Ultrasonic surgical assembly with air cooling broad knife and irrigation sleeve

An ultrasonic surgical assembly to provide air cooling of an ultrasonic tip, the ultrasonic surgical assembly comprising:

• an ultrasonic instrument having a proximal region and a distal region, said ultrasonic instrument comprising:
• a housing comprising a proximal portion and a distal portion,
• a transducer at least partially disposed within said housing,
• a horn coupled to said transducer, and
• said transducer configured to be coupled to a suction source by a first coupler;
• an ultrasonic tip comprising a shaft and a cutting portion, the ultrasonic tip removably coupled to said horn by a tip coupler, wherein said shaft comprises a longitudinal axis;
• an irrigation sleeve having a distal region and a proximal region and defining a lumen, said irrigation sleeve at least partially surrounding said shaft and defining an inlet aperture configured to receive irrigation liquid from an irrigation source, said irrigation sleeve further comprising:
• a first conduit in fluid communication with the lumen, the first conduit configured to convey irrigation liquid from the inlet aperture to an outlet aperture;
• and
• a sealing member positioned between an outer surface of said ultrasonic tip and an inner surface of said lumen;
• the ultrasonic tip defining:
• a first bore defining an air inlet disposed proximal to the sealing member when the irrigation sleeve and the ultrasonic tip are coupled to the ultrasonic instrument, and
• a second bore extending from a proximal end of the ultrasonic tip to the first bore, said second bore in communication with the suction source through the tip coupler;
• the irrigation sleeve defining a third bore proximal the first bore when the irrigation sleeve and the ultrasonic tip are coupled to the ultrasonic instrument, and
• wherein the ultrasonic surgical assembly defines a path to draw air from an ambient environment through the third bore, then through the first bore, and back through the second bore before the air exits the ultrasonic surgical assembly at the first coupler.

A method of cutting bone with an ultrasonic tip, the method comprising:

• providing an ultrasonic tip comprising a shaft and a cutting portion, the ultrasonic tip removably coupled to a horn by a tip coupler, the horn coupled to a transducer, and the transducer coupled to a suction source by a first coupler;
• wherein the shaft comprises a longitudinal axis, the ultrasonic tip defining a first bore defining an air inlet and a second bore extending from a proximal end of the ultrasonic tip to the first bore, the first bore being transverse to the second bore, the second bore in communication with the suction source via the tip coupler;
• providing an irrigation sleeve having a distal region and a proximal region and defining a lumen, the irrigation sleeve at least partially surrounding the shaft and configured to be coupled to an irrigation source with an inlet aperture configured to receive irrigation liquid from the irrigation source, said irrigation sleeve defining a first conduit in fluid communication with the lumen, the first conduit configured to convey irrigation liquid from the inlet aperture to an outlet aperture;
• and
• providing a sealing member between the outer surface of said ultrasonic tip and an inner surface of the lumen of the irrigation sleeve, wherein the first bore is disposed proximal to said sealing member;
• the method further comprising:
• drawing air via the suction source through the second bore and the first bore to cool the ultrasonic tip.