Ultrasonic transducer assembly for ultrasonic surgical instruments

Abstract

An ultrasonic transducer assembly of an ultrasonic surgical instrument includes a horn, a piezoelectric stack proximal of the horn and defining a longitudinal opening extending therethrough, a proximal mass proximal of the piezoelectric stack and defining a longitudinal opening, and a rod fixed to the horn and extending proximally from the horn through the longitudinal opening of the piezoelectric stack and the longitudinal opening of the proximal mass. The rod is fixed to the proximal mass to pre-compress the piezoelectric stack between the horn and the proximal mass.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit and priority of U.S. Provisional Patent Application No. 63 / 027,367, filed May 20, 2020, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to ultrasonic surgical instruments, and more specifically, to ultrasonic transducer assemblies for ultrasonic surgical instruments. Background Technology

[0004] Ultrasonic surgical instruments utilize ultrasonic energy, or ultrasonic vibration, to process tissue. More precisely, ultrasonic surgical instruments utilize mechanical vibration energy transmitted at ultrasonic frequencies to coagulate, burn, fuse, seal, cut, dry, and / or otherwise process tissue.

[0005] Ultrasonic surgical instruments typically employ transducers coupled to the instrument's handle and configured to generate ultrasonic energy for transmission along a waveguide to an end effector designed to treat tissue using this ultrasonic energy. The transducer may be driven by an onboard (e.g., located on or within the handle of the ultrasonic surgical instrument) or remotely positioned (e.g., as a set-top box connected to the ultrasonic surgical instrument via a cable) ultrasonic generator. The end effector of the ultrasonic surgical instrument may include: a blade that receives ultrasonic energy from the waveguide to apply to tissue; and a clamping member configured to clamp tissue between the blade and the clamping member to facilitate tissue treatment. Summary of the Invention

[0006] As used herein, the term "far side" refers to the portion described as being farther from the user, while the term "proximal side" refers to the portion described as being closer to the user. Furthermore, to a consistent degree, any or all aspects described herein may be used in conjunction with any or all other aspects described herein.

[0007] According to various aspects of this disclosure, an ultrasonic transducer assembly for an ultrasonic surgical instrument is provided, comprising: an amplitude transformer; a piezoelectric stack located proximal to the amplitude transformer and defining a longitudinal opening extending therethrough; a proximal mass located proximal to the piezoelectric stack and defining a longitudinal opening extending therethrough; and a rod attached to the amplitude transformer and extending proximally from the amplitude transformer through the longitudinal opening of the piezoelectric stack and the longitudinal opening of the proximal mass.

[0008] In one aspect of this disclosure, the proximal mass further defines a transverse lumen communicating with the longitudinal opening of the proximal mass, such that a portion of the rod is exposed through the transverse lumen. The exposed portion of the rod is fused to the proximal mass within the transverse lumen to maintain pre-compression of the piezoelectric stack between the amplitude rod and the proximal mass.

[0009] In another aspect of this disclosure, the proximal portion of the rod extends proximal to the proximal mass block and is fused to the proximal mass block.

[0010] In another aspect of this disclosure, the proximal mass defines a plurality of transverse lumens communicating with a longitudinal opening of the proximal mass, such that multiple portions of the rod are exposed through the plurality of transverse lumens. In this aspect, the multiple exposed portions of the rod are fused to the proximal mass within the plurality of transverse lumens.

[0011] In another aspect of this disclosure, an electrode assembly comprising at least one electrode is disposed between piezoelectric elements of a piezoelectric stack.

[0012] In another aspect of this disclosure, a distal mass is positioned between the piezoelectric stack and the amplitude transformer, such that the piezoelectric stack remains compressed against the amplitude transformer when the distal mass is positioned therebetween.

[0013] In another aspect of this disclosure, the proximal mass further defines a transverse lumen communicating with the longitudinal opening of the proximal mass, the rod further defines a transverse lumen through its proximal portion, and the wedge extends at least partially through the transverse lumen of the proximal mass and the transverse lumen of the rod to maintain the piezoelectric stack under pre-compression between the amplitude rod and the proximal mass.

[0014] In another aspect of this disclosure, the distal portion of the rod is housed within a proximal cavity defined within the amplitude rod.

[0015] In another aspect of this disclosure, the longitudinal opening of the proximal mass is a tapered longitudinal opening, and the rod further includes a distal body and an expandable proximal wedge that is at least partially housed within the tapered longitudinal opening of the proximal mass, the expandable proximal wedge being configured to expand outward, thereby pushing the proximal mass distally to pre-compress the piezoelectric stack between the amplitude rod and the proximal mass.

[0016] In another aspect of this disclosure, the expandable proximal wedge includes a threaded cavity, and a threaded insert is configured to engage within the threaded cavity to expand the proximal wedge outward. Alternatively, such expandable wedges and threaded insert assemblies can be used, for example, to secure a rod to a distal mass or ultrasonic amplitude transformer to maintain pre-compression of the piezoelectric stack. Likewise, any of the other pre-compression mechanisms detailed herein can be used to secure a rod to a distal mass or ultrasonic amplitude transformer to maintain pre-compression of the piezoelectric stack, rather than securing the rod and proximal mass. Attached Figure Description

[0017] The above and other aspects and features of this disclosure will become more apparent when considered in conjunction with the accompanying drawings, which identify similar or identical elements, in the following detailed description.

[0018] Figure 1 This is a side perspective view of the ultrasonic surgical instruments provided in this disclosure;

[0019] Figure 2 yes Figure 1 An enlarged longitudinal cross-sectional view of the proximal portion of an ultrasonic surgical instrument;

[0020] Figure 3 yes Figure 1 Longitudinal cross-sectional view of the ultrasonic transducer assembly of an ultrasonic surgical instrument.

[0021] Figure 4 It is constructed for use with Figure 1 A longitudinal cross-sectional view of another ultrasonic transducer assembly used in conjunction with ultrasonic surgical instruments; and

[0022] Figure 5 It is constructed for use with Figure 1 A longitudinal cross-sectional view of another ultrasonic transducer assembly used in conjunction with ultrasonic surgical instruments. Detailed Implementation

[0023] refer to Figure 1 and Figure 2 The ultrasonic surgical instruments provided according to various aspects of this disclosure are generally identified by reference numeral 10. The ultrasonic surgical instrument 10 includes a handle assembly 100 and an elongated assembly 200 extending distally from the handle assembly 100. The handle assembly 100 includes a housing 110 defining a body portion 112 and a handle portion 114. The handle assembly 100 also includes an activation button 120 and a clamping trigger 130.

[0024] The main body portion 112 of the housing 110 is configured to support an ultrasonic transducer and generator assembly (“TAG”) 300, which includes a generator assembly 310 and an ultrasonic transducer assembly 320. The TAG 300 may be permanently engaged with or removable from the main body portion 112 of the housing 110. The generator assembly 310 includes a housing 312 configured to house internal electronics 314 of the generator assembly 310 and a support 316 configured to rotatably support the ultrasonic transducer assembly 320. Alternatively, the generator assembly 310 may be remotely positioned and coupled to the ultrasonic surgical instrument 10 via a cable.

[0025] The ultrasonic transducer assembly 320 typically includes a piezoelectric stack 322, an amplitude transformer 324, a housing 326, and an electrode assembly 330. The ultrasonic transducer 320 also includes a knob 329. The housing 326 and the knob 329 engage and cooperate to form a closed enclosure to enclose the internal components of the ultrasonic transducer assembly 320, wherein a portion of the amplitude transformer 324 extends distally from the housing 326. The knob 329 is externally accessible from the handle assembly 100 and configured for manual rotation to rotate the ultrasonic transducer assembly 320 relative to the generator assembly 310 and the housing 110.

[0026] Continue to refer to Figure 1 and Figure 2 A set of connectors 332 and corresponding rotary contacts 334, respectively associated with the generator assembly 310 and the ultrasonic transducer assembly 320, enable a drive signal to be transmitted from the generator assembly 310 to the piezoelectric stack 322 of the ultrasonic transducer assembly 320 to drive the ultrasonic transducer assembly 320, regardless of the direction of rotation of the ultrasonic transducer assembly 320. More specifically, the connectors 332 and rotary contacts 334 enable a drive signal voltage to be applied from the generator assembly 310 to the piezoelectric stack 322 via the positive and negative electrodes of the electrode assembly 330. The piezoelectric stack 322 then converts the applied voltage into mechanical energy in the form of ultrasonic vibrations, which is transmitted to the ultrasonic amplitude transformer 324 (through a compression engagement therebetween, detailed below). The amplitude rod 324 is then configured to transmit the ultrasonic energy generated by the piezoelectric stack 322 to the waveguide 230 of the elongated assembly 200, and along it to the blade 282 of the end effector 280 of the elongated assembly 200.

[0027] Still referencing Figure 1 and Figure 2The fixed handle portion 114 of the housing 110 defines a compartment 116 configured to house the battery assembly 400 and a door 118 configured to close the compartment 116. An electrical connection assembly 140 is disposed within the housing 110 of the handle assembly 100 and is used to electrically connect the start button 120, the generator assembly 310 of the TAG 300, and the battery assembly 400 to each other when the TAG 300 is supported on or within the main body portion 112 of the housing 110 and the battery assembly 400 is disposed within the compartment 116 of the fixed handle portion 114 of the housing 110, thereby enabling the ultrasonic surgical instrument 10 to be activated in response to pressing the start button 120. More specifically, when the start button 120 is activated in an appropriate manner, depending on the activation mode of the start button 120, the basic dual-mode switch assembly of the start button 120 is activated in either a "low" power mode or a "high" power mode to supply power from the battery assembly 400 to the TAG 300. The start button 120 can move in the same direction from the off position to the "low" power mode, then to the "high" power mode, or in any other suitable manner between them. Alternatively, a separate start button and / or different operating modes are also considered.

[0028] When the generator assembly 310 is located away from the ultrasonic surgical instrument 10, there is no need to provide a battery assembly 400 and a fixed handle portion 114 for housing the battery assembly 400, because the generator assembly 310 can be powered by a standard wall socket or other power source.

[0029] The elongated assembly 200 of the ultrasonic surgical instrument 10 includes an outer drive sleeve 210, an inner support sleeve 220 disposed within the outer drive sleeve 210, a waveguide 230 extending through the inner support sleeve 220, a drive assembly 250, a knob 270, and an end effector 280 including a blade 282 and a clamp 284. The proximal portion of the outer drive sleeve 210 is operatively coupled to a clamp trigger 130 of the handle assembly 100 via the drive assembly 250, while the distal portion of the outer drive sleeve 210 is operatively coupled to the clamp 284. Thus, the clamp trigger 130 can be selectively actuated to move the outer drive sleeve 210 about the inner support sleeve 220 to a position that pivots the clamp 284 relative to the blade 282 of the end effector 280 from a spaced-apart position to an approach position for clamping tissue between the clamp 284 and the blade 282. The drive assembly 250 has a force-limiting feature, thereby limiting the clamping pressure applied to the tissue to a specific clamping pressure or limiting it to a specific clamping pressure range. The knob 270 can be rotated in either direction to allow the elongated assembly 200 to rotate relative to the handle assembly 100 in either direction.

[0030] As mentioned above, waveguide 230 extends through inner support sleeve 220. Waveguide 230 defines body 232 and blade 282 extending from the distal end of body 232. Blade 282 serves as the blade of end effector 280. Waveguide 230 further includes a proximal threaded convex connector 236 configured for threaded engagement within a threaded concave receiver 349 of amplitude transformer 324, such that ultrasonic motion generated by ultrasonic transducer assembly 320 is transmitted along waveguide 230 to blade 282 for processing tissue clamped between blade 282 and clamp 284 or located near blade 282. Other suitable engagements between waveguide 230 and amplitude transformer 324 are also contemplated.

[0031] Turning Figure 3 More precisely, the ultrasonic transducer assembly 320 includes a piezoelectric stack 322, an amplitude transformer 324, and a housing 326. Figure 2 The system comprises a proximal mass block 327a, a distal mass block 327b, and a rod 328, which, under compression, fixes the piezoelectric stack 322 between the proximal mass block 327a and the distal mass block 327b, respectively, and to the amplitude transformer 324. The pre-compression (direct or indirect) of the piezoelectric stack 322 against the amplitude transformer 324 enables efficient transmission of ultrasonic energy from the piezoelectric stack 322 to the amplitude transformer 324, for transmission along the waveguide 230 to the blade 282, for processing tissue clamped between the blade 282 and the clamp 284 or located near the blade 282 (see...). Figure 1 and 2 As mentioned above, the ultrasonic transducer assembly 320 further includes an electrode assembly 330 having at least one electrode disposed in contact with the surface of at least one piezoelectric element 323 of the piezoelectric stack 322 and at least one electrode disposed in contact with the opposing surface of at least one piezoelectric element 323 of the piezoelectric stack 322, so that a drive signal voltage can be applied to the piezoelectric stack 322. In some configurations, the distal mass 327a is omitted, and the amplitude transformer 324 acts as the distal mass against which the piezoelectric stack 322 is directly compressed.

[0032] As mentioned above, under compression, the rod 328 secures the piezoelectric stack 322 between the proximal mass block 327a and the distal mass block 327b, respectively, and to the amplitude transformer 324. This is achieved by securing the rod 328 to the amplitude transformer 324 at its distal end and to the proximal mass block 327a at its proximal end. Alternatively, the rod 328 and the amplitude transformer 324 can be integrally formed as a single, monolithic component before assembling the ultrasonic transducer assembly 320. Thus, since the rod 328 already has the amplitude transformer 324 formed within it, it is not necessary to secure the rod 328 to the amplitude transformer 324 at its distal end during assembly. The proximal and / or distal mass blocks 327a, 327b can each define a disc-shaped configuration or any other configuration, and include a central opening to allow longitudinal reception of the rod 328 passing through it.

[0033] For assembling the ultrasonic transducer assembly 320, the electrodes of the electrode assembly 330 are positioned between the piezoelectric elements 323 of the piezoelectric stack 322, with proximal mass 327a and distal mass 327b respectively arranged at the proximal and distal ends of the piezoelectric stack 322. The distal portion of the rod 328 is secured, for example, by threaded engagement, welding, pressing, a combination thereof, or any other suitable method, within a proximal-facing cavity 325a defined within the amplitude rod 324. Alternatively, as mentioned above, the rod 328 and the amplitude rod 324 can be integrally formed, thereby eliminating the need for such fixation. Furthermore, the rod 328 can be integrally formed with the distal mass 327b. The electrodes, piezoelectric element 323, and proximal and distal mass blocks 327a and 327b of electrode assembly 330 are arranged around rod 328, for example, wherein rod 328 is received longitudinally through its central opening and positioned such that distal mass block 327b is adjacent to amplitude transformer rod 324. Some or all of the above steps may be performed in the order detailed above, in any other suitable order, simultaneously and / or in a time relationship that overlaps with each other.

[0034] Regardless of the specific order of the steps, the above results in a configuration in which the distal portion of the rod 328 is secured within a proximal cavity 325a of the amplitude rod 324, and wherein the distal mass 327b, the piezoelectric stack 322 (containing electrodes of an electrode assembly 330 disposed between piezoelectric elements 323 of the piezoelectric stack 322), and the proximal mass 327a are positioned around the rod 328 in a direction extending from the amplitude rod 324 from distal to proximal. Once this position is reached, the assembly can be loaded into a fastener (not shown), whereby the fastener contacts and holds the assembly in said position at both the distal position (e.g., at the amplitude rod 324) and the proximal position (e.g., at the proximal mass 327a).

[0035] With the fastener holding the assembly in place, the fastener can then be manipulated, actuated, or otherwise adjusted to apply a longitudinal compressive force to the assembly until proper pre-compression of the piezoelectric stack 322 is achieved between the proximal mass 327a and the amplitude transformer 324. Since the piezoelectric stack 322 generates a voltage when compressed, a longitudinal compressive force can be applied until a predetermined voltage generated by the piezoelectric stack 322 is measured, or until a voltage within a predetermined voltage range is measured. This voltage or voltage range may correspond to a predetermined pre-compression force or pre-compression force range. Alternatively, a force gauge can be used to determine the pre-compression force.

[0036] Continue to refer to Figure 3 Once the desired pre-compression force (or a pre-compression force within the desired range) is reached, the fasteners are locked or otherwise maintained to hold the assembly in place, thereby maintaining the piezoelectric stack 322 between the proximal mass 327a and the amplitude rod 324 under compression. Thereafter, at one or more locations "L" at the interface between the rod 328 and the proximal mass 327a, such as at one or more annular locations around the outer periphery of the rod 328 adjacent to the proximal side of the proximal mass 327a, the proximal portion of the rod 328 is secured to the proximal mass 327a, for example, by fusion (e.g., welding).

[0037] The proximal mass 327a includes one or more transverse lumens 350 that extend laterally through and communicate with its central opening, such that the transverse lumens 350 expose portions of a rod 328 extending through the central opening of the proximal mass 327a. These exposed portions of the rod 328 provide additional fusion (e.g., welding) locations “L” to secure the proximal portion of the rod 328 to the proximal mass 327a, for example, in one or more annular locations around the periphery of the rod 328 adjacent to the proximal and / or distal inner surfaces of the proximal mass 327a defining each transverse lumen 350. The fusion locations “L” established by the transverse lumens 350 are not limited to any specific location within the transverse lumens 350; in fact, any suitable one or more locations “L” defined by the transverse lumens 350 may be utilized. Any suitable arrangement can provide any suitable number of transverse lumens 350, such as a pair of exactly opposite orifices, four orifices arranged around the proximal mass 327a at 0, 90, 180, and 270 degrees, and / or other radially symmetrical or asymmetrical arrangements. Furthermore, the transverse lumens 350 need not be arranged perpendicular to the longitudinal axis of the rod 328, but can be arranged at any suitable angle intersecting the central opening of the proximal mass 327a and thus exposing a portion of the rod 328.

[0038] In some configurations, instead of the fusion position "L" established by the transverse lumen 350 serving as an additional fusion position "L," the rod 328 and the proximal mass 327a can be fused together using only the fusion position "L" defined by the transverse lumen 350. Similarly, instead of fusion at the proximal interface between the rod 328 and the proximal mass 327a (where the rod 328 emerges from the proximal end through the central opening defined by the proximal mass 327a), the rod 328 and the proximal mass 327a can be secured at this proximal interface in another suitable manner, such as by a nut that partially engages with a threaded portion around the rod 328. In any of the above configurations, securing the rod 328 and the proximal mass 327a at the fusion position "L" defined by the transverse lumen 350 (itself or among other fasteners) helps maintain a predetermined pre-compression or compression force on the piezoelectric stack 322 between the proximal mass 327a and the amplitude transformer 324. It should be noted that, for example, due to the expansion or stretching of the component during release, temperature, etc., the predetermined pre-compression force or the compression force within the predetermined range of compression force applied during assembly may not be equal to the maintained compression force; therefore, a predetermined pre-compression force or a pre-compression force within the predetermined range of pre-compression force may be selected to achieve the obtained maintained compression force.

[0039] Once the above assembly is completed, the housing 326 and knob 329 can be positioned and secured around the assembly to complete the assembly of the ultrasonic transducer assembly 320 (see [link]). Figure 2 ).

[0040] See Figure 4 Another mechanism shown, used with the ultrasonic transducer assembly 320 to maintain the piezoelectric stack 322 under compression between the proximal mass 327a and the amplitude rod 324, typically includes a transverse lumen 1350a defined at least partially through and communicating with the central orifice of the proximal mass 327a. In some configurations, the transverse lumen 1350a extends entirely through the proximal mass 327a. The rod 328 also includes a transverse lumen 1350b extending proximally through it.

[0041] Regarding assembly, as mentioned above... Figure 3 The detailed assembly of the ultrasonic transducer assembly 320 involves the distal portion of the rod 328 being secured, for example by threaded engagement, welding, pressing, combination thereof, integral formation, or any other suitable means, within the proximal cavity 325a of the amplitude rod 324, and the distal mass 327b, the piezoelectric stack 322 (including the electrodes of the electrode assembly 330 disposed between the piezoelectric elements 323 of the piezoelectric stack 322), and the proximal mass 327a being positioned around the rod 328 in a direction extending from the distal to the proximal end of the amplitude rod 324.

[0042] Once the above assembly is completed, whether or not the above-mentioned points are required... Figure 3 As detailed, when a compressive force is applied, the transverse cavity 1350b of rod 328 and the transverse cavity 1350a of proximal mass block 327a partially overlap each other.

[0043] Continue to refer to Figure 4 Once the transverse cavity 1350b of rod 328 and the transverse cavity 1350a of proximal mass 327a partially overlap, the wedge 1350c is driven through the transverse cavity 1350a of proximal mass 327a and into the transverse cavity 1350b of rod 328. Driving the wedge 1350c through the transverse cavity 1350a and into the transverse cavity 1350b pushes rod 328 proximally and / or proximal mass 327a distally relative to each other, thereby applying precompression between proximal mass 327a and amplitude rod 324. The wedge 1350c may be a tapered pin or other suitable structure used to increase the precompression between proximal mass 327a and amplitude rod 324 upon further driving through the transverse cavity 1350a and into the transverse cavity 1350b.

[0044] The wedge 1350 can be driven to a predetermined position, or can be driven until a desired pre-compression or a pre-compression range within the desired pre-compression range of the piezoelectric stack 322 between the proximal mass 327a and the amplitude rod 324 is achieved. Pre-compression can be measured by voltage sensing as described above or by any other suitable method. In some configurations, the rod 328 and the proximal mass 327a and / or the wedge 1350c and the proximal mass 327a can be provided fused (e.g., welded) or otherwise further fixed relative to each other, to further maintain their relative positions and sustain the pre-compression between the proximal mass 327a and the amplitude rod 324.

[0045] Once the above assembly is completed, the housing 326 and knob 329 can be positioned and secured around the assembly to complete the assembly of the ultrasonic transducer assembly 320 (see [link]). Figure 2 ).

[0046] refer to Figure 5This illustrates another mechanism used with the ultrasonic transducer assembly 320 to maintain the piezoelectric stack 322 under compression between the proximal mass 327a and the amplitude transformer 324, wherein the proximal mass 327a defines a tapered central opening 2350b that gradually decreases in inner diameter in a proximal-to-far direction. The transformer 328 includes a cylindrical distal body portion 2350c and a proximal wedge-shaped portion 2350d that gradually decreases in outer diameter in a proximal-to-far direction. The cylindrical distal body portion 2350c and the proximal wedge-shaped portion 2350d may be integrally formed together as a single piece, or they may be formed separately and subsequently joined, for example, by welding. The proximal wedge-shaped portion 2350d of the rod 328 further includes a proximal cavity 2350e defined therein, the proximal cavity including a threaded cylindrical portion 2350f that opens to an open proximal end of the proximal cavity 2350e, and a tapered portion 2350g that gradually narrows in a proximal direction and extends distally from the threaded cylindrical portion 2350f to a closed distal end of the proximal cavity 2350e. An insert 2350h defined in the tapered distal portion 2350i that gradually narrows in a proximal direction and a threaded cylindrical portion 2350j extending proximally from the tapered distal portion 2350i are configured for threaded engagement within the proximal cavity 2350e.

[0047] Regarding assembly, as mentioned above... Figure 3 The detailed assembly of the ultrasonic transducer assembly 320 involves the cylindrical distal body portion 2350c of the rod 328 being secured, for example, by threaded connection, welding, pressing, combination thereof, integral formation, or any other suitable means, within the proximal cavity 325a of the amplitude rod 324, and the distal mass 327b, the piezoelectric stack 322 (including the electrodes of the electrode assembly 330 disposed between the piezoelectric elements 323 of the piezoelectric stack 322), and the proximal mass 327a being positioned around the rod 328 in a direction extending from the distal to the proximal end of the amplitude rod 324.

[0048] Because the maximum outer diameter of the proximal wedge-shaped portion 2350d of the rod 328 is large enough to prevent the minimum inner diameter of the tapered central opening 2350b of the proximal mass block 327a from passing through, the aforementioned assembly can be achieved by first inserting the rod 328 distally through the proximal mass block 327a, the piezoelectric stack 322 (containing the electrodes of the electrode assembly 330), and the distal mass block 327b, and then fixing the cylindrical distal body portion 2350c of the rod 328 to the proximal-facing cavity 325a of the amplitude rod 324. Other suitable fixing sequences and / or methods may also be considered.

[0049] Once the aforementioned parts have been assembled, the insert 2350h is at least partially threaded into, or further at least partially threaded into, the proximal cavity 2350e of the proximal wedge portion 2350d of the rod 328, to advance the insert 2350h distally within the proximal cavity 2350e and relative to the proximal wedge portion 2350d of the rod 328, as indicated by arrow "A". Due to the tapered construction of the insert 2350h and the proximal cavity 2350e, the distal advancement of the insert 2350h pushes the proximal wedge portion 2350d of the rod 328 outwardly, as indicated by arrow "B". Furthermore, due to the conical structure of the proximal wedge-shaped portion 2350d of the rod 328 and the conical central opening 2350b of the proximal mass block 327a, the outward expansion of the proximal wedge-shaped portion 2350d of the rod 328 pushes the proximal mass block 327a distally, thereby compressing the piezoelectric stack 322 between the proximal mass block 327a and the amplitude transformer 234. It should be noted that when the proximal mass block 327a is pushed distally, fasteners (not shown) or other suitable structures can be used to maintain the amplitude transformer 234 in a substantially fixed position, thereby achieving compression of the piezoelectric stack 322.

[0050] The insert 2350h can be driven to a predetermined position, or can be driven until a desired pre-compression or a pre-compression within a desired range is achieved in the piezoelectric stack 322 between the proximal mass 327a and the amplitude rod 324. Pre-compression can be measured by voltage sensing as described above or by any other suitable method. In some configurations, fusion (e.g., welding) or other methods can be provided to fix the rod 328, proximal mass 327a, and / or insert 2350h relative to each other to further maintain their relative positions and sustain pre-compression between the proximal mass 327a and the amplitude rod 324. Alternatively, as an alternative to the insert 2350h being threaded into the proximal cavity 2350e, the insert 2350h can be slidable (e.g., wedged) into the proximal cavity 2350e, thereby increasing the expanded proximal wedge portion 2350d, and then fused (e.g., welded) in place after the desired pre-compression of the piezoelectric stack 322 is achieved. In this type of configuration, a compression fastener (not shown) can be used to hold the component and drive the insert 2350h to slide into the proximal cavity 2350e.

[0051] Once the above assembly is completed, the housing 326 and knob 329 can be positioned and secured around the assembly to complete the assembly of the ultrasonic transducer assembly 320 (see [link]). Figure 2 ).

[0052] Return to reference Figure 1In addition to the handheld, manually operated handle assembly 100, aspects and features of this disclosure are also applicable to use with robotic surgical systems, often referred to as "remote surgery." Such systems employ various robotic elements to assist surgeons and allow for remote (or partially remote) operation of surgical instruments. For this purpose, various robotic arms, gears, cams, pulleys, electric motors, and mechanical motors can be employed, and these can be designed to assist surgeons during the procedure or treatment. Such robotic systems can include remotely operable systems, automated flexible surgical systems, remote flexible surgical systems, remote articulated surgical systems, wireless surgical systems, modular or selectively configured remotely operated surgical systems, etc.

[0053] Robotic surgical systems can be employed in conjunction with one or more consoles located immediately adjacent to the operating room or at a remote location. In this example, a team of surgeons or nurses can prepare the patient for surgery and construct the robotic surgical system using one or more of the instruments disclosed herein, while another surgeon (or a group of surgeons) remotely controls the instruments via the robotic surgical system. As can be understood, a highly skilled surgeon can perform multiple procedures in multiple locations without leaving his / her remote console, which is economically advantageous and beneficial to the patient or a group of patients.

[0054] The robotic arm of a surgical system is typically coupled to a pair of master handles via a controller. The surgeon can move the handles to produce corresponding movements of the working end of any type of surgical instrument (e.g., end effector, gripper, scalpel, scissors, etc.). The movement of the master handles can be proportionally adjusted so that the corresponding movement of the working end differs from, is less than, or is greater than the movement performed by the surgeon's operating hand. The scaling factor or gear ratio can be adjustable, allowing the operator to control the resolution of the working end of the surgical instrument.

[0055] The main handle may include various sensors to provide surgeons with feedback on a range of tissue parameters or conditions, such as tissue resistance due to manipulation, cutting, or other treatments; pressure exerted by instruments on the tissue; tissue temperature; and tissue impedance. These sensors provide surgeons with enhanced tactile feedback that simulates real-world conditions. The main handle may also include a variety of actuators for manipulating or treating delicate tissues, further enhancing the surgeon's ability to simulate real-world scenarios.

[0056] While several aspects and features of this disclosure have been detailed above and illustrated in the drawings, it is not intended to limit this disclosure, but rather to have the broad scope permitted by the art and the understanding thereof. Therefore, the above description and drawings should not be construed as limiting, but merely as illustrative. Those skilled in the art will contemplate other modifications within the scope and spirit of the appended claims.

Claims

1. An ultrasonic transducer assembly for an ultrasonic surgical instrument, comprising: Amplitude lever; A piezoelectric stack is located near the amplitude transformer and defines a longitudinal opening extending therethrough; A proximal mass block, located proximal to the piezoelectric stack and defining a longitudinal opening extending therethrough, the proximal mass block further defining a transverse lumen communicating with the longitudinal opening of the proximal mass block; as well as A rod, which is fixed to the amplitude rod and extends proximally through the longitudinal opening of the piezoelectric stack and the longitudinal opening of the proximal mass block, such that a portion of the rod is exposed through the transverse lumen. The exposed portion of the rod, which is exposed through the transverse lumen, is fused to the proximal mass block within the transverse lumen to maintain the pre-compression of the piezoelectric stack between the amplitude rod and the proximal mass block.

2. The ultrasonic transducer assembly of claim 1, wherein the proximal portion of the rod extends proximally from the proximal mass block, and wherein the proximal portion of the rod is fused to the proximal mass block.

3. The ultrasonic transducer assembly of claim 1, wherein the proximal mass defines a plurality of transverse lumens communicating with the longitudinal opening of the proximal mass, such that a plurality of portions of the rod are exposed through the plurality of transverse lumens, and wherein the plurality of exposed portions of the rod exposed through the plurality of transverse lumens are fused to the proximal mass within the plurality of transverse lumens.

4. The ultrasonic transducer assembly of claim 1, further comprising an electrode assembly including at least one electrode disposed between the piezoelectric elements of the piezoelectric stack.

5. The ultrasonic transducer assembly of claim 1, further comprising a distal mass block disposed between the piezoelectric stack and the amplitude transformer, wherein, with the distal mass block disposed therebetween, the piezoelectric stack maintains compression against the amplitude transformer.

6. An ultrasonic transducer assembly for an ultrasonic surgical instrument, comprising: Amplitude lever; A piezoelectric stack is located near the amplitude transformer and defines a longitudinal opening extending therethrough; A proximal mass block, located proximal to the piezoelectric stack and defining a longitudinal opening extending therethrough, the proximal mass block further defining a transverse lumen communicating with the longitudinal opening of the proximal mass block; A rod, which is fixed to the amplitude rod and extends proximally from the amplitude rod through the longitudinal opening of the piezoelectric stack and the longitudinal opening of the proximal mass block, the rod defining a transverse lumen through its proximal portion; as well as A wedge-shaped element, which extends at least partially through the transverse lumen of the proximal mass block and the transverse lumen of the rod, to maintain the pre-compression of the piezoelectric stack between the amplitude rod and the proximal mass block.

7. The ultrasonic transducer assembly of claim 6, wherein the distal portion of the rod is received within a proximal cavity defined within the amplitude rod.

8. The ultrasonic transducer assembly of claim 6, further comprising an electrode assembly including at least one electrode disposed between the piezoelectric elements of the piezoelectric stack.

9. The ultrasonic transducer assembly of claim 6, further comprising a distal mass disposed between the piezoelectric stack and the amplitude transformer, wherein, with the distal mass disposed therebetween, the piezoelectric stack maintains compression against the amplitude transformer.

10. An ultrasonic transducer assembly for an ultrasonic surgical instrument, comprising: Amplitude lever; A piezoelectric stack is located near the amplitude transformer and defines a longitudinal opening extending therethrough; A proximal mass block, located on the proximal side of the piezoelectric stack and defining a tapered longitudinal opening extending therethrough; A rod, fixed to the amplitude transformer and extending proximally through the longitudinal opening of the piezoelectric stack and the tapered longitudinal opening of the proximal mass block, the rod comprising a distal body and an expandable proximal wedge, the expandable proximal wedge being at least partially received within the tapered longitudinal opening of the proximal mass block. The expandable proximal wedge is configured to expand outward, thereby pushing the proximal mass block distally to pre-compress the piezoelectric stack between the amplitude rod and the proximal mass block.

11. The ultrasonic transducer assembly of claim 10, wherein the expandable proximal wedge includes a threaded cavity, and wherein a threaded insert is configured to engage within the threaded cavity to cause the expandable proximal wedge to expand outward.

12. The ultrasonic transducer assembly of claim 10, wherein the distal portion of the rod is received within a proximal cavity defined within the amplitude rod.

13. The ultrasonic transducer assembly of claim 10, further comprising an electrode assembly including at least one electrode disposed between the piezoelectric elements of the piezoelectric stack.

14. The ultrasonic transducer assembly of claim 10, further comprising a distal mass disposed between the piezoelectric stack and the amplitude transformer, wherein, with the distal mass disposed therebetween, the piezoelectric stack maintains compression against the amplitude transformer.

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