 43, wherein both tab centerlines are a predetermined distance below the mounting axis on an opposite side of the mounting axis from the pivot axis. [Feature 45] 45. The surgical tool of any one of features 41 to 44, wherein the detent plunger is disposed on the collar. [Feature 46] 46. ​​The surgical tool of any one of features 41 to 45, wherein the safety switch is slidably disposed inside the lever. [Feature 47] 47. The surgical tool of feature 46, wherein a lever extension is slidably disposed outside of the lever. [Feature 48] a housing including two receiving channels formed in the proximal end thereof, the receiving channels being defined at least in part by a circumferential wall, the channels extending axially away from the proximal end of the housing toward a distal end of the housing, a first side of each channel defining a first channel contact point thereof and a second side of each channel defining a second channel contact point thereof; respective positioning tabs extending a second predetermined length in a distal direction, each tab including a first side defining a first tab contact point thereof and a second side defining a second tab contact point thereof, each first tab contact point contacting the first channel contact point of the respective channel and each second tab contact point contacting the second channel contact point of the respective channel when the collar is engaged with the housing; 48. The surgical tool of any one of features 41-47, further comprising a detent plunger disposed on an inner diameter of the collar and one of an angled groove defining a bias surface. [Feature 49] 50. The surgical tool of claim 48, wherein a notch in the housing defines the bias surface and the detent plunger is disposed on an inner diameter of the collar. [Feature 50] 50. The surgical tool of feature 49, wherein the bias surface faces partially distally and is engaged by the plunger when the respective contact points are engaged. [Feature 51] 1. An electrical connector for a surgical tool, comprising: an axially extending cable end receiver, an inner sleeve including a resilient clip including a first retaining wedge; a pin holder secured to the inner sleeve and including a core and a plurality of pins secured to the core; 1. An electrical connector comprising: a cable end receiver comprising: an outer sleeve slidably receiving substantially the entirety of the cable end receiver, the outer sleeve including a first window that receives the retention wedge, the outer sleeve having a range of slideability relative to the receiver, the range extending from a latched position in which the wedge is substantially axially aligned with the window to a released position in which the wedge is axially offset from alignment with the window. [Feature 52] 52. The electrical connector of claim 51, wherein the cable end receiver further comprises a bushing disposed between the pin holder and the inner sleeve. [Feature 53] 53. The electrical connector of feature 52, wherein the bushing includes a cable engagement foot extending radially inwardly for engaging a cable having a conductor connecting to the pin. [Feature 54] 53. The electrical connector of claim 52, wherein the bushing is disposed entirely within the inner sleeve. [Feature 55] 55. The electrical connector of any one of features 51 to 54, wherein the released position of the outer sleeve relative to the cable end receiver is proximal to the latched position of the outer sleeve. [Feature 56] 56. The electrical connector of any one of features 51 to 55, wherein in the released position, a sloped surface of the wedge engages a second surface of the window and a stop surface of the wedge is spaced from a first surface of the window. [Feature 57] 57. The electrical connector of any one of features 51 to 56, wherein the cable end receiver further includes a retaining nut disposed on the inner sleeve and threadably secured thereto. [Feature 58] 58. The electrical connector of any one of features 51 to 57, wherein the outer sleeve has a raised alignment surface. [Feature 59] 59. The electrical connector of any one of features 51 to 58, wherein the elastic clip further includes a beam secured to the inner sleeve at both ends, the wedge being secured to the beam between the ends. [Feature 60] 52. The electrical connector of feature 51, wherein the inner sleeve further includes a second wedge and the outer sleeve includes a second window. [Feature 61] 1. An electrical cable assembly for use with a surgical tool, comprising: a cable including a plurality of conductors; a connector, the connector comprising: an axially extending cable end receiver, an inner sleeve including a resilient clip including a first retaining wedge; a pin holder including a core and a plurality of pins secured to the core, the pin holder being secured to and completely disposed within the inner sleeve; an outer sleeve for slidably receiving substantially the entirety of the cable end receiver, the outer sleeve including a first window for receiving the retention wedge, the outer sleeve having a range of slideability relative to the receiver, the range extending from a latched position in which the wedge is substantially axially aligned with the window to a released position in which the wedge is axially offset from alignment with the window; A plurality of said conductors are electrically connected to a plurality of said pins. [Feature 62] 62. The electrical cable assembly of claim 61, wherein the cable end receiver further comprises a bushing disposed between the pin holder and the inner sleeve. [Feature 63] 63. The electrical cable assembly of feature 62, wherein the bushing includes a cable engagement foot extending radially inwardly for engaging a cable connecting to the pin. [Feature 64] 63. The electrical cable assembly of claim 62, wherein the bushing is disposed entirely within the inner sleeve. [Feature 65] 65. The electrical cable assembly of any one of features 61 to 64, wherein the released position of the outer sleeve relative to the cable end receiver is proximal to the latched position of the outer sleeve. [Feature 66] 66. The electrical cable assembly of any one of features 61 to 65, wherein in the released position, an inclined surface of the wedge engages a second surface of the window and a stop surface of the wedge is spaced from a first surface of the window. [Feature 67] 67. The electrical cable assembly of any one of features 61 to 66, wherein the cable end receiver further includes a retaining nut disposed on the inner sleeve and threadably secured thereto. [Feature 68] 68. The electrical cable assembly of any one of features 61 to 67, wherein the outer sleeve has a raised alignment surface. [Feature 69] 69. The electrical cable assembly of any one of features 61 to 68, wherein the elastic clip further includes a beam secured to the inner sleeve at both ends, the wedge being secured to the beam between the ends. [Feature 70] 70. The electrical cable assembly of any one of features 61 to 69, wherein the inner sleeve further includes a second wedge and the outer sleeve includes a second window. [Feature 71] 1. A surgical system comprising a handpiece and a connector, The handpiece includes a housing, an electric drive motor disposed therein, and a cable assembly including a cable having a plurality of conductors; The connector comprises: an axially extending cable end receiver, an inner sleeve including a resilient clip including a first retaining wedge; the cable end receiver including a pin holder including a core and a plurality of pins secured to the core, the pin holder being secured to and completely disposed within the inner sleeve; an outer sleeve for slidably receiving substantially the entirety of the cable end receiver, the outer sleeve including a first window for receiving the retention wedge, the outer sleeve having a range for sliding movement relative to the receiver, the range extending from a latched position in which the wedge is substantially axially aligned with the window to a released position in which the wedge is axially offset from alignment with the window; A surgical system, wherein a plurality of said conductors are electrically connected to a plurality of said pins. [Feature 72] 72. The surgical system of feature 71, wherein the cable end receiver further comprises a bushing disposed between the pin holder and the inner sleeve. [Feature 73] 73. The surgical system of feature 72, wherein the bushing includes a cable engagement foot extending radially inwardly for engaging a cable connecting to the pin. [Feature 74] 73. The surgical system of feature 72, wherein the bushing is disposed entirely within the inner sleeve. [Feature 75] 75. The surgical system of any one of features 71 to 74, wherein the released position of the outer sleeve relative to the cable end receiver is proximal to the latched position of the outer sleeve. [Feature 76] 76. The surgical system of any one of features 71 to 75, wherein in the released position, an inclined surface of the wedge engages a second surface of the window and a stop surface of the wedge is spaced from a first surface of the window. [Feature 77] 77. The surgical system of any one of features 71 to 76, wherein the cable end receiver further includes a retaining nut disposed on the inner sleeve and threadably secured thereto. [Feature 78] 78. The surgical system of any one of features 71 to 77, wherein the outer sleeve has a raised alignment surface. [Feature 79] 79. The surgical system of any one of features 71 to 78, wherein the elastic clip further includes a beam secured to the inner sleeve at both ends, the wedge being secured to the beam between the ends. [Feature 80] 80. The surgical system of any one of features 71 to 79, wherein the inner sleeve further includes a second wedge and the outer sleeve includes a second window.

Claims

1. 1. A powered surgical handpiece including a hand switch, comprising: a mounting base defining a pivot axis; an elongated lever defining a lever axis substantially perpendicular to a direction of at least said pivot axis, the elongated lever including a proximal end pivotally connected to said mounting base at said pivot axis, a distal end opposite said proximal end, an inner first track, and an outer second track opposite said inner track, both tracks being substantially parallel to said lever axis; a spring between the base and the lever biasing the lever about the pivot axis; a safety switch slidably disposed on the first track; a lever extension slidably disposed on the second track; A powered surgical handpiece, wherein a detent is disposed between the lever and the lever extension.

2. The powered surgical handpiece of claim 1 , wherein at least one of the first track and the second track is one of a T-slot and a T-track.

3. The powered surgical handpiece of claim 2 , wherein the first track and the second track are both T-tracks.

4. 4. The powered surgical handpiece of claim 1, wherein the lever has first and second sides connecting the inner and outer sides, and the safety switch has at least one outboard face extending laterally beyond at least one of the sides.

5. The powered surgical handpiece of claim 4 , wherein the outboard surface is defined by an indicator arm.

6. 4. The powered surgical handpiece of claim 1, wherein the lever has an internal slot for receiving at least one of a magnet and a magnet holder secured to the safety switch.

7. The powered surgical handpiece of claim 6 , wherein the slot has a length less than a length of the lever, and the slot defines a range of travel of the safety switch.

8. 4. The powered surgical handpiece of claim 1, wherein a detent is disposed between the safety switch and the lever.

9. 9. The powered surgical handpiece of claim 8, wherein the detent includes a safety switch plunger, a first notch associated with an actuated position of the safety switch, and a second notch associated with an unactuated position of the safety switch.

10. The powered surgical handpiece of claim 9 , wherein the safety switch plunger is disposed on the lever and the notch is disposed on the switch.

11. 2. The powered surgical handpiece of claim 1, wherein the detent includes an extension plunger and first, second, third and fourth notches associated with first, second, third and fourth positions of the lever extension, respectively.

12. The powered surgical handpiece of claim 11 , wherein the extension plunger is disposed on the lever and the notch is disposed on the lever extension.

13. 4. The powered surgical handpiece of claim 1, wherein the mounting base includes an annular collar defining a mounting axis substantially perpendicular to a direction of at least the pivot axis, the annular collar being sized for slidable placement on a proximal end of the powered surgical handpiece.

14. the annular collar defining a positioning tab extending axially in a distal direction, the tab including an angled wedge surface; The powered surgical handpiece of claim 13, further comprising one of a detent plunger disposed on an inner diameter of the annular collar and a detent notch defining a bias surface.

15. An electric surgical handpiece as described in claim 14, wherein the annular collar includes at least a second positioning tab, the second positioning tab also extending axially in the distal direction and including an angled wedge surface.

16. The powered surgical handpiece of claim 15, wherein the detent plunger is disposed on the annular collar.

17. 1. A surgical tool having a powered surgical handpiece and a hand switch, comprising: The powered surgical handpiece includes a longitudinally extending handpiece housing extending along a housing axis; a magnetic field sensor disposed within the handpiece housing; The hand switch is a mounting base defining a pivot axis having an orientation substantially perpendicular to the housing axis and a mounting surface extending in a first direction; an elongate lever defining a lever axis substantially perpendicular to the direction of said pivot axis, a proximal end pivotally connected to the mounting base at the pivot axis; a distal end opposite the proximal end; and an inner first track substantially facing the housing axis; an elongated lever including a second track on an outer side opposite the inner side, both tracks being substantially parallel to the lever axis; a spring between the base and the lever biasing the lever about the pivot axis; a safety switch slidably disposed on the first track to which a magnet is fixed; a lever extension slidably disposed on the second track; A surgical tool, wherein a detent is disposed between the lever and the lever extension.

18. 1. A hand switch for a powered surgical handpiece, comprising: a mounting base defining a pivot axis; an elongated lever defining a lever axis substantially perpendicular to a direction of at least said pivot axis, the elongated lever including a proximal end pivotally connected to said mounting base at said pivot axis, a distal end opposite said proximal end, an inner first track, and an outer second track opposite said inner track, both tracks being substantially parallel to said lever axis; a spring between the base and the lever biasing the lever about the pivot axis; a safety switch slidably disposed on the first track; a lever extension slidably disposed on the second track; A hand switch, wherein a detent is disposed between the lever and the lever extension.

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