US20010025184A1 - Blades with functional balance asymmetries for use with ultrasonic surgical instruments - Google Patents

Abstract

Disclosed is an ultrasonic surgical instrument that combines end-effector geometry to best affect the multiple functions of a shears-type configuration. The shape of the blade is characterized by a radiused cut offset by some distance to form a curved geometry. The cut creates a curved surface with multiple asymmetries causing multiple imbalances within the blade. Imbalance due to the curve of the instrument is corrected by a non-functional asymmetry proximal to the functional asymmetry. Imbalance due to the asymmetric cross-section of the blade is corrected by the appropriate selection of the volume and location of material removed from a functional asymmetry. The shape of the blade in one embodiment of the present invention is characterized by two radiused cuts offset by some distance to form a curved and potentially tapered geometry. These two cuts create curved surfaces including a concave surface and a convex surface. The length of the radiused cuts affects, in part, the acoustic balancing of the transverse motion induced by the curved shape.

Description

FIELD OF THE INVENTION
• The present invention relates, in general, to ultrasonic surgical instruments and, more particularly, to multifunctional curved blades with functional asymmetries for use with ultrasonic surgical instruments to minimize undesirable motion.[0001]
BACKGROUND OF THE INVENTION
• This application is related to the following copending patent applications: application Ser. No. 08/948,625 filed Oct. 10, 1997; application Ser. No. 08/949,133 filed Oct. 10, 1997; application Ser. No. 09/106,686 filed Jun. 29, 1998; application Ser. No. 09/337,077 filed Jun. 21, 1999; application Ser. No. ______ [Attorney Docket No. END-610]; application Ser. No. ______ [Attorney Docket No. END-616]; and application Ser. No. ______ [Attorney Docket No. END-618] which are hereby incorporated herein by reference.[0002]
• Ultrasonic instruments, including both hollow core and solid core instruments, are used for the safe and effective treatment of many medical conditions. Ultrasonic instruments, and particularly solid core ultrasonic instruments, are advantageous because they may be used to cut and/or coagulate organic tissue using energy in the form of mechanical vibrations transmitted to a surgical end-effector at ultrasonic frequencies. Ultrasonic vibrations, when transmitted to organic tissue at suitable energy levels and using a suitable end-effector, may be used to cut, dissect, or cauterize tissue. Ultrasonic instruments utilizing solid core technology are particularly advantageous because of the amount of ultrasonic energy that may be transmitted from the ultrasonic transducer through the waveguide to the surgical end-effector. Such instruments are particularly suited for use in minimally invasive procedures, such as endoscopic or laparoscopic procedures, wherein the end-effector is passed through a trocar to reach the surgical site.[0003]
• Ultrasonic vibration is induced in the surgical end-effector by, for example, electrically exciting a transducer which may be constructed of one or more piezoelectric or magnetostrictive elements in the instrument hand piece. Vibrations generated by the transducer section are transmitted to the surgical end-effector via an ultrasonic waveguide extending from the transducer section to the surgical end-effector. The waveguides and end-effectors are designed to resonate at the same frequency as the transducer. Therefore, when an end-effector is attached to a transducer the overall system frequency is still the same frequency as the transducer itself.[0004]
• The amplitude of the longitudinal ultrasonic vibration at the tip, d, behaves as a simple sinusoid at the resonant frequency as given by:[0005]
• d=Asin (ωt)  (equation 1)
• where:[0006]
• ω=the radian frequency which equals 2π times the cyclic frequency, f; and[0007]
• A=the zero-to-peak amplitude.[0008]
• The longitudinal excursion is defined as the peak-to-peak (p-t-p) amplitude, which is just twice the amplitude of the sine wave or 2A.[0009]
• Solid core ultrasonic surgical instruments may be divided into two types, single element end-effector devices and multiple-element end-effector. Single element end-effector devices include instruments such as scalpels, and ball coagulators, see, for example, U.S. Pat. No. 5,263,957. While such instruments as disclosed in U.S. Pat. No. 5,263,957 have been found eminently satisfactory, there are limitations with respect to their use, as well as the use of other ultrasonic surgical instruments. For example, single-element end-effector instruments have limited ability to apply blade-to-tissue pressure when the tissue is soft and loosely supported. Substantial pressure is necessary to effectively couple ultrasonic energy to the tissue. This inability to grasp the tissue results in a further inability to fully coapt tissue surfaces while applying ultrasonic energy, leading to less-than-desired hemostasis and tissue joining.[0010]
• The use of multiple-element end-effectors such as clamping coagulators include a mechanism to press tissue against an ultrasonic blade, that can overcome these deficiencies. A clamp mechanism disclosed as useful in an ultrasonic surgical device has been described in U.S. Pat. Nos. 3,636,943 and 3,862,630 to Balamuth. Generally, however, the Balamuth device, as disclosed in those patents, does not coagulate and cut sufficiently fast, and lacks versatility in that it cannot be used to cut/coagulate without the clamp because access to the blade is blocked by the clamp.[0011]
• Ultrasonic clamp coagulators such as, for example, those disclosed in U.S. Pat. Nos. 5,322,055 and 5,893,835 provide an improved ultrasonic surgical instrument for cutting/coagulating tissue, particularly loose and unsupported tissue, wherein the ultrasonic blade is employed in conjunction with a clamp for applying a compressive or biasing force to the tissue, whereby faster coagulation and cutting of the tissue, with less attenuation of blade motion, are achieved.[0012]
• Improvements in technology of curved ultrasonic instruments such as described in U.S. patent application Ser. No. 09/106,686 previously incorporated herein by reference, have created needs for improvements in other aspects of curved clamp coagulators. For example, U.S. Pat. No. 5,873,873 describes an ultrasonic clamp coagulating instrument having an end-effector including a clamp arm comprising a tissue pad. In the configuration shown in U.S. Pat. No. 5,873,873 the clamp arm and tissue pad are straight.[0013]
• The shape of an ultrasonic surgical blade or end-effector used in a clamp coagulator device defines at least four important aspects of the instrument. These are: (1) the visibility of the end-effector and its relative position in the surgical field, (2) the ability of the end-effector to access or approach targeted tissue, (3) the manner in which ultrasonic energy is coupled to tissue for cutting and coagulation, and (4) the manner in which tissue can be manipulated with the ultrasonically inactive end-effector. It would be advantageous to provide an improved ultrasonic clamp coagulator optimizing these four aspects of the instrument.[0014]
• However, as features are added to ultrasonic surgical instrument blades, the altered shape and asymmetries cause the blade to become unbalanced, meaning that the blade has the tendency to vibrate in directions other than the longitudinal direction along the length of the instrument. U.S. patent application Ser. No. 09/106,686 previously incorporated herein by reference, addressed balancing blades proximal to functional asymmetries using balance asymmetries. While U.S. patent application Ser. No. 09/106,686 has proven eminently successful at balancing blades and waveguides proximal to the balance asymmetry, there are some applications where some balancing may be desirable within the functional portion of an asymmetric blade.[0015]
• It would be desirable to provide a balanced ultrasonic surgical instrument blade within the functional area of the blade to optimize instrument performance. The blade described herein has been developed to address this desire.[0016]
SUMMARY OF THE INVENTION
• Disclosed is an ultrasonic surgical instrument that combines end-effector geometry to best affect the multiple functions of a shears-type configuration. The shape of the blade is characterized by a radiused cut offset by some distance to form a curved geometry. The cut creates a curved surface with multiple asymmetries causing multiple imbalances within the blade. Imbalance due to the curve of the instrument is corrected by a non-functional asymmetry proximal to the functional asymmetry. Imbalance due to the asymmetric cross-section of the blade is corrected by the appropriate selection of the volume and location of material removed from a functional asymmetry. The shape of the blade in one embodiment of the present invention is characterized by two radiused cuts offset by some distance to form a curved and potentially tapered geometry. These two cuts create curved surfaces including a concave surface and a convex surface. The length of the radiused cuts affects, in part, the acoustic balancing of the transverse motion induced by the curved shape.[0017]
BRIEF DESCRIPTION OF THE DRAWINGS
• The novel features of the invention are set forth with particularity in the appended claims. The invention itself, however, both as to organization and methods of operation, together with further objects and advantages thereof, may best be understood by reference to the following description, taken in conjunction with the accompanying drawings in which:[0018]
• FIG. 1 illustrates an ultrasonic surgical system including an elevational view of an ultrasonic generator, a sectioned plan view of an ultrasonic transducer, and a partially sectioned plan view of a clamp coagulator in accordance with the present invention;[0019]
• FIG. 2A is an exploded perspective view of a portion of a clamp coagulator in accordance with the present invention;[0020]
• FIG. 2B is an exploded perspective view of a portion of a clamp coagulator in accordance with the present invention;[0021]
• FIG. 3 is a partially sectioned plan view of a clamp coagulator in accordance with the present invention with the clamp arm assembly shown in an open position;[0022]
• FIG. 4 is a partially sectioned plan view of a clamp coagulator in accordance with the present invention with the clamp arm assembly shown in a closed position;[0023]
• FIG. 5 is a side view of a collar cap of the clamp coagulator;[0024]
• FIG. 6 is a front view of a collar cap of the clamp coagulator;[0025]
• FIG. 7 is a side view of a force limiting spring of the clamp coagulator;[0026]
• FIG. 8 is a front view of a force limiting spring of the clamp coagulator;[0027]
• FIG. 9 is a side view of a washer of the clamp coagulator;[0028]
• FIG. 10 is a front view of a washer of the clamp coagulator;[0029]
• FIG. 11 is a side view of a tubular collar of the clamp coagulator;[0030]
• FIG. 12 is a rear view of a tubular collar of the clamp coagulator;[0031]
• FIG. 13 is a front view of a tubular collar of the clamp coagulator;[0032]
• FIG. 14 is a side view of an inner knob of the clamp coagulator;[0033]
• FIG. 15 is a front view of an inner knob of the clamp coagulator;[0034]
• FIG. 16 is a bottom view of an inner knob of the clamp coagulator;[0035]
• FIG. 17 is a rear view of an outer knob of the clamp coagulator;[0036]
• FIG. 18 is a top view of an outer knob of the clamp coagulator;[0037]
• FIG. 19 is a top view of a yoke of the clamp coagulator;[0038]
• FIG. 20 is a side view of a yoke of the clamp coagulator;[0039]
• FIG. 21 is a front view of a yoke of the clamp coagulator;[0040]
• FIG. 22 is a perspective view of a yoke of the clamp coagulator;[0041]
• FIG. 23 is a perspective view of an end-effector of the clamp coagulator;[0042]
• FIG. 24 is a top perspective view of a clamp arm of the camp coagulator;[0043]
• FIG. 25 is a top view of an end-effector of the clamp coagulator;[0044]
• FIG. 26 is a side view of an end-effector of the clamp coagulator with the clamp arm open;[0045]
• FIG. 27 is a top view of a tissue pad of the clamp coagulator;[0046]
• FIG. 28 is a side view of a tissue pad of the clamp coagulator;[0047]
• FIG. 29 is a front view of a tissue pad of the clamp coagulator;[0048]
• FIG. 30 is a perspective view of a tissue pad of the clamp coagulator;[0049]
• FIG. 31 is a bottom perspective view of a clamp arm of the clamp coagulator;[0050]
• FIG. 32 is a first cross-sectional view of the clamp arm illustrated in FIG. 31;[0051]
• FIG. 33 is a second cross-sectional view of the clamp arm illustrated in FIG. 31;[0052]
• FIG. 34 is a bottom plan view of a blade of the clamp coagulator;[0053]
• FIG. 35 is a cross-sectional view of a blade of the clamp coagulator;[0054]
• FIG. 35A is a cross-sectional view of an alternate embodiment of a blade of the clamp coagulator; and[0055]
• FIG. 36 is a perspective view of an end-effector of the clamp coagulator.[0056]
DETAILED DESCRIPTION OF THE INVENTION
• The present invention will be described in combination with ultrasonic instruments as described herein. Such description is exemplary only, and is not intended to limit the scope and applications of the invention. For example, the invention is useful in combination with a multitude of ultrasonic instruments including those described in, for example, U.S. Pat. Nos. 5,938,633; 5,935,144; 5,944,737; 5,322,055, 5,630,420; and 5,449,370.[0057]
• FIG. 1 illustrates[0058]ultrasonic system10 comprising anultrasonic signal generator15 withultrasonic transducer82,hand piece housing20, and clampcoagulator120 in accordance with the present invention.Clamp coagulator120 may be used for open or laparoscopic surgery. Theultrasonic transducer82, which is known as a “Langevin stack”, generally includes atransduction portion90, a first resonator or end-bell92, and a second resonator or fore-bell94, and ancillary components. Theultrasonic transducer82 is preferably an integral number of one-half system wavelengths (nλ/2) in length as will be described in more detail later. Anacoustic assembly80 includes theultrasonic transducer82,mount36,velocity transformer64 andsurface95.
• The distal end of end-[0059]bell92 is connected to the proximal end oftransduction portion90, and the proximal end of fore-bell94 is connected to the distal end oftransduction portion90. Fore-bell94 and end-bell92 have a length determined by a number of variables, including the thickness of thetransduction portion90, the density and modulus of elasticity of the material used to manufacture end-bell92 and fore-bell94, and the resonant frequency of theultrasonic transducer82. The fore-bell94 may be tapered inwardly from its proximal end to its distal end to amplify the ultrasonic vibration amplitude asvelocity transformer64, or alternately may have no amplification.
• The[0060]piezoelectric elements100 may be fabricated from any suitable material, such as, for example, lead zirconate-titanate, lead meta-niobate, lead titanate, or other piezoelectric crystal material. Each of thepositive electrodes96,negative electrodes98, andpiezoelectric elements100 has a bore extending through the center. The positive andnegative electrodes96 and98 are electrically coupled towires102 and104, respectively.Wires102 and104 are encased withincable25 and electrically connectable toultrasonic signal generator15 ofultrasonic system10.
• [0061]Ultrasonic transducer82 of theacoustic assembly80 converts the electrical signal fromultrasonic signal generator15 into mechanical energy that results in primarily longitudinal vibratory motion of theultrasonic transducer82 and an end-effector180 at ultrasonic frequencies. A suitable generator is available as model number GEN01, from Ethicon Endo-Surgery, Inc., Cincinnati, Ohio. When theacoustic assembly80 is energized, a vibratory motion standing wave is generated through theacoustic assembly80. The amplitude of the vibratory motion at any point along theacoustic assembly80 depends on the location along theacoustic assembly80 at which the vibratory motion is measured. A minimum or zero crossing in the vibratory motion standing wave is generally referred to as a node (i.e., where motion is usually minimal), and an absolute value maximum or peak in the standing wave is generally referred to as an anti-node. The distance between an anti-node and its nearest node is one-quarter wavelength (λ/4).
• [0062]Wires102 and104 transmit the electrical signal from theultrasonic signal generator15 topositive electrodes96 andnegative electrodes98. Thepiezoelectric elements100 are energized by an electrical signal supplied from theultrasonic signal generator15 in response to afoot switch118 to produce an acoustic standing wave in theacoustic assembly80. The electrical signal causes disturbances in thepiezoelectric elements100 in the form of repeated small displacements resulting in large compression forces within the material. The repeated small displacements cause thepiezoelectric elements100 to expand and contract in a continuous manner along the axis of the voltage gradient, producing longitudinal waves of ultrasonic energy. The ultrasonic energy is transmitted through theacoustic assembly80 to the end-effector180.
• In order for the[0063]acoustic assembly80 to deliver energy to end-effector180, all components ofacoustic assembly80 must be acoustically coupled to the ultrasonically active portions ofclamp coagulator120. The distal end of theultrasonic transducer82 may be acoustically coupled atsurface95 to the proximal end of anultrasonic waveguide179 by a threaded connection such asstud50.
• The components of the[0064]acoustic assembly80 are preferably acoustically tuned such that the length of any assembly is an integral number of one-half wavelengths (nλ/22), where the wavelength λ is the wavelength of a pre-selected or operating longitudinal vibration drive frequency f_dof theacoustic assembly80, and where n is any positive integer. It is also contemplated that theacoustic assembly80 may incorporate any suitable arrangement of acoustic elements.
• Referring now to FIGS. 2A and 2B, a[0065]clamp coagulator120 of thesurgical system10 in accordance with the present invention is illustrated. Theclamp coagulator120 is preferably attached to and removed from theacoustic assembly80 as a unit. The proximal end of theclamp coagulator120 preferably acoustically couples to thedistal surface95 of theacoustic assembly80 as shown in FIG. 1. It will be recognized that theclamp coagulator120 may be coupled to theacoustic assembly80 by any suitable means.
• The[0066]clamp coagulator120 preferably includes aninstrument housing130, and anelongated member150. Theelongated member150 can be selectively rotated with respect to theinstrument housing130 as further described below. Theinstrument housing130 includes apivoting handle portion136, and a fixedhandle132A and132B, coupled to aleft shroud134 and aright shroud138 respectively.
• The[0067]right shroud138 is adapted to snap fit on theleft shroud134. Theright shroud138 is preferably coupled to theleft shroud134 by a plurality of inwardly facingprongs70 formed on theright shroud138. The plurality ofprongs70 are arranged for engagement in corresponding holes orapertures140, which are formed in theleft shroud134. When theleft shroud134 is attached to theright shroud138, a cavity is formed therebetween to accommodate various components, such as anindexing mechanism255 as further described below.
• The[0068]left shroud134, and theright shroud138 of theclamp coagulator120 are preferably fabricated from polycarbonate. It is contemplated that these components may be made from any suitable material without departing from the spirit and scope of the invention.
• [0069]Indexing mechanism255 is disposed in the cavity of theinstrument housing130. Theindexing mechanism255 is preferably coupled or attached oninner tube170 to translate movement of thehandle portion136 to linear motion of theinner tube170 to open and close theclamp arm assembly300. When the pivotinghandle portion136 is moved toward the fixedhandle portion130, theindexing mechanism255 slides theinner tube170 rearwardly to pivot theclamp arm assembly300 into a closed position. The movement of the pivotinghandle portion136 in the opposite direction slides theindexing mechanism255 to displace theinner tube170 in the opposite direction, i.e., forwardly, and hence pivot theclamp arm assembly300 into its open position.
• The[0070]indexing mechanism255 also provides a ratcheting mechanism to allow theelongated member150 to rotate about its longitudinal axis relative toinstrument housing130. The rotation of theelongated member150 enables theclamp arm assembly300 to be turned to a selected or desired angular position. Theindexing mechanism255 preferably includes atubular collar260 andyoke280.
• The[0071]tubular collar260 of theindexing mechanism255 is preferably snapped onto the proximal end of theinner tube170 and keyed into opposingopenings168. Thetubular collar260 is preferably fabricated from polyetherimide. It is contemplated that thetubular collar260 may be constructed from any suitable material.
• [0072]Tubular collar260 is shown in greater detail in FIGS. 11 through 13. Thetubular collar260 preferably includes anenlarged section262, and abore266 extending therethrough. Theenlarged section262 preferably includes aring272 formed around the periphery of thetubular collar260 to formgroove268. Thegroove268 has a plurality of detents orteeth269 for retaining theelongated member150 in different rotational positions as theelongated member150 is rotated about its longitudinal axis. Preferably, thegroove268 has twelve ratchet teeth to allow the elongated portion to be rotated in twelve equal angular increments of approximately 30 degrees. It is contemplated that thetubular collar260 may have any number of teeth-like members. It will be recognized that the teeth-like members may be disposed on any suitable part of thetubular collar260 without departing from the scope and spirit of the present invention.
• Referring back now to FIGS. 2A through 4, the pivoting[0073]handle portion136 includes athumb loop142, afirst hole124, and asecond hole126. Apivot pin153 is disposed throughfirst hole124 ofhandle portion136 to allow pivoting as shown byarrow121 in FIG. 3. Asthumb loop142 of pivotinghandle portion136 is moved in the direction ofarrow121, away frominstrument housing130, alink128 applies a forward force toyoke280, causingyoke280 to move forward.Link128 is connected to pivotinghandle portion136 by apin129, and link128 is connected to base284 by apin127.
• Referring back now to FIG. 2A,[0074]yoke280 generally includes a holding or supportingmember282 and abase284. The supportingmember282 is preferably semi-circular and has a pair of opposingpawls286 that extend inwardly to engage with theteeth269 of thetubular collar260. It is contemplated that thepawls286 may be disposed on any suitable part of theyoke280 for engagement with theteeth269 of thetubular collar260 without departing from the spirit and scope of the invention. It will also be recognized that theyoke280 may have any number of ratchet arms.
• [0075]Yoke280 is shown in greater detail in FIGS. 19 through 22. The pivotinghandle portion136 preferably is partially disposed in aslot147 of thebase284 of theyoke280. The base284 also includes abase opening287, anactuator travel stop290, and a base pin-hole288. Thepivot pin153 is disposed through thebase opening287.Yoke280pawls286 transfer opening force toinner tube170 throughtubular collar260, resulting in the opening ofclamp arm assembly300.
• The[0076]yoke280 of theclamp coagulator120 is preferably fabricated from polycarbonate. Theyoke280 may also be made from a variety of materials including other plastics, such as ABS, NYLON, or polyetherimide. It is contemplated that theyoke280 may be constructed from any suitable material without departing from the spirit and scope of the invention.
• As illustrated in FIGS. 3 and 4,[0077]yoke280 also transfers a closing force to clamparm assembly300 as pivotinghandle portion136 is moved towardinstrument housing130. Actuator travel stop290contacts pivot pin153 at the bottom of the stroke of pivotinghandle portion136, stopping any further movement, or overtravel, of pivotinghandle portion136.Pawls286 ofyoke280 transfer force totubular collar260 through awasher151, aforce limiting spring155, andcollar cap152.Collar cap152 is rigidly attached totubular collar260 afterwasher151 andforce limiting spring155 have been assembled ontotubular collar260 proximal toenlarged section262.Collar cap152 is illustrated in greater detail in FIGS. 5 and 6.Force limiting spring155 is illustrated in greater detail in FIGS. 7 and 8, andwasher151 is illustrated in greater detail in FIGS. 9 and 10. Thickness ofwasher151 may be adjusted during design or manufacturing ofclamp coagulator120 to alter the pre-load offorce limiting spring155.Collar cap152 is attached totubular collar260 by ultrasonic welding, but may alternately be press fit, snap fit or attached with an adhesive.
• Referring to FIGS. 5 through 10,[0078]tubular collar260,washer151,force limiting spring155, andcollar cap152 provide a force limiting feature to clamparm assembly300. As pivotinghandle portion136 is moved towardinstrument housing130,clamp arm assembly300 is rotated towardultrasonic blade88. In order to provide both ultrasonic cutting, and hemostasis, it is desirable to limit the maximum force ofclamp arm assembly300 to 0.5 to 3.0 Lbs.
• FIGS. 5 and 6 illustrate[0079]collar cap152 including aspring surface158. FIGS. 7 and 8 illustrateforce limiting spring155 including acap surface156, awasher surface157, and a plurality ofspring elements159.Force limiting spring155 is described in the art as a wave spring, due to the shape ofspring elements159. It is advantageous to use a wave spring forforce limiting spring155 because it provides a high spring rate in a small physical size well suited to an ultrasonic surgical instrument application where a central area is open forultrasonic waveguide179.Force limiting spring155 is biased betweenspring surface158 ofcollar cap152 andspring face165 ofwasher151.Washer151 includes a pawl face167 (FIGS. 9 and 10) that contacts pawls286 ofyoke280 after assembly of clamp coagulator120 (see FIGS. 2 through 4).
• Referring now to FIGS. 2A, 2B, and FIGS. 14 through 18, a[0080]rotational knob190 is mounted on theelongated member150 to turn theelongated member150 so that thetubular collar260 rotates with respect to theyoke280. Therotational knob190 may be fabricated from polycarbonate. Therotational knob190 may also be made from a variety of materials including other plastics, such as a polyetherimide, nylon, or any other suitable material.
• The[0081]rotational knob190 preferably has an enlarged section orouter knob192, aninner knob194, and anaxial bore196 extending therethrough.Inner knob194 includeskeys191 that attach cooperatively tokeyways189 ofouter knob192. Theouter knob192 includes alternatinglongitudinal ridges197 andgrooves198 that facilitate the orientation of therotational knob190 and theelongated member150 by a surgeon. Theaxial bore196 of therotational knob190 is configured to snugly fit over the proximal end of theelongated member150.
• The[0082]inner knob194 extends through anopening139 in the distal end of theinstrument housing130.Inner knob194 includes achannel193 to rotatably attachinner knob194 intoopening139. Theinner knob194 of therotational knob190 has a pair of opposingholes199. The opposingholes199 are aligned as part of apassageway195 that extends through theelongated member150, as will be described later.
• A coupling member, such as, for example,[0083]pin163, may be positioned through opposingholes199 of thepassageway195. Thepin163 may be held in thepassageway195 of theelongated member150 by any suitable means, such as, for example, trapped between ribs inhousing130, or a silicone or cyanoacrylate adhesive. Thepin163 allows rotational torque to be applied to theelongated member150 from therotational knob190 in order to rotate theelongated member150.
• When the[0084]rotational knob190 is rotated, theteeth269 of thetubular collar260 engage and ride up slightly on thecorresponding pawls286 of theyoke280. As thepawls286 ride up on theteeth269, the supportingmember282 of theyoke280 deflects outwardly to allowpawls286 to slip or pass over theteeth269 of thetubular collar260.
• In one embodiment, the[0085]teeth269 of thetubular collar260 are configured as ramps or wedges, and thepawls286 of theyoke280 are configured as posts. Theteeth269 of thetubular collar260 and thepawls286 of theyoke280 may be reversed so that theteeth269 of thetubular collar260 are posts, and thepawls286 of theyoke280 are ramps or wedges. It is contemplated that theteeth269 may be integrally formed or coupled directly to the periphery of theelongated member150. It will also be recognized that theteeth269 and thepawls286 may be cooperating projections, wedges, cam surfaces, ratchet-like teeth, serrations, wedges, flanges, or the like which cooperate to allow theelongated member150 to be indexed at selective angular positions, without departing from the spirit and scope of the invention.
• As illustrated in FIG. 2B, the[0086]elongated member150 of theclamp coagulator120 extends from theinstrument housing130. As shown in FIGS. 2B through 4, theelongated member150 preferably includes an outer member orouter tube160, an inner member orinner tube170, and a transmission component orultrasonic waveguide179.
• The[0087]outer tube160 of theelongated member150 preferably includes ahub162, atubular member164, and a longitudinal opening oraperture166 extending therethrough. Theouter tube160 preferably has a substantially circular cross-section and may be fabricated from stainless steel. It will be recognized that theouter tube160 may be constructed from any suitable material and may have any suitable cross-sectional shape.
• The[0088]hub162 of theouter tube160 preferably has a larger diameter than thetubular member164 does. Thehub162 has a pair of outer tube holes161 to receivepin163 to allow thehub162 to be coupled torotational knob190. As a result, theouter tube160 will rotate when therotational knob190 is turned or rotated.
• The[0089]hub162 of theouter tube160 also includeswrench flats169 on opposite sides of thehub162. Thewrench flats169 are preferably formed near the distal end of thehub162. Thewrench flats169 allow torque to be applied by a torque wrench to thehub162 to tighten theultrasonic waveguide179 to thestud50 of theacoustic assembly80. For example, U.S. Pat. Nos. 5,059,210 and 5,057,119, which are hereby incorporated herein by reference, disclose torque wrenches for attaching and detaching a transmission component to a mounting device of a hand piece assembly.
• Located at the distal end of the[0090]tubular member164 of theouter tube160 is an end-effector180 for performing various tasks, such as, for example, grasping tissue, cutting tissue and the like. It is contemplated that the end-effector180 may be formed in any suitable configuration.
• End-[0091]effector180 and its components are shown in greater detail in FIGS. 23 through 33. The end-effector180 generally includes a non-vibratingclamp arm assembly300 to, for example, grip tissue or compress tissue against theultrasonic blade88. The end-effector180 is illustrated in FIGS. 23 and 26 in a clamp open position, and clamparm assembly300 is preferably pivotally attached to the distal end of theouter tube160.
• Looking first to FIGS. 23 through 26, the[0092]clamp arm assembly300 preferably includes aclamp arm202, ajaw aperture204, afirst post206A, asecond post206B, and atissue pad208. Theclamp arm202 is pivotally mounted about apivot pin207A andpivot pin207B to rotate in the direction ofarrow122 in FIG. 3 whenthumb loop142 is moved in the direction indicated byarrow121 in FIG. 3. By advancing the pivotinghandle portion136 toward theinstrument housing130, theclamp arm202 is pivoted about thepivot pin207A andpivot pin207B into a closed position. Retracting the pivotinghandle portion136 away from theinstrument housing130 pivots theclamp arm202 into an open position.
• The[0093]clamp arm202 hastissue pad208 attached thereto for squeezing tissue between theultrasonic blade88 and clamparm assembly300. Thetissue pad208 is preferably formed of a polymeric or other compliant material and engages theultrasonic blade88 when theclamp arm202 is in its closed position. Preferably, thetissue pad208 is formed of a material having a low coefficient of friction but which has substantial rigidity to provide tissue-grasping capability, such as, for example, TEFLON, a trademark name of E. I. Du Pont de Nemours and Company for the polymer polytetraflouroethylene (PTFE). Thetissue pad208 may be mounted to theclamp arm202 by an adhesive, or preferably by a mechanical fastening arrangement as will be described below.
• As illustrated in FIGS. 23, 26 and[0094]28,serrations210 are formed in the clamping surfaces of thetissue pad208 and extend perpendicular to the axis of theultrasonic blade88 to allow tissue to be grasped, manipulated, coagulated and cut without slipping between theclamp arm202 and theultrasonic blade88.
• [0095]Tissue pad208 is illustrated in greater detail in FIGS. 27 through 29.Tissue pad208 includes a T-shapedprotrusion212, aleft protrusion surface214, aright protrusion surface216, atop surface218, and abottom surface219.Bottom surface219 includes theserrations210 previously described.Tissue pad208 also includes a beveledfront end209 to ease insertion during assembly as will be described below.
• Referring now to FIG. 26, the distal end of the[0096]tubular member174 of theinner tube170 preferably includes a finger orflange171 that extends therefrom. Theflange171 has an opening173A and an opening173B (not shown) to receive thefirst post206A andsecond post206B of theclamp arm202. When theinner tube170 of theelongated member150 is moved axially, theflange171 moves forwardly or rearwardly while engaging thefirst post206A andsecond post206B of theclamp arm assembly300 to open and close theclamp arm202.
• Referring now to FIGS. 24, 25, and[0097]31 through33, theclamp arm202 of end-effector180 is shown in greater detail.Clamp arm202 includes anarm top228 and anarm bottom230, as well as astraight portion235 and acurved portion236.Straight portion235 includes a straight T-slot226.Curved portion236 includes a firsttop hole231, a secondtop hole232, a thirdtop hole233, a fourthtop hole234, a first bottom cut-out241, a second bottom cut-out242, a third bottom cut-out243, a forth bottom cut-out244, afirst ledge221, asecond ledge222, athird ledge223, afourth ledge224, and afifth ledge225.
• [0098]Top hole231 extends fromarm top228 throughclamp arm202 tosecond ledge222.Top hole232 extends fromarm top228 throughclamp arm202 tothird ledge223.Top hole233 extends fromarm top228 throughclamp arm202 tofourth ledge224.Top hole234 extends fromarm top228 throughclamp arm202 tofifth ledge225. The arrangement ofholes231 through234 and ledges211 through225 enablesclamp arm202 to include both thestraight portion235 and thecurved portion236, while being moldable from a process such as, for example, metal injection molding (MIM).Clamp arm202 may be made out of stainless steel or other suitable metal utilizing the MIM process.
• Referring to FIGS. 30 and 31, tissue pad[0099]208 T-shapedprotrusion212 is insertable intoclamp arm202 straight T-slot226.Clamp arm202 is designed such thattissue pad208 may be manufactured as a straight component by, for example, injection molding, machining, or extrusion. Asclamp arm202 is inserted into straight T-slot226 and moved progressively throughcurved portion236, beveledfront edge209 facilitates bending oftissue pad208 to conform to the curvature ofclamp arm202. The arrangement ofholes231 through234 and ledges211 through225 enablesclamp arm202 to bend and holdtissue pad208.
• FIGS. 32 and 33 illustrate how[0100]clamp arm202 holdstissue pad208 in place while maintaining a bend intissue pad208 that conforms tocurved portion236 ofclamp arm202. As illustrated in FIG. 32,third ledge223 contactsright protrusion surface216 providing acontact edge238, whileleft protrusion surface214 is unsupported at this position. At a distal location, illustrated in FIG. 33,fourth ledge224 contacts leftprotrusion surface214 providing acontact edge239, whileright protrusion surface216 is unsupported at this location.
• Referring back now to FIG. 2 again, the[0101]inner tube170 of theelongated member150 fits snugly within theopening166 of theouter tube160. Theinner tube170 preferably includes an inner hub172, atubular member174, acircumferential groove176, a pair of opposingopenings178, a pair of opposingopenings178, and a longitudinal opening oraperture175 extending therethrough. Theinner tube170 preferably has a substantially circular cross-section, and may be fabricated from stainless steel. It will be recognized that theinner tube170 may be constructed from any suitable material and may be any suitable shape.
• The inner hub[0102]172 of theinner tube170 preferably has a larger diameter than thetubular member174 does. The pair of opposingopenings178 of the inner hub172 allow the inner hub172 to receive thepin163 to allow theinner tube170 and theultrasonic waveguide179 to transfer torque for attachingultrasonic waveguide179 tostud50 as previously described. An O-ring220 is preferably disposed in thecircumferential groove176 of the inner hub172.
• The[0103]ultrasonic waveguide179 of theelongated member150 extends throughaperture175 of theinner tube170. Theultrasonic waveguide179 is preferably substantially semi-flexible. It will be recognized that theultrasonic waveguide179 may be substantially rigid or may be a flexible wire. Ultrasonic vibrations are transmitted along theultrasonic waveguide179 in a longitudinal direction to vibrate theultrasonic blade88.
• The[0104]ultrasonic waveguide179 may, for example, have a length substantially equal to an integral number of one-half system wavelengths (nλ/2). Theultrasonic waveguide179 may be preferably fabricated from a solid core shaft constructed out of material which propagates ultrasonic energy efficiently, such as titanium alloy (i.e., Ti-6Al-4V) or an aluminum alloy. It is contemplated that theultrasonic waveguide179 may be fabricated from any other suitable material. Theultrasonic waveguide179 may also amplify the mechanical vibrations transmitted to theultrasonic blade88 as is well known in the art.
• As illustrated in FIG. 2, the[0105]ultrasonic waveguide179 may include one or more stabilizing silicone rings or damping sheaths110 (one being shown) positioned at various locations around the periphery of theultrasonic waveguide179. The dampingsheaths110 dampen undesirable vibration and isolate the ultrasonic energy from theinner tube170 assuring the flow of ultrasonic energy in a longitudinal direction to the distal end of theultrasonic blade88 with maximum efficiency. The dampingsheaths110 may be secured to theultrasonic waveguide179 by an interference fit such as, for example, a damping sheath described in U.S. patent application Ser. No. 08/808,652 hereby incorporated herein by reference.
• Referring again to FIG. 2, the[0106]ultrasonic waveguide179 generally has afirst section182, asecond section184, and athird section186. Thefirst section182 of theultrasonic waveguide179 extends distally from the proximal end of theultrasonic waveguide179. Thefirst section182 has a substantially continuous cross-section dimension.
• The[0107]first section182 preferably has at least oneradial waveguide hole188 extending therethrough. Thewaveguide hole188 extends substantially perpendicular to the axis of theultrasonic waveguide179. Thewaveguide hole188 is preferably positioned at a node but may be positioned at any other suitable point along theultrasonic waveguide179. It will be recognized that thewaveguide hole188 may have any suitable depth and may be any suitable shape.
• The[0108]waveguide hole188 of thefirst section182 is aligned with the opposingopenings178 of the hub172 and outer tube holes161 ofhub162 to receive thepin163. Thepin163 allows rotational torque to be applied to theultrasonic waveguide179 from therotational knob190 in order to rotate theelongated member150.Passageway195 ofelongated member150 includes opposingopenings178, outer tube holes161,waveguide hole188, and opposingholes199.
• The[0109]second section184 of theultrasonic waveguide179 extends distally from thefirst section182. Thesecond section184 has a substantially continuous cross-section dimension. The diameter of thesecond section184 is smaller than the diameter of thefirst section182. As ultrasonic energy passes from thefirst section182 of theultrasonic waveguide179 into thesecond section184, the narrowing of thesecond section184 will result in an increased amplitude of the ultrasonic energy passing therethrough.
• The[0110]third section186 extends distally from the distal end of thesecond section184. Thethird section186 has a substantially continuous cross-section dimension. Thethird section186 may also include small diameter changes along its length. The third section preferably includes aseal187 formed around the outer periphery of thethird section186. As ultrasonic energy passes from thesecond section184 of theultrasonic waveguide179 into thethird section186, the narrowing of thethird section186 will result in an increased amplitude of the ultrasonic energy passing therethrough.
• The[0111]third section186 may have a plurality of grooves or notches (not shown) formed in its outer circumference. The grooves may be located at nodes of theultrasonic waveguide179 or any other suitable point along theultrasonic waveguide179 to act as alignment indicators for the installation of a dampingsheath110 during manufacturing.
• Still referring to FIG. 2, damping[0112]sheath110 of thesurgical instrument150 surrounds at least a portion of theultrasonic waveguide179. The dampingsheath110 may be positioned around theultrasonic waveguide179 to dampen or limit transverse side-to-side vibration of theultrasonic waveguide179 during operation. The dampingsheath110 preferably surrounds part of thesecond section184 of theultrasonic waveguide179. It is contemplated that the dampingsheath110 may be positioned around any suitable portion of theultrasonic waveguide179. The dampingsheath110 preferably extends over at least one antinode of transverse vibration, and more preferably, a plurality of antinodes of transverse vibration. The dampingsheath110 preferably has a substantially circular cross-section. It will be recognized that the dampingsheath110 may have any suitable shape to fit over theultrasonic waveguide179 and may be any suitable length.
• The damping[0113]sheath110 is preferably in light contact with theultrasonic waveguide179 to absorb unwanted ultrasonic energy from theultrasonic waveguide179. The dampingsheath110 reduces the amplitude of non-axial vibrations of theultrasonic waveguide179, such as, unwanted transverse vibrations associated with the longitudinal frequency of 55,500 Hz as well as other higher and lower frequencies.
• The damping[0114]sheath110 is constructed of a polymeric material, preferably with a low coefficient of friction to minimize dissipation of energy from the axial motion or longitudinal vibration of theultrasonic waveguide179. The polymeric material is preferably floura-ethylene propene (FEP) which resists degradation when sterilied using gamma radiation. It will be recognized that the dampingsheath110 may be fabricated from any suitable material, such as, for example, The dampingsheath110 preferably has an opening extending therethrough, and a longitudinal slit111. The slit111 of the dampingsheath110 allows the dampingsheath110 to be assembled over theultrasonic waveguide179 from either end. It will be recognized that the dampingsheath110 may have any suitable configuration to allow the dampingsheath110 to fit over theultrasonic waveguide179. For example, the dampingsheath110 may be formed as a coil or spiral or may have patterns of longitudinal and/or circumferential slits or slots. It is also contemplated that the dampingsheath110 may be fabricated without a slit111 and theultrasonic waveguide179 may be fabricated from two or more parts to fit within the dampingsheath110.
• It will be recognized that the[0115]ultrasonic waveguide179 may have any suitable cross-sectional dimension. For example, theultrasonic waveguide179 may have a substantially uniform cross-section or theultrasonic waveguide179 may be tapered at various sections or may be tapered along its entire length.
• The[0116]ultrasonic waveguide179 may also amplify the mechanical vibrations transmitted through theultrasonic waveguide179 to theultrasonic blade88 as is well known in the art. Theultrasonic waveguide179 may further have features to control the gain of the longitudinal vibration along theultrasonic waveguide179 and features to tune theultrasonic waveguide179 to the resonant frequency of the system.
• The proximal end of the[0117]third section186 ofultrasonic waveguide179 may be coupled to the distal end of thesecond section184 by an internal threaded connection, preferably near an antinode. It is contemplated that thethird section186 may be attached to thesecond section184 by any suitable means, such as a welded joint or the like.Third section186 includesultrasonic blade88. Although theultrasonic blade88 may be detachable from theultrasonic waveguide179, theultrasonic blade88 andultrasonic waveguide179 are preferably formed as a single unit.
• The[0118]ultrasonic blade88 may have a length substantially equal to an integral multiple of one-half system wavelengths (nλ/2). The distal end ofultrasonic blade88 may be disposed near an antinode in order to provide the maximum longitudinal excursion of the distal end. When the transducer assembly is energized, the distal end of theultrasonic blade88 is configured to move in the range of, for example, approximately 10 to 500 microns peak-to-peak, and preferably in the range of about 30 to 150 microns at a predetermined vibrational frequency.
• The[0119]ultrasonic blade88 is preferably made from a solid core shaft constructed of material which propagates ultrasonic energy, such as a titanium alloy (i.e., Ti-6Al-4V) or an aluminum alloy. It will be recognized that theultrasonic blade88 may be fabricated from any other suitable material. It is also contemplated that theultrasonic blade88 may have a surface treatment to improve the delivery of energy and desired tissue effect. For example, theultrasonic blade88 may be micro-finished, coated, plated, etched, grit-blasted, roughened or scored to enhance coagulation and cutting of tissue and/or reduce adherence of tissue and blood to the end-effector. Additionally, theultrasonic blade88 may be sharpened or shaped to enhance its characteristics. For example, theultrasonic blade88 may be blade shaped, hook shaped, or ball shaped.
• As illustrated in FIGS. 34, 35 and[0120]36, the geometry of theultrasonic blade88 in accordance with the present invention delivers ultrasonic power more uniformly to clamped tissue than predicate devices. The end-effector180 provides for improved visibility of the blade tip so that a surgeon can verify that theblade88 extends across the structure being cut or coagulated. This is especially important in verifying margins for large blood vessels. The geometry also provides for improved tissue access by more closely replicating the curvature of biological structures.Blade88 provides a multitude of edges and surfaces, designed to provide a multitude of tissue effects: clamped coagulation, clamped cutting, grasping, back-cutting, dissection, spot coagulation, tip penetration and tip scoring.
• The distal most tip of[0121]blade88 has asurface54 perpendicular to tangent63, a line tangent to the curvature at the distal tip. Two fillet-like features61A and61B are used to blendsurfaces51,52 and54, thus giving a blunt tip that can be utilized for spot coagulation. The top of theblade88 is radiused and blunt, providing a broad edge, orsurface56, for clamping tissues between it and clamparm assembly300.Surface56 is used for clamped cutting and coagulation as well as manipulating tissues while the blade is inactive.
• The bottom surface has a[0122]spherical cut53 that provides a narrow edge, orsharp edge55, along the bottom ofblade88. The material cut is accomplished by, for example, sweeping a spherical end mill through an arc of radius R1 and then finishing the cut using a second, tighter radius R2 that blends the cut with abottom surface58 of theblade88. Radius R1 is preferably within the range of 0.5 inches to 2 inches, more preferably within the range of 0.9 inches to 1.1 inches, and most preferably about 1.068 inches. Radius R2 is preferably within the range of 0.125 inches to 0.5 inches, and most preferably about 0.25 inches. The second radius R2 and the corresponding blend with thebottom surface58 ofblade88 diminishes the stress concentrated at the end of the spherical cut relative to stopping the cut without this blend. Thesharp edge55 facilitates dissection and unclamped cutting (back-cutting) through less vascular tissues.
• Spherical cut[0123]53 onbottom surface58 ofblade88 createssharp edge55 while removing a minimal amount of material fromblade88. Spherical cut53 on the bottom ofblade88 creates asharp edge55 with an angle of α as described below. This angle a may be similar to predicate shears devices such as, for example, the LCS-K5 manufactured by Ethicon Endo-Surgery, Inc., Cincinnati, Ohio. However theblade88 of the present invention cuts faster than predicate devices by virtue of the orientation of the angle α with respect to the typical application force. For the predicate shears devices, the edges are symmetric, spanning the application force equally. The edges for the present invention are asymmetric, with the asymmetry of the edges dictating how quickly tissue is separated or cut. The asymmetry is important in that it provides for an effectively sharper edge when ultrasonically activated, without removing a significant volume of material, while maintaining blunt geometry. This asymmetric angle as well as the curvature of the blade act to self tension tissue during back-cutting utilizing a slight hook-like or wedge-like action.
• [0124]Sharp edge55 ofultrasonic blade88 is defined by the intersection ofsurface53 and asecond surface57 left afterbottom surface58 has receivedspherical cut53.Clamp arm assembly300 is pivotally mounted on said distal end ofouter tube160 for pivotal movement with respect toultrasonic blade88, for clamping tissue betweenclamp arm assembly300 andultrasonic blade88. Reciprocal movement ofinner tube170 pivots clamparm assembly300 through an arc of movement, defining avertical plane181. A tangent60 ofspherical cut53 atsharp edge55 defines an angle α with a tangent62 ofsecond surface57, as illustrated in FIG. 35. Thebisection59 of angle a preferably does not lie invertical plane181, but is offset by an angle β. Preferably the tangent60 ofspherical cut53 lies within about 5 to 50 degrees ofvertical plane181, and most preferably the tangent ofspherical cut53 lies about 38.8 degrees fromvertical plane181. Preferably angle a is within the range of about 90 to 150 degrees, and most preferably angle a is about 121.6 degrees.
• Looking to FIG. 35A, an alternate embodiment of the present invention is illustrated with an asymmetric narrow edge. A tangent[0125]60A of aspherical cut53A at asharp edge55A defines an angle αA with a tangent62A of asecond surface57A, as illustrated in FIG. 35A. Abisection59A of angle αA preferably does not lie in avertical plane181A, but is offset by an angle βA.
• The curved shape of the design of[0126]ultrasonic blade88 also results in a more uniformly distributed energy delivery to tissue as it is clamped against theblade88. Uniform energy delivery is desired so that a consistent tissue effect (thermal and transection effect) along the length of end-effector180 is achieved. The distal most 15 millimeters ofblade88 is the working portion, used to achieve a tissue effect. As will be further described below, the displacement vectors for locations along thecurved shears blade88 have directions that, by virtue of the improvements of the present invention over predicate instruments, lie largely in the x-y plane illustrated in FIGS. 34 and 35. The motion, therefore, ofblade88 lies within a plane (the x-y plane) that is perpendicular to the direction of the clamping force fromclamp arm assembly300.
• Straight symmetric ultrasonic blades in general have tip excursions that lie along the longitudinal axis, designated the x-axis in FIGS. 34 and 35. Transverse motion is usually undesirable because it results in undesirable heat generation in[0127]inner tube170. When a functional asymmetry is added to an ultrasonic blade, such as a curved end-effector as described in U.S. patent application Ser. No. 09/106,686 previously incorporated herein by reference, the functional asymmetry creates an imbalance in the ultrasonic waveguide. If the imbalance is not corrected, then undesirable heat, noise, and compromised tissue effect occur. Although U.S. patent application Ser. No. 09/106,686 teaches how to provide ultrasonic blades that are balanced proximal to the balance asymmetry, the distal portion of the end-effector has an excursion in at least two axes. If the end-effector has a single plane of functional asymmetry, such as a curved end-effector, but the blade is otherwise symmetric, then the excursion will lie in a plane at the distal most end.
• It is often desirable to minimize any[0128]ultrasonic blade88 excursion in the z-axis direction. Excursion ofultrasonic blade88 in the z-axis direction causes system inefficiencies, resulting in undesirable heating, power loss, and possibly noise. Excursion ofultrasonic blade88 in the z-axis direction at end-effector180 causes theultrasonic blade88 to impact tissue lying betweenultrasonic blade88 and clamparm assembly300. It is desirable to limitultrasonic blade88 excursion to the x-y plane shown in FIGS. 34 and 35. This allowsultrasonic blade88 to rub tissue lying betweenultrasonic blade88 and clamparm assembly300 without impact, which optimizes heating of the tissue, and thus provides optimal coagulation. Minimizing z-axis excursion both proximal to the end-effector180, and inultrasonic blade88, may be accomplished by proper selection of aspherical cut53.
• However, an ultrasonic end-[0129]effector180 with anultrasonic blade88 that has multiple functional asymmetries, such asultrasonic blade88 as illustrated in FIGS. 34 through 36, will naturally have a tendency to include tip excursion in all three axes, x, y, and z if not balanced properly. For example,ultrasonic blade88 as illustrated in FIG. 34 is curved in the y direction at its distal end. This curvature, although balanced proximal to end-effector180, will causeultrasonic blade88 to have excursions in both the x and y directions when activated. Addingspherical cut53 subsequently adds another level of asymmetry toultrasonic blade88, causing tip excursion in all three axes if not corrected, and also causing z-axis imbalances inultrasonic waveguide179 which decreases efficiency.
• It is possible to minimize z-axis tip excursion proximal to the functional asymmetry, and therefore maximize efficiency with improved tissue effect, by providing a functional asymmetry optimized to minimize z-axis excursion in[0130]ultrasonic waveguide179. As illustrated in FIG. 34,spherical cut53 may extend proximally intoultrasonic blade88, from the most distal end, to any position. For example, FIG. 34 illustrates afirst position66, asecond position67, and athird position68, forspherical cut53 to extend intoultrasonic blade88.
• Table 1 below describes three possible lengths of[0131]spherical cuts53 forultrasonic blade88 illustrated in FIG. 34 asfirst position66,second position67, andthird position68. The rows of Table 1 correspond to the length of cut into theultrasonic blade88, and the columns of Table 1 correspond to the balance condition and excursions along each axis for each cut length. It can be appreciated from Table 1 that providingspherical cut53 to a length corresponding tofirst position68 minimizes the z axis excursion proximal to the functional asymmetry. It is preferable to balanceultrasonic blade88 below 15% z axis excursion proximal to the functional asymmetry and it is most preferable to balanceultrasonic blade88 below 5% z axis excursion proximal to the functional asymmetry. Preferably clampcoagulator120 is designed to be balanced when activated in air (loaded only by air), and then balance is verified under other load conditions.
• In Table 1, a normalized excursion percentage (% z) in a clamping instrument at the end-[0132]effector88 is calculated by taking the magnitude of the excursion in the direction normal to the clamp arm when the clamp arm is in its fully closed position, and dividing that magnitude by the magnitude of the maximum tip vibration excursion (also called the primary tip vibration excursion), and then multiplying the dividend by one hundred. Primary tip vibration excursion is the magnitude of the major axis of the ellipse or ellipsoid created by a point on the distal most end ofultrasonic blade88 when theultrasonic blade88 is activated. The measurement of excursions is more fully explained in IEC international standard 61847, titled Measurement and Declaration of the Basic Output Characteristics of ultrasonic surgical systems, hereby incorporated herein by reference. A normalized excursion percentage (%x, %y, %z) inultrasonic blade88 orultrasonic waveguide179 is calculated by taking the magnitude of a secondary vibration excursion, and dividing that magnitude by the magnitude of the primary tip vibration excursion, and then multiplying the dividend by one hundred. Secondary tip vibration excursion is the magnitude of a minor axis, or other arbitrary axis, of the ellipse or ellipsoid created by a point on the distal most end ofultrasonic blade88 when theultrasonic blade88 is activated.
• Table 1. Three possible lengths to provide a range of balances for a 0.946 inch long blade with a radius of R[0133]1 manufactured from Ti6Al-4V with the blade including a functional asymmetry.

  	% x at distal	% y at distal	% z at distal
  	end of blade	end of blade	end of blade	% z proximal
  	88	88	88	toblade 88

  Cut Length =	71.83	69.47	4.15	0.40
  12.8 mm,
  Location atfirst
  position
  68
  Cut Length = 14.8	72.49	68.87	1.60	12.43
  mm, Location at
  second position 67
  Cut Length = 8.2	74.54	66.03	9.21	8.25
  mm, Location at
  third position 66
  5

• Referring now to FIGS.[0134]1-4, the procedure to attach and detach theclamp coagulator120 from theacoustic assembly80 will be described below. When the physician is ready to use theclamp coagulator120, the physician simply attaches theclamp coagulator120 onto theacoustic assembly80. To attach theclamp coagulator120 toacoustic assembly80, the distal end ofstud50 is threadedly connected to the proximal end of the transmission component orultrasonic waveguide179. Theclamp coagulator120 is then manually rotated in a conventional screw-threading direction to interlock the threaded connection between thestud50 and theultrasonic waveguide179.
• Once the[0135]ultrasonic waveguide179 is threaded onto thestud50, a tool, such as, for example, a torque wrench, may be placed over theelongated member150 of theclamp coagulator120 to tighten theultrasonic waveguide179 to thestud50. The tool may be configured to engage thewrench flats169 of thehub162 of theouter tube160 in order to tighten theultrasonic waveguide179 onto thestud50. As a result, the rotation of thehub162 will rotate theelongated member150 until theultrasonic waveguide179 is tightened against thestud50 at a desired and predetermined torque. It is contemplated that the torque wrench may alternately be manufactured as part of theclamp coagulator120, or as part of thehand piece housing20, such as the torque wrench described in U.S. Pat. No. 5,776,155 hereby incorporated herein by reference.
• Once the[0136]clamp coagulator120 is attached to theacoustic assembly80, the surgeon can rotate therotational knob190 to adjust theelongated member150 at a desired angular position. As therotational knob190 is rotated, theteeth269 of thetubular collar260 slip over thepawls286 of theyoke280 into the adjacent notch or valley. As a result, the surgeon can position the end-effector180 at a desired orientation.Rotational knob190 may incorporate an indicator to indicate the rotational relationship betweeninstrument housing130 and clamparm202. As illustrated in FIGS. 17 and 18, one of theridges197 ofrotational knob190 may be used to indicate the rotational position ofclamp arm202 with respect toinstrument housing130 by utilizing, for example, anenlarged ridge200. It is also contemplated that alternate indications such as the use of coloring, symbols, textures, or the like may also be used onrotational knob190 to indicate position similarly to the use ofenlarged ridge200.
• To detach the[0137]clamp coagulator120 from thestud50 of theacoustic assembly80, the tool may be slipped over theelongated member150 of thesurgical tool120 and rotated in the opposite direction, i.e., in a direction to unthread theultrasonic waveguide179 from thestud50. When the tool is rotated, thehub162 of theouter tube160 allows torque to be applied to theultrasonic waveguide179 through thepin163 to allow a relatively high disengaging torque to be applied to rotate theultrasonic waveguide179 in the unthreading direction. As a result, theultrasonic waveguide179 loosens from thestud50. Once theultrasonic waveguide179 is removed from thestud50, theentire clamp coagulator120 may be thrown away.
• While preferred embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. Accordingly, it is intended that the invention be limited only by the spirit and scope of the appended claims.[0138]

Claims (18)

What is claimed is:

1. An ultrasonic clamp coagulator apparatus comprising:

a housing, said housing comprising an actuator;

an outer tube having a proximal end joined to said housing, and a distal end, said outer tube defining a longitudinal axis;

an actuating element reciprocably positioned within said outer tube, said actuating element operatively connected to said actuator;

an ultrasonic waveguide positioned within said outer tube, said ultrasonic waveguide having an end-effector extending distally from said distal end of said outer tube,

wherein said end-effector comprises a broad edge and a narrow edge, wherein said narrow edge is defined by the intersection of a first surface and a second surface, wherein said first surface extends proximally into said end-effector defining a length of said first surface; and

a clamp arm pivotally mounted on said distal end of said outer tube for pivotal movement with respect to said end-effector for clamping tissue between said clamp arm and said end-effector, said pivotal movement occurring about a horizontal axis, the arc of said pivotal movement of said clamp arm defining a vertical plane, said vertical plane having a vertical axis orthogonal to both said longitudinal axis and said horizontal axis, said clamp arm operatively connected to said actuating element so that reciprocal movement of said actuating element pivots said clamp arm along said vertical plane;

wherein said length of said first surface balances said waveguide such that excursion of said waveguide is minimized in said vertical plane.

2. An ultrasonic clamp coagulator apparatus according to

claim 1

, wherein excursion of said end-effector along said vertical axis is limited to less than 15%.

3. An ultrasonic clamp coagulator apparatus according to

claim 1

, wherein excursion of said end-effector along said vertical axis is limited to less than 10%.

4. An ultrasonic clamp coagulator apparatus according to

claim 1

, wherein excursion of said end-effector along said vertical axis is limited to less than 5%.

5. A blade for an ultrasonic surgical instrument comprising:

a proximal end;

a distal end;

a broad edge; and

a narrow edge, wherein said narrow edge is defined by the intersection of a first surface and a second surface, wherein said first surface extends proximally into said blade from said distal end toward said proximal end, defining a length of said first surface;

wherein said length of said first surface balances said blade such that a secondary tip excursion of said blade is less than 15% of the primary tip excursion of said blade.

6. An ultrasonic surgical instrument according to

claim 5

, wherein a secondary tip excursion of said blade is less than 10% of the primary tip excursion of said blade.

7. An ultrasonic surgical instrument according to

claim 5

, wherein a secondary tip excursion of said blade is less than 5% of the primary tip excursion of said blade.

8. An ultrasonic surgical instrument according to

claim 5

, wherein said first surface is concave.

9. An ultrasonic surgical instrument according to

claim 6

, wherein said first surface is concave.

10. An ultrasonic surgical instrument according to

claim 7

, wherein said first surface is concave.

11. An ultrasonic surgical instrument according to

claim 8

, wherein said second surface is convex.

12. An ultrasonic surgical instrument according to

claim 9

, wherein said second surface is convex.

13. An ultrasonic surgical instrument according to

claim 10

, wherein said second surface is convex.

14. A method of balancing an ultrasonic blade comprising the steps of:

A) selecting a maximum acceptable level of undesirable blade excursion;

B) adding a functional asymmetry to said blade by removing an amount of material from a portion of said blade along a length of said blade, wherein said length of said functional asymmetry satisfies said acceptable level of undesirable excursion identified in step A.

15. A method of balancing an ultrasonic blade according to

claim 14

, wherein said maximum acceptable level of undesirable blade excursion in step A is 15% normalized excursion.

16. A method of balancing an ultrasonic blade according to

claim 14

, wherein said maximum acceptable level of undesirable blade excursion in step A is 10% normalized excursion.

17. A method of balancing an ultrasonic blade according to

claim 14

, wherein said maximum acceptable level of undesirable blade excursion in step A is 5% normalize excursion.

18. A method of balancing an ultrasonic blade according to

claim 14

, wherein in step B, said functional asymmetry is a narrow edge, wherein said narrow edge is defined by the intersection of a first surface and a second surface, wherein said first surface extends proximally into said blade from a distal end of said blade toward a proximal end of said blade, defining said length of said functional asymmetry;

wherein said length of said functional asymmetry balances said blade such that a secondary tip excursion of said blade is less than 15% of the primary tip excursion of said blade.

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