Ultrasonic Surgical Handpiece Thermal Diffuser and Anti-Rotation Design
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Solution Overview
Problem
Existing ultrasonic surgical handpieces face issues with thermal performance and structural stability, leading to 'hot spots' and failure due to concentrated stress and torque during surgical procedures, which affect the surgeon's comfort and the device's longevity.
Innovation Solution
The implementation of a thermal diffuser with a conductive layer and an insulating layer between the housing and the ultrasonic transducer, along with an anti-rotation feature using a hexacog design to distribute torque and reduce stress on the polymer housing, addresses the thermal and structural issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a polymer housing is used for electrical safety, then electrical insulation is improved, but thermal performance deteriorates causing hot spots
Solution Approach 1:
The patent employs a composite housing structure combining polymer and metal materials. The polymer housing provides electrical insulation and safety, while integrated metal components (thermal diffuser, heat sink, or thermal conduit) provide thermal conduction to dissipate hot spots. This composite approach allows simultaneous achievement of electrical safety and thermal management.
2Reliability
If high torque is applied to tighten surgical tip, then acoustic coupling is improved, but structural stability deteriorates due to concentrated stress on polymer housing
Solution Approach 1:
The patent uses a composite housing structure where metal components are integrated into the polymer housing. The metal portions (such as the thermal diffuser or heat sink) serve as reinforcement elements that distribute mechanical stress from high torque application, preventing structural failure while allowing sufficient torque to be applied for adequate acoustic coupling.
Solution Approach 2:
The housing is segmented into polymer and metal components with distinct functional roles. The polymer provides electrical insulation while metal reinforcement elements provide mechanical strength. This segmentation allows each material to optimize its properties without compromising the other.
3Stability of the object's composition
If transducer rotation is prevented using metallic constraints, then structural stability is improved, but electrical safety deteriorates
Solution Approach 1:
The patent integrates metal anti-rotation constraints directly into the polymer housing structure. The metal elements provide rigid mechanical constraints to prevent transducer rotation, while the surrounding polymer material maintains electrical insulation. This composite integration allows mechanical stability without compromising electrical safety.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The thermal diffuser effectively reduces temperature hot spots, making the handpiece more comfortable for surgeons, while the anti-rotation feature enhances the structural stability and prevents failure under high torque conditions, ensuring reliable performance during prolonged surgical procedures.
Implementation Method 1
a thermal diffuser disposed between the housing and the ultrasonic transducer
Implementation Method 2
an insulating layer between the housing and the ultrasonic transducer
Implementation Method 3
an ultrasonically vibrating horn or tip operably connected to the ultrasonic transducer
Data Source
Figure 1
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Figure 4
AI summary
A surgical handpiece is provided. The surgical handpiece comprises a housing (50), an electrical component (19) within the housing; and a thermal diffuser (100) disposed between the housing and the electrical component and comprising a thermal conductive layer (110) and an electrical insulating layer (120). The thermal conductive layer is closer to the housing than the electrical insulating layer, and the thermal conductive layer and the electrical insulating layer are bonded with an adhesive.