ULTRASONIC DENTAL INSTRUMENTS, INSERT ASSEMBLIES, AND INSERTS WITH IMPROVED PERFORMANCE DURABILITY

Abstract

Ultrasonic dental instruments, inserts, and insert assemblies are provided which include an acoustic transformer and a tip that, in combination, are configured to operate at an operational frequency different from the frequency of resonance of the transducer that drives the combination. As a result, the ultrasonic dental instruments, inserts, and insert assemblies provide improved performance durability by providing improved output stroke ranges over nominal wear lengths between, for example, 2 mm and 3 mm, which results in more durable performance over a longer service life.

Claims

1. A dental ultrasonic insert assembly, comprising: a transducer defining a frequency of resonance; an acoustic transformer; and a tip coupled to a distal portion of the acoustic transformer, where a mesial portion of a combination of the acoustic transformer and the tip is coupled to the transducer, and wherein an operational frequency of the combination is not equal to the frequency of resonance of the transducer, wherein, at a full length L of the tip, a force at a junction of the transducer and the acoustic transformer is finite, and wherein, at a reduced length L−X, wherein X represents an amount of wear of the tip, the force is substantially zero and an output stroke of the tip is substantially at a maximum.

2. The dental ultrasonic insert assembly according to claim 1, wherein, at the full length L, the operational frequency of the combination of the acoustic transformer and tip is less than the frequency of resonance of the transducer.

3. The dental ultrasonic insert assembly according to claim 1, wherein, at the full length L, the operational frequency of the combination of the acoustic transformer and the tip is greater than the frequency of resonance of the transducer.

4. The dental ultrasonic insert assembly according to claim 1, wherein the operational frequency at the reduced length L−X is coincident with the frequency of resonance.

5. The dental ultrasonic insert assembly according to claim 1, wherein X is greater than 1 mm.

6. The dental ultrasonic insert assembly according to claim 1, wherein X is greater than 0 mm and less than 4 mm.

7. The dental ultrasonic insert assembly according to claim 1, wherein the operational frequency is between 18 kHz and 50 kHz.

8. The dental ultrasonic insert assembly according to claim 1, wherein the tip is press fitted onto the acoustic transformer or an integral part of the acoustic transformer.

9. The dental ultrasonic insert assembly according to claim 1, wherein the transducer is piezoelectric.

10. The dental ultrasonic insert assembly according to claim 1, wherein the transducer is magnetostrictive.

11. A dental ultrasonic insert assembly, comprising: a transducer having a frequency of resonance and defining a length substantially equal to one-half wavelength of the frequency of resonance; an acoustic transformer; and a tip extending distally from the acoustic transformer, wherein a combination of the acoustic transformer and the tip is configured to operate at an operational frequency below the frequency of resonance, and wherein the combination defines a length greater than one-half wavelength of the frequency of the transducer, and wherein the operational frequency of the combination approaches the frequency of resonance as a length of the tip is reduced from a full length.

12. The dental ultrasonic insert assembly according to claim 11, wherein the operational frequency is between 18 kHz and 50 kHz.

13. The dental ultrasonic insert assembly according to claim 11, wherein the tip is press fitted onto the acoustic transformer.

14. The dental ultrasonic insert assembly according to claim 11, wherein the tip is an integral part of the acoustic transformer.

15. The dental ultrasonic insert assembly according to claim 11, wherein the transducer is piezoelectric.

16. The dental ultrasonic insert assembly according to claim 11, wherein the transducer is magnetostrictive.

17. A dental ultrasonic insert assembly, comprising: a transducer defining a length substantially equal to one-half wavelength of a frequency of resonance thereof; and a combination of a tip and an acoustic transformer, the combination defining a length greater than one-half wavelength of the frequency of the transducer and configured to operate at an operational frequency below the frequency of resonance, wherein the combination has a non-monotonic stroke value that includes a maxima as the length of the tip is reduced, and wherein the operational frequency of the combination approaches the frequency of resonance as the length of the tip is reduced.

18. The dental ultrasonic insert assembly according to claim 17, wherein the operational frequency is between 18 kHz and 50 kHz.

19. The dental ultrasonic insert assembly according to claim 17, wherein the transducer is piezoelectric.

20. The dental ultrasonic insert assembly according to claim 17, wherein the transducer is magnetostrictive.

21. The dental ultrasonic insert assembly according to claim 17, wherein the tip is press fitted onto the acoustic transformer.

22. The dental ultrasonic insert assembly according to claim 17, wherein the tip is an integral part of the acoustic transformer.

23. A dental ultrasonic insert assembly, comprising: a transducer defining a length substantially equal to one-half wavelength of a frequency of resonance thereof; and a combination of a tip and an acoustic transformer, the combination configured to operate at an operational frequency below the frequency of resonance and defining a length greater than one-half wavelength of the frequency of resonance; wherein the tip has a bend radius, wherein a ratio of a distance from a distal point of the tip to tangency with the bend radius is greater than 1.25, and wherein the tip defines two angles, wherein a ratio of a more-proximal of the two angles to a more-distal of the two angles is greater than 3.

24. The dental ultrasonic insert assembly according to claim 23, wherein the operational frequency is between 18 kHz and 50 kHz.

25. The dental ultrasonic insert assembly according to claim 23, wherein the transducer is piezoelectric.

26. The dental ultrasonic insert assembly according to claim 23, wherein the transducer is magnetostrictive.

27. The dental ultrasonic insert assembly according to claim 23, wherein the tip is press fitted onto the acoustic transformer.

28. The dental ultrasonic insert assembly according to claim 23, wherein the ratio of the distance is greater than 1.25 and less than 2.25.

29. The dental ultrasonic insert assembly according to claim 23, wherein the ratio of the distance is such that an output stroke remains within 25% of an initial output stroke over a reduction in a length of the tip of at least 3.0 mm.

30. The dental ultrasonic insert assembly according to claim 23, wherein the ratio of the more-proximal angle to the more-distal angle is such that an output stroke remains within 25% of an initial output stroke over a reduction in a length of the tip of at least 2.0 mm.

31. The dental ultrasonic insert assembly according to claim 23, wherein the ratio of the more-proximal angle to the more-distal angle is such that an output stroke remains within 25% of an initial output stroke over a reduction in a length of the tip of at least 3.0 mm.

32. The dental ultrasonic insert assembly according to claim 23, wherein the ratio of the more-proximal angle to the more-distal angle in combination with the ratio of the distance are such that an output stroke remains within 25% of an initial output stroke over a reduction in a length of the tip of at least 2.0 mm.

33. The dental ultrasonic insert assembly according to claim 23, wherein the ratio of the more-proximal angle to the more-distal angle in combination with the ratio of the distance are such that an output stroke remains within 25% of an initial output stroke over a reduction in a length of the tip of at least 3.0 mm.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0038] FIG. 1 is an exploded, perspective view of a magnetostrictive ultrasonic insert assembly in accordance with the present disclosure;

[0039] FIG. 2 is a side view of a magnetostrictive stack including curves depicting the relationship between the velocity and force along the length of the stack at a frequency of resonance;

[0040] FIG. 3A is a side view of a tapered acoustic transformer including curves depicting the relationship between velocity and force along its length where the frequency of operation is less than the frequency of resonance;

[0041] FIG. 3B is a side view of another tapered acoustic transformer including curves depicting the relationship between velocity and force along its length where the frequency of operation is greater than the frequency of resonance;

[0042] FIG. 4 is a side view of a one-half wavelength magnetostrictive stack coupled to a Connecting Body Tip Assembly (CBTA) which is greater than one-half wavelength of the resonant stack, as depicted by the accompanying curves;

[0043] FIG. 5 is a side view of a CBTA wherein an acoustic transformer is coupled to a tip;

[0044] FIG. 6A is a chart showing the relationship between a prior art tool and a durable performance insert in accordance with the present disclosure with comparison to Finite Element Analysis of a durable performance insert of the present disclosure;

[0045] FIG. 6B is a graph showing percent change in Tip Stroke versus Tip Wear for the prior art tool and durable performance insert in accordance with the present disclosure;

[0046] FIG. 7A is a chart showing the relationship between durability and tip angle parameters for various durable performance inserts in accordance with the present disclosure;

[0047] FIG. 7B is a graph showing percent change in Tip Stroke versus Tip Angles for the various durable performance inserts;

[0048] FIG. 8 is a side view of an insert tip illustrating including bend angles, radius of bend, and length parameters; and

[0049] FIG. 9 is a simplified graphic illustration comparing the operational stroke parameter for a prior art insert and a durable performance insert of the present disclosure using a normal curve to describe the characteristic output stroke values as the tips wear.

DETAILED DESCRIPTION

[0050] Aspects and features of the present disclosure are described herein with reference to the accompanying drawings. In the following descriptions, well known functions or constructions are summarily described or omitted entirely to avoid obscuring the present disclosure in unnecessary detail. The terms insert, insert tip, and tip are used interchangeably herein, while the term tip portion refers to a distal end portion of the insert, insert tip, or tip. In addition, the terms insert assembly, tip assembly, or insert tip assembly are used interchangeably and include, in addition to the insert, insert tip, or tip, one or more additional components (whether monolithically formed or otherwise directly or indirectly coupled with the insert, insert tip, or tip), thus forming an assembly. The assembly may itself be or may be connectable to a tool or instrument, which terms are used interchangeably as well. Further, although the aspects and features of the present disclosure are described herein, by way of example, with respect to magnetostrictive systems, it is understood that the aspects and features of the present disclosure also apply equally to piezoelectric systems.

[0051] Referring to FIG. 1, a dental ultrasonic insert 1 is configured to connect to a magnetostrictive transducer 2 to drive a free end portion (e.g., the tip portion) of the insert tip 3, at ultrasonic frequencies to facilitate treating a patient's teeth. The transducer 2 may operate in a frequency range of, for example, from 18 kHz to 50 kHz. Magnetostrictive stack assemblies (transducers), such as transducer 2, used in dental devices are unilaterally loaded, therefore, the mass of the transducer is crucial for the transmission of acoustic power. The equivalent in a piezoelectric system would be referred to as a loading mass that is used to compress the crystals (not shown). This asymmetric action by the transducer 2 is referred to as initial drive.

[0052] With continued reference to FIG. 1, the mass of the combination of the transducer 2, and combination of the acoustic transformer 4 (also referred to herein as a connecting body tip assembly (CBTA) 4) and tip 3, are supported in a nodal area 5, with nodal pin 6, captured by support sleeve 7. A grip 8 is coupled via a resilient member 9, e.g., an O-ring, to support sleeve 7. Assembly of the insert assembly 1 is completed with attachment of nose cone 10, where a resilient member 11, e.g., an O-ring, prevents fluid exit on the circumference of the exit port 12 on nose cone 10. Assembling the insert assembly 1 to a dental handpiece (not shown) is performed via insertion of support sleeve 7 into the dental handpiece, wherein a resilient member 13, e.g., an O-ring, mounted about support sleeve 7 provides a fluid seal between the insert assembly 1 and the dental handpiece while enabling 360-degree rotation of the mounted insert assembly 1.

[0053] With reference to FIG. 2, transducer 2 is shown as a stack assembly consisting of several Permanickel laminations. Transducer 2 is activated at its frequency of resonance, which is determined by its length (LS). Under these conditions, a force 15, is equal to zero at both ends 16 and 17. The velocity 14 is zero at the node N and has its maxima at both ends 16 and 17.

[0054] With reference to FIG. 3A, in aspects, a tapered acoustic transformer 18 is provided wherein the force 22 is finite, for example, greater than zero at the mesial end 20 of the acoustic transformer 18, and has a zero value at the distal end 19. The velocity 21 is a relative maxima at the distal end 19 of the acoustic transformer 18 and will become a maxima as the length of the acoustic transformer 18 approaches its half wavelength value (see FIG. 5B, as described hereinbelow). In such aspects, the magnification ratio and the nodal point are determined by the various configurations herein described and are different from values, for example, of a resonant section.

[0055] Referring to FIG. 3B, another tapered acoustic transformer 23, similar to transformer 18 of FIG. 3A, is shown wherein the force 26 on the acoustic transformer 23 is finite at the mesial end 25, for example, less than zero, and velocity 27 is a relative maxima at the distal end 24.

[0056] Referring to FIG. 4, connecting body-tip assembly (CBTA) 4 and transducer 2 (also referred to as stack assembly 2) are shown attached at the mesial junction 28 of the combination, wherein force 22 is substantially zero at the distal end 29 of tip 3 and substantially zero at distal end of transducer 2, and has a finite value, for example greater than zero at the junction 28 of transducer 2 and CBTA 4. The velocity value crosses zero in the nodal area 5 on CBTA 4 and at the nodal area N (see FIG. 2) on transducer 2.

[0057] With continued reference to FIG. 4, the finite value of force 22 at the mesial junction 28 of the configuration depicts a frequency of the connecting body tip assembly 4 to be less than the resonant frequency of the transducer 2. In this configuration, the velocity 21 has relative maxima at the distal end 17 of the transducer 2 and the distal end 29 of the tip 3. These velocities approach their maxima as the tip or distal portion of the tip 3 wears (from the distal end 29) during clinical use and the frequency of the combination transducer 2 and connecting body tip assembly 4 approach resonance.

[0058] In some aspects, the present insert assembly includes a transducer defining a frequency of resonance; an acoustic transformer; and a tip coupled to a distal portion of the acoustic transformer, where a mesial portion of a combination of the acoustic transformer and the tip is coupled to the transducer, and wherein an operational frequency of the combination is not equal to the frequency of resonance of the transducer, e.g., wherein, at a full length of the tip, a force at a junction of the transducer and the acoustic transformer is finite, and wherein, at a reduced length due to an amount of wear of the tip, the force is substantially zero and an output stroke of the tip is substantially at a maximum.

[0059] In some aspects, for example, the operational frequency at the reduced length is coincident with the frequency of resonance. In additional or alternative aspects, the wear is greater than 1 mm and/or greater than 0 mm and less than 4 mm. In aspects, at the full length, the operational frequency of the combination of the acoustic transformer and tip is less than the frequency of resonance of the transducer. In aspects, the tip is press fitted onto the acoustic transformer, connected by threaded engagement, or is an integral part of the acoustic transformer. In aspects, at the full length, the operational frequency of the combination of the acoustic transformer and the tip is greater than the frequency of resonance of the transducer.

[0060] Referring to FIG. 5, insert tip 3 is shown wherein the mass of the insert tip 3 is increased by making it longer (e.g., defining a length L2, in combination with the length of acoustic transformer 4, that is greater than a length of insert tip 3 shown in FIG. 4, for example), wherein the operational frequency is lowered and force at the mesial end 28 is finite when operated in the configuration described above with respect to FIG. 4. In aspects, the operational frequency may be higher than the frequency of resonance. The connecting body tip assembly 4 may be configured to attach to form the insert assembly 1 (FIG. 1), as detailed above, via nodal pin 6 (FIG. 1) through a nodal port 5′ located within the nodal area L3. Attachment to form other suitable insert assemblies are also contemplated. In some embodiments, L2 is greater than

[00003]$\frac{n\lambda }{4}$

at resonance, wherein n can be 1 or 2.

[0061] With reference to FIG. 6A, the response of the output tip stroke for an ultrasonic dental insert configured in accordance with the present disclosure, and that of a prior art insert, are shown. The inserts and insert assemblies in accordance with the present disclosure provide a percent change in actual stroke 31 that initially increases over a first portion of tip wear 29 (e.g., from 0.0 mm to about 3.0 mm) and then decreases back towards the initial level over a second portion of tip wear 29 (e.g., for tip wear greater than 3.0 mm). The percent change in tip stroke versus tip wear for a prior art insert 32, wherein the response is monotonic, is contrasted with a Finite Element Analysis (FEA) 30 of an insert of the present disclosure shown in FIG. 1, which is nonmonotonic, and the actual results 31 of an insert of the present disclosure.

[0062] Referring to FIG. 6B, a graphical representation 34 of the data in FIG. 6A is shown. The plot of percent change in stroke for FEA 46 wherein the frequency of the acoustic transformer is less than the frequency of the transducer depicts essentially a nonmonotonic stroke change, e.g., change less than or equal to 10%, between 0 wear and 1.5 mm wear. The change in stroke increases between 1.5 mm wear and 3.0 mm wear, with a decrease after 3.0 mm wear. The change in stroke for a durable performance tip of the present disclosure, based on actual data, e.g., recorded on a microscope, shows a similar response 47.

[0063] Further reference to FIG. 6B illustrates a contrast between the stroke response of the inserts of the present disclosure and the actual stroke response for a prior art ultrasonic tool 48, wherein the prior art tool response 48 has a substantially monotonic decrease in stroke under the full range of tip wear (e.g., a percent change in stroke of −20% at approximately 1 mm wear).

[0064] In aspects, the insert assembly includes a transducer having a frequency of resonance and defining a length substantially equal to a frequency of resonance; wherein the length is defined by a

[00004]$\frac{n\lambda }{4}$

section, where n=1 or 2, and an acoustic transformer; and a tip extending distally from the acoustic transformer, wherein a combination of the acoustic transformer and the tip is configured to operate at an operational frequency below the frequency of resonance, and wherein the combination defines a length greater than

[00005]$\frac{n\lambda }{4}$

of the frequency of the transducer, where n=1 or 2, e.g., wherein the operational frequency of the combination approaches the frequency of resonance as a length of the tip is reduced from a full length.

[0065] In aspects, for example, the operational frequency is between 18 kHz and 50 kHz.

[0066] In aspects, the combination of the transducer, acoustic transformer and tip are configured to operate at an operational frequency below the frequency of resonance, e.g., wherein the combination has a non-monotonic stroke value that includes a maxima as the length of the tip is reduced, and wherein the operational frequency of the combination approaches the frequency of resonance as the length of the tip is reduced, such as wherein the operational frequency is between 18 kHz and 50 kHz, and the transducer is piezoelectric or magnetostrictive.

[0067] FIG. 7A shows a chart 35 of results for further aspects of inserts of the present disclosure wherein the combination of the contra bend and terminal bend angles are controlled, as is the ratio of the terminal angle to terminal tip length in the presence of finite forces at the mesial end of the acoustic transformer, to produce a non-monotonical output stroke (see FIG. 7B). More specifically, tip wear is provided in column 36 and indicated for each of a first column 37 that provides results where the terminal angle is 65 degrees and the contra angle is 10 degrees; a second column 38 that provides results where the terminal angle is 60 degrees and the contra angle is 15 degrees; a third column 39 that provides results where the terminal angle is 70 degrees and the contra angle is 10 degrees; and a fourth column 40 that provides results where the terminal angle is 70 degrees and the contra angle is 15 degrees.

[0068] With reference to FIG. 7B, a graph is shown depicting the relationship between terminal bend angles. Tip wear is shown over a range of 0 to 4.0 mm, wherein the percent change graphs 42, 43, 44, and 45, are plotted versus tip wear. The percent stroke change graphs 42, 43, 44, and 45 correspond to the configurations detailed above with respect to columns 39, 37, 40, and 38, respectively. As shown, changes in the contra angle with a constant terminal angle, e.g., as shown by comparison of graphs 42 and 44 and/or columns 39 and 40, provide a moderate increase in stroke range versus tip wear. A similar change in the terminal angle, e.g., as shown by comparison of graphs 43 and 45 and/or columns 37 and 37, has a greater effect on the stroke level than the stroke range.

[0069] Referring to FIG. 8, the tip 3 is shown defining a geometry including a contra bend α2, a terminal bend α1, and a straight section LL1 located in the distal third of the tip 3. The point of the tip 3 is located a distance LL2 from the centerline CL, and a distance LL3 from a proximal end of the tip 3. The inside edge of the tip 3 is defined by radius R1. Analysis of the variation of α1 and α2 in combination are detailed herein with reference to FIGS. 7A and 7B.

[0070] In aspects, the insert assembly includes a transducer defining a length substantially equal to

[00006]$\frac{n\lambda }{4}$

at a frequency of resonance thereof, where n=1 or n=2, and a combination of a tip and an acoustic transformer, wherein the combination is configured to operate at an operational frequency below the frequency of resonance, e.g., wherein the tip has a bend radius, wherein a ratio of a distance from a distal point of the tip to tangency with the bend radius is greater than 1.25, and wherein the tip defines two angles, wherein a ratio of a more-proximal of the two angles to a more-distal of the two angles is greater than 3.

[0071] In aspects, the ratio of the distance is greater than 1.25 and less than 2.25.

[0072] In aspects, the ratio of the more-proximal angle to the more-distal angle is such that an output stroke remains within 25% of an initial output stroke over a reduction in a length of the tip of at least 2.0 mm.

[0073] In aspects, the ratio of the distance is such that an output stroke remains within 25% of an initial output stroke over a reduction in a length of the tip of at least 3.0 mm.

[0074] In aspects, the ratio of the more-proximal angle to the more-distal angle is such that an output stroke remains within 25% of an initial output stroke over a reduction in a length of the tip of at least 2.0 mm.

[0075] In aspects, the ratio of the more-proximal angle to the more-distal angle is such that an output stroke remains within 25% of an initial output stroke over a reduction in a length of the tip of at least 3.0 mm.

[0076] In aspects, the ratio of the more-proximal angle to the more-distal angle in combination with the ratio of the distance are such that an output stroke remains within 25% of an initial output stroke over a reduction in a length of the tip of at least 2.0 mm.

[0077] In aspects, the ratio of the more-proximal angle to the more-distal angle in combination with the ratio of the distance LL1 are such that an output stroke remains within 25% of an initial output stroke over a reduction in a length of the tip of at least 3.0 mm.

[0078] With reference to FIG. 9, two normal curves 56 and 57 are shown, one for a prior art tip and the other for a tip in accordance with the present disclosure. The prior art curve 56 has a horizontal line 49 with length LLL3 representing 1 mm wear, and a second horizontal line 52 with LLL4 representing 2 mm wear. Vertical line 54 bisects curve 56 and shows a solid line segment 50 to the right of line 54. The intersection of solid line segment 50 with line 49 represents a point of approximately 25% reduction in output stroke. The dashed continuation of line segment 50 intersects line 52, which represents approximately 50% reduction in output stroke for the prior art insert. The stroke versus wear starts at the stroke maxima, for example, of the prior art insert and is located in its entirety to the right of line 54, wherein the output stroke decreases monotonically as the tip wears. This graphical representation shows that the prior art provides the current standard of care over approximately 1 mm of wear.

[0079] With continued reference to FIG. 9, normal curve 57 shows the output stroke versus wear characteristics for a durable ultrasonic insert in accordance with the present disclosure, e.g., as shown in FIGS. 1-5 and 8 and/or as described herein. Horizontal line 53 relates the two normal curves 56 and 57, showing a non-limiting example of crossing curve 56 at approximately 90% of its maximum value. Vertical line 55 intersects line 53 at the point of initial stroke value for an example durable ultrasonic insert of the present disclosure. Length LLL5 represents the distance from the intersection of lines 53 and 55 to the maximum value for curve 57. The solid line segment 51 represents the output stroke versus tip wear, whereas length LLL6 represents the loss of tip length where the output stroke is approximately equal to the initial value. Graph 57 points out the inherently different characteristics of the prior art inserts shown in graph 56 wherein the solid line segment 51 for the durable performance inserts of the present disclosure lies substantially on both sides of the maximum value showing a non-monotonic stroke as the tip wears. Graph 57 also demonstrates an advantage of an increased service life for the durable performance insert, in part, based on the ratio of LLL6:LLL3. In some embodiments, the LLL6:LLL3 ratio is greater than about 1, such as, for example, greater than about 1.5, greater than about 2, greater than about 3, or even greater than about 4.

[0080] Referring still to FIG. 9, the increased width of graph 57 compared to graph 56 is a result of the physical characteristics of the inserts and insert assemblies 1 (FIG. 1) of the present disclosure, e.g., as shown in FIGS. 1-5 and 8 and/or as described herein, as well as the gain of the combination of the transducer 2, acoustic transformer 4, and tip 3 (see FIGS. 4 and 8), as is detailed herein.

[0081] It should be understood that various aspects disclosed herein may be combined in different combinations than the combinations specifically presented in the description and accompanying drawings.