ULTRASONIC SURGICAL INSTRUMENT WITH PROBE AT ANGLE TO HANDPIECE

Abstract

An ultrasonic surgical instrument includes a handpiece casing and an electromechanical transducer assembly disposed inside the handpiece casing, where the transducer assembly includes a front driver and the transducer assembly has a longitudinal axis. A probe is operatively connected to the front driver at an acute angle to the longitudinal axis of the transducer assembly. A sheath surrounds the probe and is connected at a proximal end to the handpiece casing. The sheath is attached to the casing by a twist quick release coupling. A diaphragm seal inside the proximal end of the sheath blocks liquid irrigant in a cylindrical space between the sheath and the probe from penetrating proximally of a port feeding irrigant to the space. The front driver is geometrically configured to enable an angled connection of probe to handpiece proximate a nodal plane.

Claims

1. An ultrasonic surgical instrument comprising: a handpiece casing; an electromechanical transducer assembly disposed inside said handpiece casing, said transducer assembly including a front driver, said transducer assembly having a longitudinal axis; a probe operatively connected to said front driver at an acute angle to said longitudinal axis, said probe having a distal end provided with an end effector; a sheath surrounding said probe and connected at a proximal end to said handpiece casing, said end effector extending distally of a distal tip of said sheath, said sheath being provided at a proximal end with an annular sealing member engaging a distal surface of said handpiece casing; and at least two first closure elements and a like number of second closure elements, said at least two first closure elements being provided on one of said distal surface of said handpiece casing and said proximal end of said sheath, said second closure elements being disposed on the other of said distal surface of said handpiece casing and said proximal end of said sheath, said at least two first closure elements each taking the form of a projection extending in a radial direction, said second closure elements each taking the form of an annular open channel having one tapered end defined by a camming surface.

2. The ultrasonic surgical instrument defined in claim 1 wherein said annular sealing member is made of a resiliently compressible material, said at least two first closure elements and said second closure elements being configured to frictionally lock said sheath to said handpiece casing by compression of said annular sealing member.

3. The ultrasonic surgical instrument defined in claim 2 wherein said handpiece casing is fastened to said sheath by only one locking mechanism, said only one locking mechanism comprising said annular sealing member, said at least two first closure elements, and said second closure elements.

4. The ultrasonic surgical instrument defined in claim 1 wherein said projections are annular ribs extending in a plane transverse to an axis of said sheath.

5. The ultrasonic surgical instrument defined in claim 1 wherein said camming surface is located along a distal side of said annular open channel and faces in a proximal direction towards said handpiece casing.

6. The ultrasonic surgical instrument defined in claim 1 wherein said probe is connected to said front driver in close proximity to a nodal plane.

7. An ultrasonic surgical instrument comprising: a handpiece casing; an electromechanical transducer assembly disposed inside said handpiece casing, said transducer assembly including a front driver, said transducer assembly having a longitudinal axis; a probe operatively connected to said front driver at an acute angle to said longitudinal axis, said probe having a distal end provided with an end effector; a sheath surrounding said probe and connected at a proximal end to said handpiece casing, said end effector extending distally of a distal tip of said sheath, said sheath being provided proximate the proximal end with a port connectable to a source of pressurized liquid coolant for flowing said pressurized liquid coolant into a tubular space between said probe and an inner surface of said sheath; and a diaphragm seal disposed inside said proximal end of said sheath proximally of said port, said diaphragm seal having an annular outer surface in liquid-tight contact with said inner surface of said sheath, said diaphragm being provided at a distal end with an annular inwardly extending flange circumferentially engaging an outer surface of said probe in a liquid-tight seal.

8. The ultrasonic surgical instrument defined in claim 7 wherein said diaphragm is provided at a proximal end with an annular outwardly extending flange clamped between a proximal end surface of said sheath and a distal end surface of said handpiece casing.

9. The ultrasonic surgical instrument defined in claim 7 wherein said diaphragm is spaced from said probe except at said annular inwardly extending flange.

10. The ultrasonic surgical instrument defined in claim 7 wherein said sheath has a main body at a proximal end made of rigid material, said sheath further comprising a distal end portion made of silicone polymer.

11. The ultrasonic surgical instrument defined in claim 7 wherein said front driver has two mutually parallel planar outer surfaces extending parallel to the longitudinal axis of said transducer assembly, each of said two mutually parallel planar outer surfaces being contiguous with said first cylindrical outer surface and said second cylindrical outer surface.

12. The ultrasonic surgical instrument defined in claim 7 wherein said handpiece casing is formed at a distal end with a cylindrical first internal surface coaxial with the longitudinal axis of said transducer assembly and further formed with a cylindrical second internal surface coaxial with the longitudinal axis of said probe.

13. The ultrasonic surgical instrument defined in claim 7 wherein said probe is connected to said front driver in close proximity to a nodal plane.

14. An ultrasonic surgical instrument comprising: a handpiece casing; an electromechanical transducer assembly disposed inside said handpiece casing, said transducer assembly including a front driver having an internally threaded receptacle at a distal end, said transducer assembly having a longitudinal axis; a tubular member connected to a proximal side of said transducer assembly, said tubular member and said front driver defining a lumen of a uniform cross-section extending axially to a proximal end of said internally threaded receptacle; a probe operatively connected to said front driver at an acute angle to said longitudinal axis, said probe having a distal end provided with an end effector, said probe having a longitudinal bore, said internally threaded receptacle receiving an externally threaded proximal end connector of said probe, said internally threaded receptacle having a proximal end surface disposed at said acute angle relative to said longitudinal axis; and said lumen and said bore together defining a flow channel, said flow channel having no shoulder facing in a distal direction at a junction of said lumen and said bore.

15. The ultrasonic surgical instrument defined in claim 14, further comprising a sheath surrounding said probe and connected at a proximal end to said handpiece casing, said end effector extending distally of a distal tip of said sheath.

16. The ultrasonic surgical instrument defined in claim 1 wherein said probe is connected to said front driver in close proximity to a nodal plane.

17. (canceled)

18. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] FIG. 1 is a side elevational view of an ultrasonic surgical instrument in accordance with the present invention.

[0027] FIG. 2 is a longitudinal cross-sectional view taken parallel to the plane of the drawing in FIG. 1.

[0028] FIG. 3 is a longitudinal cross-sectional view coplanar with the view of FIG. 2, showing a probe and a transducer array that is located within a handpiece casing shown in FIGS. 1 and 2.

[0029] FIG. 4 is a front, side and top perspective view of the operative structures shown in FIG. 3, namely, the probe and the transducer array, as well as a proximal end cap assembly of the handpiece casing.

[0030] FIG. 5 is a partial longitudinal cross-sectional view, on an enlarged scale, of portion V of FIG. 3, showing a probe-to-transducer coupling.

[0031] FIG. 6 is longitudinal cross-sectional view of a front driver of the transducer array.

[0032] FIG. 7 is a side elevational view of the handpiece casing of FIGS. 1 and 2.

[0033] FIG. 8 is a front elevational view of the handpiece casing of FIGS. 1, 2, and 7.

[0034] FIG. 9 is a top, side and front perspective view of the handpiece casing of FIGS. 1, 2, 7, and 8.

[0035] FIG. 10 is a partial longitudinal cross-sectional view, on an enlarged scale, of portion X of FIG. 2, showing a diaphragm seal and a sheath-to-casing coupling.

[0036] FIG. 11 is a side elevational view of a cradle holding the ultrasonic instrument of FIGS. 1 and 2 in an orientation for manually attaching the probe (e.g., FIGS. 3, 4) to the handpiece casing.

[0037] FIG. 12 is a top, front and side partially exploded perspective view of the ultrasonic instrument of FIGS. 1 and 2, showing the handpiece supported in the cradle of FIG. 11 and the probe positioned for attachment.

[0038] FIG. 13 is a top, front and side perspective view of the assembled ultrasonic instrument of FIGS. 1 and 2 after attachment of the probe to the handpiece casing.

[0039] FIG. 14 is a top, front and side perspective view of the cradle and instrument of FIG. 13, also showing a wrench for torquing the probe to the handpiece, or for loosening the probe for removal from the handpiece.

[0040] FIG. 15 is a transverse cross-sectional view taken along line XIII-XIII in FIG. 1.

DETAILED DESCRIPTION

[0041] As illustrated in FIGS. 1 and 2, an ultrasonic surgical instrument comprises a handpiece casing 10 and an electromechanical transducer assembly 12 disposed inside the casing, where the transducer assembly includes a front driver 14 and has a longitudinal axis 16 (FIGS. 3 and 5). The instrument further comprises a probe 18 typically made of a metal alloy and operatively connected to front driver 14 at an acute angle exemplarily of 20° to longitudinal axis 16 of transducer assembly 12. Transducer assembly 12 is preferably positioned symmetrically within casing 10 so that axis 16 serves also as a longitudinal axis of symmetry of the casing. Probe 18 has a distal end (not separately designated) provided with an end effector 20 such as a bone-cutting blade (not illustrated) or a debriding head (shown). A sheath 22 surrounds probe 18 except for end effector or operative head 20 and is connected at a proximal end to handpiece casing 10. End effector or operative head 20 extends distally of a distal tip 24 of sheath 22.

[0042] Transducer assembly 12 has a structure well-known in the art and basically includes, as illustrated in FIGS. 2 and 3, a number of annular piezoelectric disks 26 and thinner annular metal electrodes 28 disposed in a linear array about longitudinal axis 16 and sandwiched between front driver 14 on a distal side and a rear driver 30 on a proximal side. Electrodes 28 are connected to an ultrasonic electrical waveform generator (not shown) whereby the piezoelectric disks undergo alternating expansion and contraction in parallel with the transducer axis 16 to generate an ultrasonic standing wave in probe 18, thereby reciprocating end effector or operative head 20 at a predetermined ultrasonic frequency.

[0043] A tubular member 32 coaxial with transducer axis 16 traverses transducer assembly 12 and terminates at a proximal end surface 34 of an internally threaded receptacle 36 provided on a distal end of front driver 14 for receiving an externally threaded connector 38 at a proximal end of probe 18. Proximal end surface 34 is disposed at the acute probe-transducer angle (20°) relative to transducer axis 16. Tubular member 32 serves as a liquid guide channel. Where end effector 20 is a debriding head, tubular member 32 conducts a slurry of irrigant and organic particles away from a surgical site to a debris collector or trap (not shown) and a suction source (not shown). At a proximal end, tubular member 32 is connected to, and passes through, an end cap assembly 40 and carries a fitting 42 for coupling a hose (not shown) that extends to the debris collector. End cap assembly 40 carries an electrical connector 43 for coupling a cable (not shown) from an ultrasonic waveform generator (not shown).

[0044] As depicted in FIGS. 2-4 and 6, front driver 14 has an outwardly projecting annular flange 44 (with an O-ring seal 44′) at a proximal end and is formed at its distal end with a first cylindrical outer surface 46 coaxial with transducer axis 16. Front driver 14 is further formed with a second cylindrical outer surface 48 at the distal end on a side opposed to cylindrical outer surface 44. Second cylindrical outer surface 48 is coaxial with a longitudinal axis 49 of probe 18. Axes 16 and 49 intersect one another at the probe-transducer angle of 20°. Front driver 14 has two mutually parallel planar outer surfaces or flats 50 and 52 extending parallel to transducer axis 16, each being contiguous with cylindrical outer surfaces 46 and 48 along respective edges or intersection loci 54, 56, 58, 60 (see FIGS. 8 and 9). Front driver 14 further exhibits a trio of mutually contiguous faces or surfaces 62 (FIG. 4), one planar and two cylindrically arcuate, extending between annular flange 44 at a proximal end and inclined cylindrical surface 48 at a distal end.

[0045] As best seen in FIG. 6, handpiece casing 10 is formed at a distal end with a cylindrical first internal surface 64 coaxial with transducer axis 16 and a cylindrical second internal surface 66 coaxial with probe axis 49. These surfaces 64 and 66 are disposed in close juxtaposition and mutually parallel relation to front-driver outer surfaces 46 and 48, respectively.

[0046] With respect to a coupling of sheath 22 to handpiece casing 10, the sheath is provided at a proximal end with an annular sealing member 96 (FIG. 10) engaging a distal surface 70 (FIGS. 8 and 9) of handpiece casing 10. As described below, sealing member 96 may be implemented as an annular outwardly extending flange of a diaphragm seal 92, when liquid irrigant is fed to a space 88 between sheath 22 and probe 18.

[0047] Sheath 22 is provided at a proximal end with a pair of closure or locking elements in the form of two inwardly and radially projecting arcuate flanges or ribs 72 and 74 (FIG. 10) extending in a plane transverse to an axis of the sheath (typically, but not necessarily, probe axis 49). Concomitantly, handpiece casing 10 is formed at its distal end with a cooperating pair of closure or locking elements in the form of two annular open channels or grooves 76, 78 (see FIG. 6) each having one end that is tapered and defined by a respective camming surface 80. Camming surfaces 80 are located along distal sides of the respective annular open channels 76 and face in a proximal direction towards handpiece casing 10.

[0048] At least two cooperating sets of closure elements 72, 74 and 76, 78 are disposed on sheath 22 and handpiece casing 10, although three or more may be provided. Annular sealing member 96 is made of a resiliently compressible material such as silicone rubber which exhibits a suitable surface coefficient of friction. Closure elements 72, 74, 76 are mutually configured to frictionally lock sheath 22 to handpiece casing 10 by compression of annular sealing member 96. The locking and the unlocking of sheath 22 to handpiece casing 10 are accomplished by twisting the sheath in opposed angular directions (clockwise, counter-clockwise) relative to the handpiece. Thus the camming mechanism comprising flanges 72 and 74 and respective camming surfaces 80 enables not only a compression-enhanced frictional lock but also enables a quick coupling of sheath 22 to handpiece 10, and a quick de-coupling as well. Thus, handpiece casing 10 may be fixed to sheath 22 by a single locking mechanism consisting of annular sealing member 96, the first closure elements 72 and 74, and the second closure elements 78, 80. Where no liquid irrigant is delivered between sheath 22 and probe 18, sealing member may have a lobed form, in the manner of a clover leaf, or may have a simple circular geometry.

[0049] As shown in FIGS. 1 and 2, sheath 22 has two parts, a proximally located main body 82 made of rigid polymeric material and a tapered distal end portion 84 made of a flexible or resilient material such as silicone polymer. Sheath 22 is provided proximate the proximal end with a port or fitting 86 connectable to a source of pressurized liquid coolant (not illustrated) for flowing the coolant into tubular space 88, between probe 18 and an inner surface 90 of the sheath. As shown in FIGS. 2 and 10, diaphragm seal 92 is disposed inside the proximal end of sheath 22 proximally of port or fitting 86. Diaphragm seal 92 has an annular outer surface 93 disposed along inner surface 90 of sheath 22 and is provided at a distal end with an annular inwardly extending flange 94 that circumferentially engages an outer surface (not separately designated) of probe 18 in a liquid-tight seal.

[0050] Diaphragm seal 92 has an annular geometry that conforms to the geometry of sheath inner surface 90 at the proximal end of the sheath. Diaphragm seal 92 is preferably spaced in its entirety from probe 18 except at annular inwardly extending flange 94. Diaphragm seal 92 serves to eliminate the painful or distracting sensation that occasionally occurs when a user grasps the proximal end portion of the sheath, as described above. Diaphragm seal 92 is further formed at a proximal end with the annular outwardly extending flange that serves as sealing member 96, clamped between a proximal end surface (not separately referenced in the drawings) of the sheath and distal end surface 70 (FIGS. 6 and 8-10) of handpiece casing 10.

[0051] As described above, tubular member 32 extends through transducer assembly 12 to a proximal end surface 34 of threaded receptacle 36. Tubular member 32 has a lumen 100 with a uniform cross-section including at a distal end opening 102 in the plane of receptacle end surface 34. Probe 18 has a longitudinal bore or channel 98 with a proximal end opening 104 of smaller cross-section than that of distal end opening 102 or tubular member 32. Probe bore 98 is aligned with distal end opening 102 of tubular member 32. Lumen 100 and bore or channel 98 together define a continuous passageway that has no shoulder facing in a distal direction at a junction of the tubular member 32 and probe bore 98.

[0052] As illustrated in FIGS. 11-14, a cradle 106 for use in manually attaching probe 18 to handpiece casing 10 at an acute angle (e.g., 20°) relative to transducer or handpiece axis 16 comprises a right rectangular prismatic container or frame 108 with an open upper side 110 and a support 112 such as a surface or a cross-bar inside the frame holding the handpiece casing at the acute angle relative to a bottom 114 of the frame. The container or frame 108 is placed on a horizontal surface such as a table top (not shown) with bottom 114 in contact with the horizontal surface. Container or frame 108 is provided with a stabilizer rod or bar 118 that extends outwardly from the container on opposite sides thereof. Stabilizer rod 118 is located with its underside (not separately enumerated) in the plane of cradle bottom 114.

[0053] In attaching probe 18 to handpiece casing 10, a user manually screws connector 38 of the probe into receptacle 36. This step may be performed after, but preferably before, the placement of handpiece casing 10 into container or frame 108. Frame 108 has a wall 116 at one end, which serves as a stop engageable with a front or distal end of handpiece casing 10. Wall or stop 116 has a slot 122 which receives a distal end portion of front driver 14, which projects outside of casing 10 (see also FIGS. 8 and 9). Slot 122 allows user access to front driver 14. To tighten probe 18 onto front driver 14 and therefore to casing 10, one pivots a torque wrench 120 (FIG.

[0054] 14) about probe axis 49 while pressing casing 10 and cradle 108 against the horizontal table top. Stabilizer rod 118 facilitates the application of torque. Wrench 120 is of the kind with a torque detector that automatically arrests further rotation of the wrench about attainment of a preselected amount of torque.

[0055] An ultrasonic surgical instrument pursuant to the present invention provides for safe and effective removal of hard tissue such as bone in minimally invasive surgery, under microscope or loop magnification, where the operative end of the instrument is inserted through a tubular retractor or cannula with an internal diameter as small as 18 mm and a probe length of up to 80 mm. The instrument is utilizable with other kinds of retractors. An ultrasonic surgical instrument pursuant to the present invention may have an external diameter in the tissue access area of less than 10 mm, with an instrument working length of up to 165 mm. The angled design (20°) provides a direct line of sight to the instrument distal end compatible with a microscope setup (microscope focal length approx. 300 mm)

[0056] An ultrasonic surgical instrument pursuant to the present invention preferably has a combined handpiece and probe length suitable for a full wave (two half-waves) operation at a frequency of approximately 23 KHz, with the angled transition located at approximately ¼-wave length from the proximal end of the handpiece. Thus the resonator assembly may consist of a ¼ wave handpiece and a ¾ wave probe, where the probe connected proximate to the first nodal plane.

[0057] The present invention contemplates a viable ultrasonic handpiece-probe assembly with the probe connected to the handpiece at an acute angle in close proximity to a nodal plane. In contrast, the prior art (see U.S. Pat. No. 5,222,937) teaches that an angled connection must be located at an anti-note (loop). Where the handpiece is not angled, the angled feature must occur with the length of the probe or else an angled adaptor must be provided. As set forth in U.S. Pat. No. 5,222,937, a connection at a loop (i.e., anti-node) is necessary to avoid breakage of the “screw-connected portion.” It is noted that the motional amplitudes of the present instrument are within the same range (100-300 μm) as the prior art and the assembly does not fracture.

[0058] As illustrated in FIG. 15, sheath 22 is provided along inner surface 90 with at least one circular array of circumferentially spaced projections or nubs 124 extending inwardly from surface 90 to the probe 18 to ensure separation or spacing of the sheath and the probe from one another while enabling irrigant flow in a distal direction from port or fitting 86 to distal sheath tip 24. The array of circumferentially spaced projections 124 is positioned proximate to the second nodal plane of the transducer-probe ultrasonic resonator.

[0059] Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed invention. Accordingly, it is to be understood that the drawings and descriptions herein are proffered by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof.