Navigated Malleable Surgical Instrument

Abstract

A surgical instrument is disclosed having an elongated body portion having a proximal end and a distal end. The body portion is formed from a plastically deformable material such that the body portion can be bent between the proximal and distal ends from a first configuration to a second bent configuration and maintains the bent configuration. A flexible circuit having at least a pair of lead wires disposed around the body portion. The pair of lead wires are configured to conform to the bent configuration of the body portion such that they do not break during bending of the body portion. A tracking device adapted to cooperate with a navigation system to track the distal end of the instrument is coupled to the flexible circuit.

What is claimed is: 
     
         1 . A surgical instrument, comprising:
 an elongated body extending from a proximal end to a distal end, the elongated body is tubular-shaped and has a first internal passage extending between the proximal end and the distal end;   a handle coupled to the proximal end of the elongated body, the handle having a second internal passage in fluid communication with the first internal passage; and   a first tracking coil positioned adjacent to the distal end of the elongated body, the first tracking coil extending between a first end and a second end and having an overall non-linear shape to conform to a surface of the elongated body, wherein a diameter of the first tracking coil between the first and second ends is different from a diameter at the first and second ends to maximize an amount of coil windings while minimizing a dimension of the elongated body.   
     
     
         2 . The surgical instrument of  claim 1 , wherein the dimension is an outer diameter of the elongated body or an inner diameter of the elongated body. 
     
     
         3 . The surgical instrument of  claim 1 , wherein:
 the first tracking coil is disposed on an exterior surface of the elongated body;   the first tracking coil has a first side and a second side, which extend between the first and second ends of the first tracking coil;   the first side opposes the second side;   the first side has a concave shape that matches a convex shape of the exterior surface of the elongated body;   the second side has a planar shape; and   the first tracking coil includes more windings at the first and second ends of the first tracking coil than at a center of the first tracking coil.   
     
     
         4 . The surgical instrument of  claim 1 , wherein:
 the first tracking coil is disposed on an interior surface of the elongated body;   the first tracking coil has a first side and a second side, which extend between the first and second ends of the first coil;   the first side opposes the second side;   the first side has a convex shape that matches a concave shape of the interior surface of the elongated body;   the second side has a planar shape; and   the first tracking coil has more windings at a center of the first tracking coil than at the first and second ends of the first tracking coil.   
     
     
         5 . The surgical instrument of  claim 1 , wherein the elongated body includes a tubular insert at the distal end and a sleeve configured to be received over the insert, wherein the first tracking coil is coupled to the sleeve adjacent to the distal end thereof. 
     
     
         6 . The surgical instrument of  claim 1 , further comprising a pair of lead wires helically wound around the elongated body from the first tracking coil to the handle. 
     
     
         7 . The surgical instrument of  claim 6 , further comprising a printed circuit board positioned adjacent the first tracking coil, wherein the printed circuit board is configured to couple the pair of lead wires to the first tracking coil. 
     
     
         8 . The surgical instrument of  claim 1 , further comprising a second tracking coil positioned adjacent the distal end of the elongated body, the second tracking coil extending between a first end and a second end and having an overall non-linear shape to conform to a surface of the elongated body, wherein a diameter of the second tracking coil between the first and second ends is different from a diameter at the first and second ends of the second tracking coil to maximize an amount of coil windings while minimizing the dimension of the elongated body. 
     
     
         9 . The surgical instrument of  claim 1 , wherein the first tracking coil is wrapped around a core and mounted adjacent to the distal end of the elongated body. 
     
     
         10 . A surgical instrument, comprising:
 a body having a proximal end and a distal end, wherein the body is tubular-shaped and has an internal passage extending between the proximal end and the distal end;   an insert received in the distal end of the body;   a sleeve received over the insert at the distal end of the body; and   a tracking coil positioned on an exterior surface of the sleeve, the tracking coil extending between a first end and a second end and having a first side and a second side, the first side opposes the second side and the first side has a concave shape that matches a convex shape of the exterior surface of the sleeve, the second side has a planar shape, wherein the tracking coil has more windings at the first and second ends of the tracking coil than at the center of the tracking coil.   
     
     
         11 . The surgical instrument of  claim 10 , wherein the body is formed from a malleable material such that the body can be bent between the proximal and distal ends from a first configuration to a second bent configuration. 
     
     
         12 . The surgical instrument of  claim 11 , wherein the insert prevents bending or flexing in a region where the insert is received in the distal end of the body and wherein the insert provides rigid support for the sleeve to prevent bending of the sleeve. 
     
     
         13 . The surgical instrument of  claim 10 , wherein the distal end of the body includes an annular recess defining an internal shoulder and the insert is partially received within the distal end in the annular recess engaging the internal shoulder. 
     
     
         14 . The surgical instrument of  claim 13 , wherein the sleeve is adjacent to and not in contact with the distal end of the body when positioned on the insert. 
     
     
         15 . The surgical instrument of  claim 12 , further comprising a printed circuit board positioned at the distal end where the insert is received in the body to prevent bending or flexing of the printed circuit board. 
     
     
         16 . A surgical instrument, comprising:
 a body having a proximal end and a distal end, wherein the body is tubular-shaped and has a first internal passage extending between the proximal end and the distal end;   an insert received in the distal end of the body;   a sleeve received over the insert at the distal end of the body; and   a tracking coil positioned on an interior surface of the sleeve, the tracking coil extending between a first end and a second end and having a first side and a second side, the first side opposing the second side and the first side has a convex shape that matches a concave shape of the interior surface of the sleeve, the second side has a planar shape, wherein the tracking coil has more windings at a center of the tracking coil than at the first and second ends of the tracking coil.   
     
     
         17 . The surgical instrument of  claim 16 , wherein the insert prevents bending or flexing in a region where the insert is received in the distal end of the body and wherein the insert provides rigid support for the sleeve to prevent bending of the sleeve, wherein the distal end of the body includes an annular recess defining an internal shoulder and the insert is partially received within the distal end in the annular recess engaging the internal shoulder. 
     
     
         18 . The surgical instrument of  claim 16 , further comprising a handle coupled to the proximal end of the body, wherein the handle includes a second internal passage extending through the handle and in fluid communication with the first internal passage. 
     
     
         19 . The surgical instrument of  claim 18 , further comprising a pair of lead wires wound around the body from the tracking coil to the handle. 
     
     
         20 . The surgical instrument of  claim 16 , wherein the tracking coil is wrapped around a core.