Ultrasonic surgical handpiece having a thermal diffuser
Inventors
Cotter, Daniel J. • Manandhar, Prakash • Kosenko, Igor V. • Gupta, Saurav V.
Assignees
Integra Lifesciences Corp • Integra Lifesciences Enterprises LLLP
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Publication Number
US-11284915-B2
Publication Date
2022-03-29
Expiration Date
Abstract
An ultrasonic surgical handpiece comprising a thermal diffuser that includes a thermal conductive layer and an electrical insulating layer. The thermal diffuser reduces hot spots that are objectionable to the user. The handpiece may also comprise an anti-rotation feature which distributes force of the metal horn applied to the polymer housing by increasing applied area under torque.
Core Innovation
The invention relates to an ultrasonic surgical handpiece that includes an internal thermal diffuser positioned between a polymer housing and an ultrasonically powered electrical transducer to reduce objectionable hot spots. The thermal diffuser includes a thermal conductive layer and an electrical insulating layer, with the thermal conductive layer disposed closer to the housing than the electrical insulating layer.
The thermal conductive layer is constructed from two or more thermal conductive material pieces that combine to form a first inner circumference and a first outer circumference, and at least a portion of a circumference of the conductive material pieces includes an overlapping area therebetween. The electrical insulating layer is arranged along circumferential regions of the conductive pieces and is disposed adjacent the housing and radially spaced outwardly from the transducer.
The diffuser construction includes conductive materials such as copper, aluminum, nickel, silver, and gold, and insulating materials such as PTFE, polycarbonate, and polypropylene. The disclosure further reports that hot spots are lowered from more than 55°C to less than 41°C, often near 37°C, while maintaining performance through operation and life testing, and includes an anti-rotation feature using a cog-style horn engagement with a matching polymer housing feature (hexacog) to prevent transducer twisting/failure during tightening/loosening events.
Claims Coverage
The independent claims are directed to an ultrasonic surgical handpiece with a thermal diffuser that includes two-layer thermal management between the housing and an electrical component/transducer. Three inventive features are identified across the claims, focused on two-layer placement, a multi-piece conductive layer with overlapping circumferential areas, and insulating layer placement along defined circumferences of the conductive pieces.
Thermal diffuser two-layer placement between housing and electrical component
A surgical handpiece comprising a housing; an electrical component within the housing; and a thermal diffuser comprising a thermal conductive layer and an electrical insulating layer, wherein both are disposed between the housing and the electrical component, and the thermal conductive layer is closer to the housing than the electrical insulating layer.
Multi-piece thermal conductive layer with overlapping circumferential area
The thermal conductive layer includes two or more thermal conductive material pieces combining to form a first inner circumference and a first outer circumference, wherein each piece includes a length, an inner radius, and an outer radius, and at least a portion of a circumference includes an overlapping area therebetween.
Overlapping circumferences with insulating layer along defined circumferences
Adjacent thermal conductive material pieces overlap defined circumferences, and the electrical insulating layer is disposed along the second inner circumference and the third inner circumference of the two or more thermal conductive material pieces forming the first inner circumference.
Across the independent claims, the inventive concept is the placement of a thermal diffuser two-layer structure between a housing and an electrical component/ultrasonically powered transducer, with the conductive layer closer to the housing and with a multi-piece conductive layer defined by inner and outer circumferences and overlapping areas.
Stated Advantages
Reduces objectionable hot spots in the ultrasonic surgical handpiece.
Maintains performance through operation and life testing.
Lowers hot spots from more than 55°C to less than 41°C, often near 37°C.
Documented Applications
Ultrasonic surgical handpiece use in which reducing objectionable hot spots is required in the vicinity of an ultrasonically powered electrical transducer.
Use of an anti-rotation feature for tightening and loosening events to prevent transducer twisting or failure in the ultrasonic surgical handpiece.
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