Compact ultrasonic transducer and ultrasonic surgical instrument including the same

A compact ultrasonic transducer for an ultrasonic surgical instrument includes a proximal casing defining a hollow interior and a piezoelectric rod array including a plurality of piezoelectric rods radially spaced-apart from one another and arranged in a longitudinally-oriented direction. The piezoelectric rod array is disposed within the hollow interior. The compact ultrasonic transducer further includes a distal horn including a distal connector configured to engage a waveguide. The distal horn is configured to engage the proximal casing to enclose the piezoelectric rod array within the hollow interior. An ultrasonic surgical instrument including the compact ultrasonic transducer is also provided.

BACKGROUND

Technical Field

The present disclosure relates to ultrasonic surgical instruments and, more specifically, to a compact ultrasonic transducer and ultrasonic surgical instrument including the same.

Background of Related Art

Ultrasonic surgical instruments utilize ultrasonic energy, i.e., ultrasonic vibrations, to treat tissue. More specifically, ultrasonic surgical instruments utilize mechanical vibration energy transmitted at ultrasonic frequencies to coagulate, cauterize, fuse, seal, cut, desiccate, and/or fulgurate tissue to effect hemostasis.

Ultrasonic surgical instruments typically employ a transducer coupled to a handle of the ultrasonic surgical instrument and configured to produce ultrasonic energy for transmission along a waveguide to an end effector of the ultrasonic surgical instrument that is designed to treat tissue with the ultrasonic energy. The transducer may be driven by an ultrasonic generator that is on-board, e.g., on or within the handle of the ultrasonic surgical instrument, or remotely disposed, e.g., as a set-top box connected to the ultrasonic surgical instrument via a surgical cable. The end effector of the ultrasonic surgical instrument may include a blade that receives the ultrasonic energy from the waveguide for application to tissue and a jaw member configured to clamp tissue between the blade and the jaw member to facilitate treatment thereof.

SUMMARY

As used herein, the term “distal” refers to the portion that is being described which is further from a user, while the term “proximal” refers to the portion that is being described which is closer to a user. Further, to the extent consistent any or all of the aspects detailed herein may be used in conjunction with any or all of the other aspects detailed herein.

In accordance with aspects of the present disclosure, a compact ultrasonic transducer for an ultrasonic surgical instrument is provided including a proximal casing defining a hollow interior, a piezoelectric rod array including a plurality of piezoelectric rods radially spaced-apart from one another, arranged in a longitudinally-oriented direction, and disposed within the hollow interior, and a distal horn including a distal connector configured to engage a waveguide. The distal horn is configured to engage the proximal casing to enclose the piezoelectric rod array within the hollow interior.

In an aspect of the present disclosure, the compact ultrasonic transducer further includes a seal disposed between the proximal casing and the distal horn and configured to engage the proximal casing and the distal horn with one another.

In another aspect of the present disclosure, the seal is configured to sealingly engage the proximal casing and the distal horn with one another such that the hollow interior is sealed closed.

In still another aspect of the present disclosure, the proximal casing and the distal horn are at least partially formed of an electrically-conductive material and the seal is at least partially formed from an insulative material to electrically isolate the proximal casing and the distal horn from one another. In such aspects, one of the proximal casing or the distal horn may be configured to communicate electrical energy at a first potential to the piezoelectric rod array and the other of the proximal casing or the distal horn may be configured to communicate electrical energy at a second potential to the piezoelectric rod array to energize the piezoelectric rod array.

In yet another aspect of the present disclosure, the piezoelectric rod array defines a radially-symmetric configuration relative to a longitudinal axis defined through the compact ultrasonic transducer.

In still yet another aspect of the present disclosure, the plurality of piezoelectric rods is maintained in compression between a proximal surface of the proximal casing and a distal surface of the distal horn.

In another aspect of the present disclosure, a distance between a center of mass of the piezoelectric rod array and the distal connector of the distal horn is one-quarter of a wavelength. Alternatively, a distance between a center of mass of the piezoelectric rod array and the distal connector of the distal horn may be another multiple of one-quarter of a wavelength.

In yet another aspect of the present disclosure, an internal cartridge is disposed within the hollow interior and configured to retain the plurality of piezoelectric rods therein.

An ultrasonic surgical instrument provided in accordance with aspects of the present disclosure includes a housing, a waveguide extending distally from the housing, an ultrasonic blade disposed at a distal end of the waveguide, and a compact ultrasonic transducer supported by the housing and coupled to the waveguide such that ultrasonic energy produced by the compact ultrasonic transducer is transmitted along the waveguide to the ultrasonic blade for treating tissue therewith. The compact ultrasonic transducer includes a proximal casing defining a hollow interior, a piezoelectric rod array including a plurality of piezoelectric rods radially spaced-apart from one another and arranged in a longitudinally-oriented direction in the hollow interior, and a distal horn configured to engage the proximal casing to enclose the piezoelectric rod array within the hollow interior.

In an aspect of the present disclosure, the compact ultrasonic transducer further includes a seal disposed between the proximal casing and the distal horn and configured to engage the proximal casing and the distal horn with one another.

In another aspect of the present disclosure, the seal is configured to sealingly engage the proximal casing and the distal horn with one another such that the hollow interior is sealed closed.

In still another aspect of the present disclosure, the proximal casing and the distal horn are at least partially formed of an electrically-conductive material and the seal is at least partially formed from an insulative material to electrically isolate the proximal casing and the distal horn from one another. In such aspects, first and second contacts may be disposed within the housing in electrical contact with the distal horn and the proximal casing, respectively, and configured to communicate electrical energy at first and second potentials to the piezoelectric rod array via the distal horn and the proximal casing, respectively, to energize the piezoelectric rod array.

In yet another aspect of the present disclosure, the compact ultrasonic transducer is rotatable relative to the housing and the first and second contacts and the first and second contacts maintain electrical contact with the distal horn and the proximal casing, respectively, regardless of a rotational orientation of the compact ultrasonic transducer relative thereto.

In still another aspect of the present disclosure, the proximal casing includes an annular flange extending radially outwardly therefrom. In such aspects, the housing includes a support configured to receive the annular flange to rotatably support the compact ultrasonic transducer at least partially within the housing.

In another aspect of the present disclosure, the distal horn includes a distal connector configured to engage the waveguide and a distance between a center of mass of the piezoelectric rod array and the distal connector is one-quarter of a wavelength.

In another aspect of the present disclosure, the ultrasonic surgical instrument further includes a clamp arm movable relative to the ultrasonic blade from an open position to a clamping position for clamping tissue therebetween.

In still another aspect of the present disclosure, the ultrasonic surgical instrument further includes a movable handle associated with the housing and operably coupled to the clamp arm such that actuation of the movable handle moves the clamp arm from the open position to the clamping position.

DETAILED DESCRIPTION

The present disclosure provides a compact ultrasonic transducer and ultrasonic surgical instrument including the same, although it is understood that the compact ultrasonic transducer of the present disclosure is equally applicable for use with other suitable surgical instruments.

Referring toFIGS. 1 and 2, an ultrasonic surgical instrument configured for use in accordance with the aspects and features of the present disclosure is shown generally identified by reference numeral10. Ultrasonic surgical instrument10includes a housing20, a movable handle40operably coupled to housing20, a shaft50extending distally from housing20, a rotation knob60supported on housing20and configured for rotating shaft50relative to housing20, and a compact ultrasonic transducer80(FIG. 2) in accordance with the present disclosure supported within housing20. Ultrasonic surgical instrument10further includes an end effector assembly100disposed at a distal end of shaft50, a waveguide120(FIG. 2) extending through housing20and shaft50and operably coupling ultrasonic transducer80to end effector assembly100, a drive assembly140(FIG. 2) operably coupled between movable handle40and end effector assembly100, and an activation assembly160operably coupled to housing20for selectively supplying energy to compact ultrasonic transducer80to drive compact ultrasonic transducer80. Ultrasonic surgical instrument10additionally includes a cable200configured to connect to a generator (not shown) or other power source for driving compact ultrasonic transducer80.

Housing20defines a longitudinally-extending barrel portion22and a fixed handle portion26extending downwardly from barrel portion22in generally perpendicular orientation relative thereto. Barrel portion22of housing20defines a support23configured to rotatably support compact ultrasonic transducer80at least partially within housing20. In embodiments, compact ultrasonic transducer80is removable from housing20. Compact ultrasonic transducer80is described in detail below. Barrel portion22further defines a distal opening25through which shaft50, the drive sleeve146of drive assembly140, and waveguide120extend in substantially coaxial arrangement. Fixed handle portion26of housing20is positioned adjacent movable handle40to enable a user to grasp fixed handle portion26of housing20and manipulate movable handle40with a single hand.

Movable handle40includes a grasping portion42configured to facilitate grasping and manipulation by a user. Movable handle40further includes a flange portion44extending into barrel portion22of housing20. Flange portion44is pivotably coupled to housing20via a pivot pin46and defines a bifurcated configuration including first and second spaced-apart flange arms48(only one flange arm48is illustrated inFIG. 2as it obscures the other flange arm48) operably couple to mandrel142of drive assembly140such that pivoting of movable handle40relative to housing20about pivot pin46from a spaced-apart position towards an approximated position translates drive sleeve146of drive assembly140relative to end effector assembly100to pivot clamp arm102of end effector assembly100relative to blade124of end effector assembly100between an open position and a clamping position for clamping tissue therebetween.

With continued reference toFIGS. 1 and 2, shaft50is rotatably supported by housing20and extends distally through distal opening25of barrel portion22of housing20. Shaft50includes end effector assembly100disposed at a distal end thereof. Shaft50is disposed about drive sleeve146of drive assembly140, although it is also contemplated that this configuration be reversed, e.g., wherein drive sleeve146is disposed about shaft50. Shaft50is longitudinally fixed relative to housing20but is rotatable relative thereto in response to rotation of rotation knob60relative to housing20via coupling therebetween. Rotation knob60is also coupled to drive sleeve146and waveguide120such that rotation of rotation knob60likewise rotates drive assembly140, waveguide120, and compact ultrasonic transducer80relative to housing20in response to rotation of rotation knob60relative to housing20.

End effector assembly100includes clamp arm102, blade124of waveguide120, a pair of clevis members112(only one clevis member112is illustrated inFIG. 1with the other being obstructed), and a drive link116. Clamp arm102includes a frame104and a tissue pad108engaged with frame104. Frame104of clamp arm102is pivotably coupled to a distal end portion of shaft50by way of clevis members112. Drive link116is coupled between frame104of clamp arm102and a distal end portion of drive sleeve146(FIG. 2) such that translation of drive sleeve146translates drive link116to thereby pivot clamp arm102between the open and clamping positions.

Waveguide120defines a body122, a blade124extending from the distal end of body122, and a proximal connector126extending from the proximal end of body122. Blade124extends distally from drive sleeve146of drive assembly140and shaft50and, as noted above, forms part of end effector assembly100in that blade124is positioned to oppose clamp arm102such that pivoting of clamp arm102from the open position to the clamping position enables clamping of tissue between clamp arm102and blade124. Blade124may define a linear configuration as shown, or may define a curved configuration. Proximal connector126of waveguide120is configured to enable engagement of waveguide120with compact ultrasonic transducer assembly80, e.g., via a threaded engagement, such that mechanical motion produced by compact ultrasonic transducer assembly80is capable of being transmitted along waveguide120to blade124for treating tissue clamped between blade124and clamp arm102or positioned adjacent blade124.

Drive assembly140includes mandrel142operably disposed about drive sleeve146. Mandrel142is configured to receive flange portion44of movable handle40such that pivoting of movable handle40imparts longitudinal motion to mandrel142. Longitudinal motion of mandrel142, in turn, translates drive sleeve146to pivot clamp arm102between the open and clamping positions. Mandrel142may be fixedly coupled to drive sleeve146or may be coupled thereto via a force-limiting connection (not shown) to limit a clamping force applied to tissue disposed between clamp arm102and blade124.

Activation assembly160includes an activation button162extending from housing20to enable manual manipulation by a user. In some embodiments, activation button162is configured as a two-mode button wherein actuation of button162to a first actuated position supplies energy to compact ultrasonic transducer80corresponding to a “LOW” power mode, and wherein actuation of button162to a second actuated position supplies energy to compact ultrasonic transducer80corresponding to a “HIGH” power mode.

Wires212,214,216extending through cable200are configured to electrically couple the generator (not shown) with activation button162and first and second contacts172,174for driving compact ultrasonic transducer80upon activation of activation button162, e.g., in either the “LOW” power mode or the “HIGH” power mode. First and second contacts172,174are fixed within housing20and configured such that first and second contacts172,174remain electrically coupled to compact ultrasonic transducer80regardless of the rotational orientation of compact ultrasonic transducer80relative to housing20.

Turning now toFIGS. 3-6, compact ultrasonic transducer80is detailed. Compact ultrasonic transducer80includes a proximal casing82, a distal horn84, an isolating seal86, a piezoelectric rod array88including a plurality of piezoelectric rods90, and, in embodiments, an internal cartridge92(FIG. 6).

Proximal casing82of compact ultrasonic transducer80includes a tubular body83adefining a hollow interior83b, a solid semi-spherical proximal cap83cclosing the proximal end of tubular body83a, and an annular flange83ddisposed about and extending radially outwardly from an exterior surface of tubular body83a. Proximal casing82is formed from an electrically-conductive material and may be monolithically formed as a single piece of material, or otherwise formed such that proximal cap83ais sealed to the proximal end of tubular body83a. Annular flange83denables rotatable mounting of compact ultrasonic transducer80within housing20via support23of housing20(seeFIG. 2). Tubular body83adefines a generally smooth surface in the vicinity of second contact174of ultrasonic surgical instrument10such that electrical communication is maintained between tubular body83aand second contact174regardless of the rotational orientation of compact ultrasonic transducer80relative to second contact1740(seeFIG. 2). Threading83eis formed on the interior annular surface of tubular body83atowards the distal end of tubular body83a, the purpose of which is detailed below. In embodiments, an internal, distally-facing surface83fof proximal cap83adefines a plurality of cylindrical-shaped indentations83g, each configured to support a proximal end of one of the piezoelectric rods90therein in complementary-fit engagement therewith. In other embodiments, indentations83gare not provided and surface83fdefines a planar configuration. In either configuration, the proximal ends of piezoelectric rods90are electrically coupled with second contact174via the electrically-conductive proximal casing82.

Distal horn84of compact ultrasonic transducer80is formed from an electrically-conductive material and may be monolithically formed as a single piece of solid material, or may otherwise be formed and/or configured. Distal horn84tapers in a proximal-to-distal direction and defines a distal connector85aconfigured to receive proximal connector126of waveguide120(FIG. 2) therein, e.g., via male-female threaded connection, to operably couple distal horn84and, thus, compact ultrasonic transducer80, with waveguide120(FIG. 2). Distal horn84further includes threading85bformed on the exterior annular surface thereof towards the proximal end thereof, the purpose of which is detailed below. Distal horn84also defines a generally smooth surface in the vicinity of first contact172of ultrasonic surgical instrument10such that electrical communication is maintained between distal horn84and first contact172regardless of the rotational orientation of compact ultrasonic transducer80relative to first contact172(seeFIG. 2).

Distal horn84additionally defines a proximally-facing surface85c. Proximally-facing surface85cmay define a plurality of cylindrical-shaped indentations85d, each configured to support a distal end of one of the piezoelectric rods90therein in complementary-fit engagement therewith. In other embodiments, indentations85dare not provided and surface85cdefines a planar configuration. In either configuration, the distal ends of piezoelectric rods90are electrically coupled with first contact172via the electrically-conductive distal horn84.

Isolating seal86is formed from an electrically-insulative material and defines a ring-shaped configuration having external threading87adefined on an outer annular surface thereof and internal threading87bdefined on an inner annular surface thereof. External threading87ais configured to engage threading83eof proximal casing82and internal threading87bis configured to engage threading85bof distal horn84to thereby sealingly engage proximal casing82and distal horn84with one another, thereby sealing off hollow interior83bof proximal casing82while maintaining proximal casing82and distal horn84electrically isolated from one another.

Continuing with reference toFIGS. 3-6, piezoelectric rod array88, as noted above, includes a plurality of piezoelectric rods90. Piezoelectric rods90are arranged in a longitudinally-oriented direction, substantially parallel (within manufacturing and material tolerances) to a longitudinal axis of compact ultrasonic transducer80, and may be arranged in a radially-symmetric or other suitable pattern. Although six (6) piezoelectric rods90(inFIGS. 4 and 5, wherein there is no central rod) or seven (7) piezoelectric rods90(inFIG. 6, wherein a central rod is provided) are shown, greater or fewer piezoelectric rods90are also contemplated. Piezoelectric rods90are configured for positioning within the sealed hollow interior83bof proximal casing82with the proximal ends thereof in contact with (and thus electrically communication with) surface83fof proximal casing82and the distal ends thereof in contact with (and thus electrically communication with) surface85cof distal horn84such that piezoelectric rods90are under compression.

In embodiments, receipt of the proximal and distal ends of piezoelectric rods90within indentations83g,85d, respectively, serves to maintain piezoelectric rods90in position. Alternatively or additionally, as illustrated inFIG. 6, internal cartridge92defining a plurality of rod-receiving receptacles94may be disposed within hollow interior83bof proximal casing82to maintain piezoelectric rods90in position.

As a result of the above-detailed configuration, compact ultrasonic transducer80may define a length wherein a distance between the center of mass of piezoelectric rod array88and distal connector85aof distal horn84is one-quarter (¼) of a wavelength. Compact ultrasonic transducer80may alternatively define a greater such length in one-quarter (¼) wavelength intervals. The above-detailed configuration also seals compact ultrasonic transducer80to enable compact ultrasonic transducer80to be autoclaved, cleaned, and/or otherwise sterilized for repeated use.

In use, upon activation, one of the contacts, e.g., first contact172, serves as the ground (neutral) electrode and the other contact, e.g., second contact174, serves as the alternating charged (+/−) electrode to energize piezoelectric rods90, thereby producing ultrasonic energy, e.g., mechanical vibration motion, that is transmitted from piezoelectric rods90through distal horn84and waveguide120(FIG. 2) to blade124(FIG. 1) for treating tissue therewith.