Ultrasonic surgical handpiece assembly

Abstract

The present disclosure relates to an ultrasonic surgical handpiece assembly comprising a surgical handpiece for use with an irrigation sleeve and ultrasonic tip. The surgical handpiece may comprise a piezoelectric transducer disposed within a housing and configured to manipulate the ultrasonic tip. One or more lumens and/or a flex circuit including an antenna may be disposed within the surgical handpiece housing. The lumen(s) may be configured to provide irrigation and/or aspiration to the irrigation sleeve and/or ultrasonic tip. The irrigation sleeve may comprise a second antenna configured to communicate with the ultrasonic handpiece antenna. The irrigation sleeve may further comprise and an alignment and/or coupling feature configured to removably secure the irrigation sleeve to the housing and orient the second antenna relative to the ultrasonic handpiece antenna. The irrigation sleeve may further comprise a lumen for supplying irrigation and/or aspiration to the ultrasonic tip.

1 . A method of making a surgical handpiece with a flex circuit having an antenna, said method comprising:
 providing an internal flex circuit having an antenna at a distal end of said internal flex circuit;   providing a first housing component and a second housing component, wherein the first and second housing components are injection molded such that one of the first and second housing components defines a void and one of the first and second housing components comprises an irrigation conduit configured to communicate irrigation fluid through the surgical handpiece;   positioning the internal flex circuit within the void of one of the first housing component and the second housing component;   securing the first housing component to the second housing component to fix the internal flex circuit into position; and   overmolding the first housing component, the second housing component, and a portion of the internal flex circuit with an autoclaveable plastic to fix the location of the antenna of the internal flex circuit in the first and second housing components   
     
     
         2 . The method of  claim 1 , further comprising the initial step of injection molding the first housing component and the second housing component. 
     
     
         3 . The method of  claim 2 , wherein the first housing component and the second housing component are injection molded to comprise corresponding channels extending longitudinally along the length of each of the first housing component and the second housing component, wherein the corresponding channels define the void when the first housing component and the second housing component are secured together. 
     
     
         4 . The method of  claim 3 , wherein the step of positioning the internal flex circuit within the void comprises inserting a portion of said internal flex circuit in the channel of the first housing component or the second housing component prior to securing the first housing component to the second housing component. 
     
     
         5 . A method of making a surgical handpiece with a flex circuit having an antenna, said method comprising:
 providing an internal flex circuit having a sensor;   providing a first housing component and a second housing component, wherein the first and second housing components are injection molded such that one of the first and second housing components defines a void and one of the first and second housing components comprises an irrigation conduit configured to communicate irrigation fluid through the surgical handpiece;   positioning the internal flex circuit within the void of one of the first housing component and the second housing component;   securing the first housing component to the second housing component to fix the internal flex circuit into position; and   overmolding the first housing component, the second housing component, and a portion of the internal flex circuit with an autoclaveable plastic to fix the location of the sensor of the internal flex circuit in the first and second housing components.   
     
     
         6 . An ultrasonic surgical handpiece comprising:
 a housing defining a cavity, said housing defining a proximal aperture and a distal aperture;   a transducer comprising a distal end and a proximal end disposed within said cavity of said housing, said transducer configured to expand and contract along a longitudinal axis of the transducer;   a tube defining a transducer lumen comprising a distal portion and a proximal portion, said lumen being configured to extend from said proximal end to said distal end of said transducer and be oriented to be generally parallel to said longitudinal axis;   a barrier member having a shell portion wholly within said cavity and a channel portion that extends proximally from said shell portion and extends through said proximal aperture, the shell portion defining a shell lumen configured to encase said transducer positioned within said housing, the channel portion configured to rout aspirated fluid from said transducer lumen to a suction line;   a horn at least partially disposed within said housing, said horn coupled to said distal end of said transducer, said horn defining a horn lumen that is in fluid communication with said transducer lumen when said horn is coupled to said transducer;   a rear seal positioned between said proximal end of said transducer and an interior surface of said cavity, said rear seal configured to abut said proximal end of said transducer and define a first aperture that engages an exterior surface of said tube and an interior surface of said barrier member, said rear seal is positioned between said shell portion and said channel portion of said barrier member such that fluid cannot enter said shell portion of said barrier member;   a front seal positioned disposed radially about an exterior surface of said horn, said front seal;   a potting seal positioned between said transducer and a distal end of said shell portion of said barrier member, said potting seal configured to abut said distal end of said transducer and define a second aperture for receiving said coupling feature of said horn;   wherein said rear seal is configured to prevent moisture ingress into said cavity proximate the proximal end of said transducer; and wherein said potting seal is configured to prevent moisture ingress into said cavity proximate said distal end of said transducer.   
     
     
         7 . The ultrasonic handpiece assembly of  claim 6 , wherein said housing further comprises:
 an attachment region formed in said distal end of said housing, said attachment region defining a recess comprising a third face and a plurality of side walls configured to receive said hub of said irrigation sleeve;   an attachment element in said third face of said recess, said attachment element configured to receive said retention finger of said irrigation sleeve to removably couple said irrigation sleeve to said ultrasonic handpiece;   wherein said irrigation outlet fitting is configured to extend from said third face of said recess to removably couple with said irrigation sleeve to provide irrigation fluid to said irrigation sleeve; and wherein said second end of said horn is configured to protrude from said face.