Ultrasonic tool and method for manufacturing the tool

Abstract

An ultrasonic cutting tool, which is designed for an ultrasonic instrument. The tool is a blade (10), which includes a flat section (113) made of at least a first blade layer (112) and a second blade layer (113), and the first blade layer and the second blade layer are each a flat metal plate arranged in parallel in sequence and bonded in sequence.

Description

Technical Field

[0001] The present invention relates to the field of ultrasonic instruments. It relates to an ultrasonic tool for ultrasonic instruments, especially for cutting or grinding processes, and also to a method for manufacturing said tool. Background Art

[0002] Ultrasonic instruments have an ultrasonic energy generator and an elongated tip or tool or blade, the proximal end of which receives ultrasonic energy from the generator and transmits it to the distal end of the tip. Depending on the application, the distal end can be shaped to use the instrument as a probe and / or for penetrating soft tissue, cutting or treating bone tissue, etc.

[0003] It is known to provide ultrasonic tools with a conduit for a coolant. The coolant can be water or a mixture of water and ethanol and / or a disinfectant. The coolant is used to cool the blade and flush away the cut material. As shown in US 4515583 and US616550A, the conduit can be double-walled to provide an additional conduit for sucking fluid material. In addition, it is known to have a cooling water channel that branches into a plurality of outflow openings, which are made of porous, sintered material as in US 5188102 or to allow water to flow out through the surface of the ultrasonic cutting blade as disclosed in US2015 / 0005774A1. Effective cooling of the blade during bone cutting remains a challenge today.

[0004] EP 3061415 discloses a blade made and attached to a waveguide by making two half-blades separated along the longitudinal axis of the blade, cutting a part of the conduit in each half-blade, welding the two half-blades into one blade, and welding the blade to the distal end of the waveguide.

[0005] US2005165345 shows a three-layer electrode (two conductors separated by an insulator) for electrocautery in a fat removal device. The electrode can replace a rotary blade.

[0006] US5695510 shows attaching a blade by means of a threaded bayonet joint.

[0007] These devices are usually prepared by complex or time-consuming processes such as machining or sintering, which makes them very costly. What is needed now is a simple-structured ultrasonic cutting tool that can be manufactured effectively and economically. Summary of the Invention

[0008] Therefore, the task of the present invention is to obtain an ultrasonic tool of the type initially mentioned, which overcomes the above-mentioned drawbacks. Another task is to obtain a method for manufacturing the tool.

[0009] These tasks are achieved by an ultrasonic tool according to the claims and a method for manufacturing the tool.

[0010] One advantage is that the coolant and the cleaning liquid are provided from the inside of the tool. This avoids large jet streams in the working area and thus improves the visibility of the working area.

[0011] An ultrasonic cutting tool for an ultrasonic instrument, the tool being a blade, the blade including at least a flat section made of a first blade layer and a second blade layer, both the first blade layer and the second blade layer being metal plates, which are arranged parallel to each other and bonded to each other. Optionally, one or more additional blade layers may be arranged between the first blade layer and the second blade layer.

[0012] This allows for the production of thin blades with a high degree of freedom in blade forming. The flat section can be manufactured at low cost, for example, by stamping or laser cutting and / or by photochemical etching or photoetching. Such operations can also involve forming structures (inside the blade) serving as channels and other structures (such as teeth) for cutting and grinding operations (outside the blade) on the blade layer.

[0013] The length of the tool can be, for example, between 10 mm and 100 mm, particularly between 20 mm and 80 mm, particularly between 30 mm and 60 mm. The thickness of the flat section can be between 0.3 mm or 0.5 mm and 3 mm.

[0014] The tool can be used in an ultrasonic instrument, which can be coupled to an ultrasonic vibration generator and serve as a blade for cutting or grinding operations. By flowing the coolant longitudinally through the tool, the tool can be cooled from the inside. Conversely, material can be sucked away from near the tool. The flat section can be machined to form a cutting tool. In particular, its flat surface can be shaped to form a file or a rasp, and / or the edge of the flat section can be shaped to form a file or a rasp or a knife.

[0015] In various embodiments, the flat section forms one or more channels adapted to guide fluid along the inside of the blade. These channels can convey the coolant to the distal end of the blade and / or suck liquid or particles through the blade.

[0016] This allows the coolant to be guided through and along the inside of the blade, particularly the flat section. This, in turn, can serve to cool the blade and its surrounding environment. Compared with external cooling, the visibility of the working area is better.

[0017] Guiding the fluid through the attachment area and the inside of the flat section makes the tool particularly suitable for use in combination with a robot that holds and moves the tool, as it eliminates the need for additional conduits or hoses for supplying the coolant.

[0018] In an embodiment, the first blade layer or the second blade layer or both comprise a recess on a face facing the other blade layer, the recess defining a channel adapted to guide a fluid along the blade, in particular wherein the recess is formed by a subtractive process, in particular by machining or by photo-etching.

[0019] In this way, a high degree of freedom is achieved in the shaping of the channels. The channels can be easily formed by creating recesses in the interior of one or both layers. The shape and in particular the width of the channels can be adapted to the cooling requirements, thereby achieving a high cooling and cleaning efficiency. The position of the channels leaving the flat section can be determined accordingly by shaping the recesses.

[0020] Etching, especially photo-etching, has the advantage of being easily scalable for production. For example, it can be implemented as a roll-to-roll process. The notches or indentations that define the channels can be created simultaneously with the outer contour of each layer. This is precise and cost-effective for large-scale production.

[0021] In an embodiment, the first blade layer and the second blade layer are welded to each other.

[0022] In an embodiment, the flat section comprises one or more welding lines by which the first blade layer and the second blade layer are welded to each other on surfaces where the first blade layer and the second blade layer abut against each other.

[0023] In other words, the two blade layers are not welded to each other at their longitudinal edges (eg, the first edge and the second edge).

[0024] In an embodiment, the welding lines extend in a longitudinal direction in which the flat section extends, and in particular one welding line extends close to a first longitudinal edge of the flat section and another welding line extends close to a second longitudinal edge of the flat section.

[0025] In other embodiments, the weld line extends near both sides of the channel.

[0026] In an embodiment, the weld lines are discontinuous where they pass through a portion of the passageway.

[0027] In an embodiment, the flat section is connected to an attachment section for attaching the blade to the sonotrode, in particular wherein the attachment section has a rotationally symmetrical body.

[0028] Such a body simplifies the construction of the attachment section, in particular if the rotationally symmetrical body is the body around which the ring is arranged, as described below.

[0029] In an embodiment, the flat section is held in the gap of the attachment section, in particular in a press-fit manner.

[0030] In an embodiment, the flat section is incorporated within the slot, for example by welding, soldering or gluing.

[0031] In an embodiment, within the region where the flat section is held within the slot, at least one of the first blade layer and the second blade layer includes holes that form blade inlets that are in fluid communication with the channel.

[0032] This creates a conduit from the attachment section to the channel that guides fluid across the surface of one of the blade layers into (or out of) the channel.

[0033] In an embodiment, the holes are only within one of the blade layers and not within the other blade layer. This closes the conduit in the direction opposite to the radial conduit.

[0034] In an embodiment, the attachment section includes a radial conduit that is in fluid communication with the blade inlet, particularly where the radial conduit is in fluid communication with a longitudinal conduit.

[0035] Thus, fluid can be guided in the opposite direction from the longitudinal conduit through the radial conduit and the blade inlet into the channel.

[0036] In an embodiment, the attachment section includes an attachment body within which a slot is arranged, and a ring is arranged around the attachment body for pressing the attachment body, in particular.

[0037] In an embodiment, the ring serves as a seal for the radial conduit.

[0038] In an embodiment, a hollow conduit or a hollow needle is arranged within the channel and extends longitudinally from the flat section into the attachment section, and a liquid-tight connection is formed between the hollow needle and the attachment section. Within the flat section, the hollow needle can extend to the distal end of the flat section, or to at least half or three-quarters of the distance from the attachment section to the distal end.

[0039] In an embodiment, the attachment section includes an internal thread or an external thread.

[0040] In an embodiment, the flat section includes one or more holes that are in fluid communication with one or more channels.

[0041] In an embodiment, one or more edges of the flat section include teeth.

[0042] In an embodiment, one or more edges of the flat section are machined to form cutting edges.

[0043] In an embodiment, one or more edges of the flat section include one or more incisions that form openings that are in fluid communication with one or more channels.

[0044] In an embodiment, the outer surface of the flat section is shaped to include a structured surface, in particular with teeth or grooves. The structured surface can act as a file.

[0045] The presence of teeth and / or cutting edges and / or notches and / or structured surfaces and / or holes can improve the efficiency of cutting and / or grinding. In particular, the edges of the holes can participate in cutting and / or grinding. The holes and / or notches in fluid communication with the channel help to direct the liquid to where the cutting and / or abrasion is to be carried out and where the cooling effect is most needed.

[0046] The manufacturing method of the blade includes:

[0047] providing a first blade layer and a second blade layer, at least one of the blade layers comprising a recess for use as a channel within the blade;

[0048] · bonding the first blade layer and the second blade layer to each other, arranging the notch therebetween, thereby forming a flat section of the blade;

[0049] • Connect the flat section to the attachment section by clamping the flat section within the gap of the attachment section.

[0050] Alternatively, the method comprises

[0051] • Providing a first blade layer and a second blade layer and one or more further blade layers, at least one blade layer comprising notches or indentations that serve as channels in the blade.

[0052] Bonding the first blade layer and the second blade layer and one or more further blade layers to each other, arranging a notch or indentation between the first blade layer and the second blade layer, thereby forming a flat section of the blade.

[0053] • Connect the flat section to the attachment section by clamping the flat section within the gap of the attachment section.

[0054] In an embodiment, connecting the flat section to the attachment section includes heating the attachment section, inserting the flat section into a gap of the attachment section, and cooling the attachment section.

[0055] In an embodiment, the method includes the further step of machining holes through the attachment section and at least one of the blade layers to form radial conduits in fluid communication with the channel.

[0056] In an embodiment, a hole is machined through only one of the blade layers.

[0057] In an embodiment, the radial ducts and the inclined sections of the longitudinal ducts are machined starting from the circumferential position of the attachment body of the attachment section, and then they are capped to form a closed duct between the radial ducts and the inclined sections.

[0058] The radial ducts and the inclined sections are machined from the same circumferential position so that they are in fluid communication. Then, the openings formed by the machining process and required for the machining process are closed.

[0059] In an embodiment, the radial ducts and the inclined sections of the longitudinal ducts are capped by fitting a ring around the attachment body.

[0060] Such a ring is simple to manufacture and can maintain the symmetry of the blade in a balanced state, which is beneficial for its oscillation.

[0061] In other embodiments, the ducts are sealed by threading, welding, or other methods for closing the openings.

[0062] According to one aspect of the present invention, there is provided a robotic system configured to be equipped with a cutting tool as described herein, and the robotic system is programmed to apply the tool to machine an object or workpiece.

[0063] In an embodiment, the workpiece is a piece of animal or human tissue, particularly bone.

[0064] In an embodiment, the robotic system is configured to provide a fluid coolant to the cutting tool when machining the workpiece.

[0065] The internally cooled tool allows the tool to be continuously cooled in a more efficient manner and better control of the cooling, thereby controlling the temperature of the tool. This in turn can allow a longer machining time window.

[0066] The longer machining time window can in turn be used to machine the workpiece without withdrawing the tool, otherwise the tool would have to be reinserted, resulting in a loss of precision. In addition, different functions can be achieved with the same tool without withdrawing the tool. These functions can be cutting, saw filing, cooling, and suction of material.

[0067] The combination of the tool and the robotic manipulator allows three-dimensional incisions and shapes to be cut or machined in a separately controlled manner.

[0068] In an embodiment, the robotic system includes a manipulator arm to which the tool is attached and through which the tool is movable, wherein coolant is provided to the tool through the manipulator arm, particularly wherein the coolant duct is arranged inside the housing of at least one outermost link of the manipulator arm.

[0069] In an embodiment, the robotic system is programmed to apply the tool to machine the workpiece in an uninterrupted program without withdrawing the tool from the area where it is applied to the workpiece.

[0070] In an embodiment, the robotic system is programmed to apply two or more different functions of a tool to machine a workpiece without retracting the tool, in particular where the functions are cutting, sawing, filing, and sucking material.

[0071] In an embodiment, the robotic system is programmed to machine different sides of a workpiece with a tool, in particular a workpiece surface, the surface normals of which are oriented at an angle of more than forty-five degrees or more than ninety degrees relative to each other.

[0072] That is, the tool is used to machine two or more different sides of the workpiece.

[0073] In an embodiment, the robotic system is programmed to apply the tool to machine the workpiece in an uninterrupted program for at least two minutes or three minutes or four minutes or five or six minutes.

[0074] In an embodiment, the tool is shaped to include the functions of at least two of a file, a saw, or a knife.

[0075] For example, the tool can include a file and a saw, or a saw and a knife, etc. This allows the tool to be applied without interrupting the machining operation and retracting the tool.

[0076] In an embodiment, the tool is shaped to include at least two variants with the same function but different parameters.

[0077] For example, the tool can include a coarse file and a fine file, or a coarse saw and a fine saw.

[0078] In an embodiment, the robotic system includes a sensing unit configured to measure the tool force applied by the tool to the workpiece and configured to control the movement of the tool based on the measured tool force.

[0079] This makes it possible to control the movement of the tool to maintain a desired machining force. This can in turn be used to optimize the machining speed and / or prevent the tool from overheating.

[0080] In an embodiment, the robotic system includes a coolant supply unit configured to intermittently supply coolant to the tool, in particular such that a first duration during which coolant is supplied alternates with a second duration during which coolant is not supplied, in particular where the time period before the first duration occurs is between one second and ten seconds, in particular between two seconds and five seconds.

[0081] In other words, the first duration during which coolant is supplied corresponds to a pulse of coolant, and the pulse can repeat with a cycle length according to the time period.

[0082] Intermittent coolant flow prevents the formation and retention of a liquid pad between the tool and the workpiece, which would in turn affect the operation of the tool. During the coolant pulse, debris generated by the tool operation can be washed away.

[0083] In an embodiment, the robotic system or the coolant supply unit includes a sensing unit configured to measure the tool temperature and a control unit configured to control the flow of coolant towards the tool based on the measured tool temperature.

[0084] This allows the flow of the coolant to be adapted to the actual cooling requirements, which in turn depend on the working conditions between the tool and the workpiece.

[0085] The control of the flow can be achieved by continuously changing the flow or by taking discrete steps, in particular by opening and closing the flow, i.e., by pulsed flow. In the latter case, the controller can set the pulse width or the pulse frequency or the coolant pulses.

[0086] In an embodiment, the sensing unit is configured to determine the tool temperature based on the oscillation frequency of the tool's actuator, and the oscillation frequency of the actuator is continuously adapted to the actual resonance frequency of the tool.

[0087] This is based on the observation that the temperature of the tool adversely affects the mechanical properties of the tool, in particular its length, and thus affects the actual resonance frequency of the tool. The actual resonance frequency can be determined by using an ultrasonic actuator that can automatically adapt its operating frequency to the actual resonance frequency of the tool. This automatic frequency adaptation is a feature of many existing ultrasonic actuators.

[0088] Therefore, the flow of the coolant can be controlled based on the actual operating frequency of the ultrasonic actuator.

[0089] The intermittent supply of coolant to the tool and / or the control of the fluid flow and / or the measurement of the temperature as described herein can also be achieved by a coolant supply unit that is part of an arrangement in which there is no robotic system.

[0090] Other embodiments are obvious in the dependent patent claims. The features of the method claims can be combined with the features of the apparatus claims and vice versa. BRIEF DESCRIPTION OF THE DRAWINGS

[0091] The subject matter of the present invention will be explained in more detail below with reference to the exemplary embodiments shown in the drawings, which schematically show:

[0092] Figures 1-4 different views and cross-sections of a blade according to one embodiment;

[0093] Figures 5-8 blade layers with channels of different shapes;

[0094] Figures 9-14 other embodiments shown in corresponding cross-sections and front views; and

[0095] Figures 15-16 Other embodiments are shown in a front view;

[0096] Figure 17 A separate first blade layer for other embodiments and its combination with a second blade layer; and

[0097] Figures 18-19 An embodiment of an axial hollow needle having a flat section for guiding fluid into the tool.

[0098] In principle, the same reference numerals are provided for the same components in the figures. Detailed Description

[0099] Figures 1-4 Different views and cross-sections of a blade according to an embodiment are shown.

[0100] Figure 1 A perspective view is shown, Figure 2 A longitudinal cross-section is shown, which is viewed in a direction orthogonal to the plane in which the blade 10 lies, Figure 3 is a longitudinal cross-section, viewed in a direction parallel to the plane, Figure 4 is an exploded view.

[0101] The blade 10 includes a flat section 11 held by an attachment section 14. The flat section 11 constitutes the working part, i.e., for cutting or grinding materials, especially bone and / or soft tissue. The flat section 11 includes a first blade layer 112 and a second blade layer 113, which are flat pieces preferably made of metal. These two layers are joined to each other, for example, by welding. The corresponding welding line 24 is shown in dashed lines. They extend near the longitudinal first edge 25 and the second edge 26. At least one of the layers includes notches forming channels 20 along the length of the flat section 11. The channels 20 can be used to guide, distribute, and dispense coolant provided through the attachment section 14.

[0102] The blade 10 can be attached to an ultrasonic vibration generator through the attachment section 14, for example, by an external thread 15 (as shown) or an internal thread.

[0103] The pumping effect caused by the ultrasonic vibration of the blade 10 and especially the flat section 11 can enhance or facilitate the delivery and distribution of fluid.

[0104] The flat section 11 is clamped at the proximal end into a slot 135 located within an attachment body 131, which is part of the attachment section 14.

[0105] The flat section 11 is clamped into the slit 135 in the following manner: the attachment section 14 is heated, inserted into the flat section 11 when the attachment section 14 is in a hot state, and the attachment section 14 is cooled again, thereby forming a press fit. Additionally or alternatively, this connection can be achieved by means of a bond such as welding, soldering, gluing, etc.

[0106] A ring 130 is assembled around the attachment body 131, which can increase the clamping force exerted by the attachment body 131 on the flat section 11. The ring 130 is also used to close the conduit that introduces fluid from the longitudinal conduit 32 in the attachment section 14 into the channel 20 (or in the other direction) in the flat section 11. Starting from a point on the circumference of the attachment body 131, the conduit is formed by machining a radial conduit 133 leading to the flat section 11 and machining an inclined conduit section 132 that is part of the longitudinal conduit 32. After machining is completed, the two conduits are closed by the ring 130.

[0107] By means of this radial conduit 133, fluid is guided from the side of one of the first blade layer 112 and the second blade layer 113 into the channel 20. This is more reliable and easier to accomplish than guiding the fluid through the relatively thin proximal edge of the flat section 11.

[0108] The main parts of the blade 10, such as the flat section 11, the attachment section 14, and the ring 130, are typically made of titanium and / or medical-grade stainless steel. Some components can be made of aluminum alloy.

[0109] In an embodiment, the flat section 11 and the ring 130 are made of stainless steel, and the attachment section 14 is also made of stainless steel. When forming a press fit, the attachment section 14 is heated to, for example, around 400 to 500 degrees Celsius before inserting the flat section 11.

[0110] The channel 20 or the corresponding single notch or multiple notches can be formed by etching, laser engraving, electrochemical machining, and other methods.

[0111] Figures 5-8 Blade layers with different channels and blade shapes are shown. These examples illustrate the diversity that can be easily achieved in both the shape of the blade 10 and the shape of the channel 20. The shown shapes represent notches in the first blade layer 112, the second blade layer 113, or both. The welding line 24 is adjusted according to the shape of the channel 20 and / or the outer contour of the blade. Figure 5 A straight channel 20 leading from the blade inlet 134 to the front edge 27 is shown. Figure 6 In addition to the outlet at the front edge 27, the channel 20 is shown to branch outwards to side channels leading to outlets along the first edge 25 and the second edge 26. The welding line 24 is discontinuous at the part passing through the side channels. Figure 7A channel 20 is shown that extends from a blade inlet 134 to a leading edge 27 and widens towards the leading edge 27. Figure 8 A flat section 11 is shown, the leading edge 27 of which is shaped to perform a cutting action during oscillation and which has a straight channel 20 extending from the blade inlet 134 to the leading edge 27.

[0112] In an embodiment not shown, there are two or more independent channels 20. The independent channels can be used to evenly distribute coolant along the flat section 11. Additionally or alternatively, they can be used for different purposes: at least one coolant channel can be used to supply coolant to the flat section 11, while at least one suction channel can be used to suction material from the area surrounding the flat section 11.

[0113] The two channels 20 are generally laterally offset relative to each other. There can be two radial ducts 133, each leading to one of the two channels. The two radial ducts 133 can enter the flat section 11 from the same side or from opposite sides. Thus, in the latter case, one of the radial ducts 133 enters the first blade layer 112 via the blade inlet 134 and the other enters the second blade layer 113 via the blade inlet 134. In other embodiments, one of the channels is in fluid communication with an axially oriented (or longitudinal) channel within the attachment body 131.

[0114] Figures 1-8 The edge of the blade shown in a simplified representation is blunt. In a real embodiment, the edge is sharp and / or includes serrations or notches, as shown in the following figure.

[0115] Figures 9-16 A transverse section and a front view of the flat section 11 of the blade 10 are shown, and longitudinal weld lines 24 are typically provided near the first longitudinal edge 25 and the second longitudinal edge 26. The major surfaces of the flat section 11 generally include structured surfaces 23, such as teeth or grooves. The channels 20 shown in the figure are formed in only one of the layers, but it can be understood that in each case they can be formed in both layers.

[0116] Generally, the first longitudinal edge 25, the second longitudinal edge 26, and the leading edge 27 can be shaped with notches 21, teeth, serrations, or be made into combinations of blades or these or even other elements in different or the same ways. The shape of one or more channels 20 is adjusted accordingly.

[0117] Figures 9-10 A transverse section and a front view of the flat section of the blade 10 having a single longitudinal channel are shown. The corresponding shape of the channel 20 can be as Figure 5 or Figure 7 shown.

[0118] Figures 11-12Shows a transverse cross-section and a front view of the flat section of the blade 10, in which there is a hole 22 that constitutes an opening to a single channel 20 (not shown) or two parallel channels 20. Each channel is formed in a respective one of two layers. Thus, only one type of layer needs to be manufactured. The edges of these holes can have a cutting effect. The diameter of these holes 22 varies longitudinally to control the distribution of the coolant flow along the length of the flat section 11. This can be used to evenly distribute the flow.

[0119] Figures 13-14 Shows a transverse cross-section and a front view of the flat section of the blade 10, in which there are notches 21 in one or more of the first edge 25 and / or the second edge 26 and / or the front edge 27. The notches 21 serve on the one hand as saw teeth for cutting and on the other hand as ducts for guiding the coolant out of the channels 20. The corresponding shape of the channels 20 can be as Figure 6 shown.

[0120] Figures 9 to 14 Shows elements such as the weld line 24, the structured surface 23, the hole 22, and the notch 21 respectively. In other embodiments, they are combined. For example, according to Figure 15 , the notch 21 is present in the first edge 25, the hole 22 is arranged near the second edge 26, and the second edge 26 can be formed as a cutting edge. The channels 20 (not shown) of corresponding shape are arranged to be in fluid communication with the hole 22 and the notch 21.

[0121] In other embodiments, depending on the shape of the channels 20 between these weld lines, there are two or more weld lines 24. The weld lines 24 can be used to strengthen the structure of the flat section 11, thereby changing its natural oscillation frequency, especially by reducing the parasitic lateral vibrations. Figure 16 Shows a weld line 24 in a fishbone pattern.

[0122] Figure 17 Shows another embodiment in which the first blade layer 112 and the second blade layer 113 each include a part of the attachment section 14, which form a cylindrical, especially tubular attachment section 14 when the layers are joined. This tubular section is in liquid communication with one or more channels 20 (not shown). These two layers can be manufactured by molding or deep drawing.

[0123] Figure 17 and 19Another embodiment is shown in which coolant is directed through the flat section 11 within the hollow needle 28. The hollow needle extends longitudinally along the blade 10. In the flat section 11, it is located within the channel 20. For illustration purposes, a gap between the hollow needle 28 and a portion of the flat section 11 is shown in the figure. However, in practice, the hollow needle 28 may be arranged and / or shaped to be in close contact with the flat section 11 (i.e., the first blade layer 112 and the second blade layer 113) to allow for heat transfer. In an embodiment, a filler with good thermal conductivity is arranged between the hollow needle 28 and the flat section 11. The hollow needle 28 extends from the flat section 11 into the attachment section 14 where it may be seated therein, for example, by a press fit. This allows for the formation of a liquid-tight conduit from the attachment section 14 to the flat section 11.

[0124] Notches such as the holes 22 and the cutouts 21 can be machined by stamping or laser cutting, especially while machining the shape of the flat section 11 or the layers. Other smaller structures, such as the structured surface 23, can be created by laser engraving or etching. The notches and other structures can be created on the first blade layer and the second blade layer either before or after welding the first blade layer 112 and the second blade layer 113 against each other.

[0125] The structured surface 23 can be formed during the process of flattening the blank to form the flat section 11.

[0126] The blade 10 can be operated with an ultrasonic driver having an operating frequency of 26 kilohertz.

[0127] Although the present invention has been described in the context of the current embodiments, it is to be clearly understood that the invention is not limited thereto, but rather can be embodied and implemented differently within the scope of the claims.

Claims

1. An ultrasonic cutting tool for an ultrasonic instrument, the tool being a blade (10), the blade comprising: A flat section (11) made of at least a first blade layer (112) and a second blade layer (113), wherein both the first blade layer and the second blade layer are flat plates, which are arranged parallel to each other and bonded to each other or to one or more intermediate layers, wherein the flat section (11) is connected to an attachment section (14) for attaching the blade (10) to an ultrasonic generator, and wherein the flat section (11) is held within a slot (135) of the attachment section (14).

2. The ultrasonic cutting tool according to claim 1, wherein the first blade layer (112) or the second blade layer (113) or both include notches on the face facing the other blade layer that define channels (20) adapted to direct fluid along the blade (10).

3. The ultrasonic cutting tool according to claim 1 or 2, wherein the first blade layer (112) and the second blade layer (113) are welded to each other.

4. The ultrasonic cutting tool according to claim 2, wherein the flat section (11) includes one or more welding lines (24), and the first blade layer (112) and the second blade layer (113) are welded to each other by the welding lines on the faces where the first blade layer (112) and the second blade layer (113) abut against each other.

5. The ultrasonic cutting tool according to claim 4, wherein the welding lines (24) extend along the longitudinal direction in which the flat section (11) extends, and one welding line (24) extends near the first longitudinal edge (25) of the flat section (11) and another welding line (24) extends near the second longitudinal edge (26) of the flat section (11).

6. The ultrasonic cutting tool according to claim 4, wherein the welding lines (24) are discontinuous at the part where they cross a portion of the channels (20).

7. The ultrasonic cutting tool according to claim 1 or 2, wherein the attachment section (14) has a rotationally symmetric body.

8. The ultrasonic cutting tool according to claim 2, wherein the flat section (11) is held within the slot (135) of the attachment section (14) by a press fit.

9. The ultrasonic cutting tool according to claim 8, wherein in the region where the flat section (11) is held within the slot (135), at least one of the first blade layer (112) and the second blade layer (113) includes holes that constitute a blade inlet (134) in fluid communication with the channels (20).

10. The ultrasonic cutting tool according to claim 9, wherein the attachment section (14) includes a radial conduit (133) in fluid communication with the blade inlet (134).

11. The ultrasonic cutting tool according to claim 10, wherein the attachment section (14) includes an attachment body (131) in which the slit (135) is arranged, and a ring (130) is arranged around the attachment body (131).

12. The ultrasonic cutting tool according to claim 11, wherein the ring (130) serves as a seal for the radial conduit (133).

13. The ultrasonic cutting tool according to claim 2, wherein a hollow conduit or a hollow needle (28) is arranged in the channel (20) and extends from the flat section (11) into the attachment section (14), forming a liquid-tight connection between the hollow needle (28) and the attachment section (14).

14. The ultrasonic cutting tool according to claim 1 or 2, wherein the attachment section (14) includes an internal thread or an external thread (15).

15. The ultrasonic cutting tool according to claim 2, wherein the flat section (11) includes one or more holes (22) that are in fluid communication with one or more of the channels (20).

16. The ultrasonic cutting tool according to claim 5, wherein one or more of the first longitudinal edge (25) and the second longitudinal edge (26) of the flat section (11) and the front edge (27) of the flat section (11) include teeth.

17. The ultrasonic cutting tool according to claim 5, wherein one or more of the first longitudinal edge (25) and the second longitudinal edge (26) of the flat section (11) and the front edge (27) of the flat section (11) are machined to form a cutting edge.

18. The ultrasonic cutting tool according to claim 5, wherein one or more of the first longitudinal edge (25) and the second longitudinal edge (26) of the flat section (11) and the front edge (27) of the flat section (11) include one or more notches (21), and the notches form openings that are in liquid communication with one or more of the channels (20).

19. The ultrasonic cutting tool according to claim 1 or 2, wherein the outer surface of the flat section (11) is machined to include a structured surface (23).

20. A method of manufacturing an ultrasonic cutting tool according to any one of claims 1 to 19, the tool being a blade (10), wherein the method includes: · Provide a first blade layer (112) and a second blade layer (113); · Bond the first blade layer (112) and the second blade layer (113) to each other to form a flat section (11) of the blade (10); · Connect the flat section (11) to the attachment section (14) by clamping the flat section (11) into a slot (135) of the attachment section (14).

21. A method of manufacturing an ultrasonic cutting tool according to any one of claims 1 to 19, said tool being a blade (10), wherein the method comprises: · Provide a first blade layer (112) and a second blade layer (113) and one or more additional blade layers; · Bond the first blade layer (112), the second blade layer (113) and one or more additional blade layers to each other to form a flat section (11) of the blade (10); · Connect the flat section (11) to the attachment section (14) by clamping the flat section (11) into a slot (135) of the attachment section (14).

22. The method according to claim 20 or 21, wherein at least one of the first blade layer (112) and the second blade layer (113) and any additional blade layers comprises a notch or recess serving as a channel (20) within the blade (10); and wherein · when the first blade layer (112) and the second blade layer (113) and one or more additional blade layers are joined to one another, the notch or recess is arranged between the first blade layer (112) and the second blade layer (113).

23. The method according to claim 20 or 21, wherein · when the first blade layer (112) and the second blade layer (113) and one or more additional blade layers are joined to one another, at least one hollow needle (28) is arranged between two of the layers; and · when the flat section (11) is connected to the attachment section (14), a portion of the hollow needle (28) extending out of the flat section (11) is inserted into the attachment section (14) and a fluid-tight connection is formed therebetween.

24. The method according to claim 20 or 21, wherein connecting the flat section (11) to the attachment section (14) comprises: Heat the attachment section (14), insert the flat section (11) into a slot (135) of the attachment section (14), and cool the attachment section (14).

25. The method according to claim 22, which comprises a further step of machining a hole through the attachment section (14) and at least one of the blade layers to form a radial conduit (133) in fluid communication with the channel (20).

26. The method according to claim 25, for manufacturing the tool according to claim 9, wherein the inclined section (132) of the radial conduit (133) and the longitudinal conduit (32) is machined starting from the circumferential position of the attachment body (131) of the attachment section (14), and is then capped to form a closed conduit between the radial conduit (133) and the longitudinal conduit (32).

27. The method according to claim 26, wherein the inclined section (132) of the radial conduit (133) and the longitudinal conduit (32) is capped by fitting a ring (130) around the attachment body (131).

28. The method according to claim 20 or 21, wherein the step of providing the blade layer (112, 113) includes forming notches defining channels (20) in at least one of the layers by a photolithography process.

29. A robotic system configured to be equipped with an ultrasonic cutting tool according to any one of claims 1-19, the robotic system being programmed to apply the tool to machine an object or workpiece.

30. The robotic system according to claim 29, comprising a manipulator arm to which the tool is attached and by which the tool is movable, wherein coolant is provided to the tool by the manipulator arm.

31. The robotic system according to any one of claims 29 to 30, programmed to apply the tool to machine the workpiece in an uninterrupted program without withdrawing the tool from the area where it acts on the workpiece.

32. The robotic system according to claim 31, programmed to apply the tool to machine the workpiece without withdrawing the tool using two or more different functions of the tool.

33. The robotic system according to any one of claims 29 to 30, programmed to apply the tool to machine different sides of the workpiece.

34. The robotic system according to any one of claims 29 to 30, programmed to apply the tool to machine the workpiece in an uninterrupted program for at least two minutes or three minutes or four minutes or five minutes or six minutes.

35. The robotic system according to any one of claims 29 to 30, wherein the tool is shaped to include the functions of at least two of a file, a saw or a knife.

36. The robotic system according to claim 35, wherein the tool is shaped to include at least two variants with the same function but different parameters.

37. The robotic system according to any one of claims 29 to 30, comprising a sensing unit configured to measure the tool force exerted by the tool on the workpiece and configured to control the movement of the tool based on the measured tool force.

38. The robotic system according to any one of claims 29 to 30, configured to intermittently supply coolant to the tool.

39. The robotic system according to any one of claims 29 to 30, comprising a sensing unit and a control unit, the sensing unit being configured to measure the tool temperature, the control unit being configured to control the coolant flowing to the tool based on the measured tool temperature.

40. The robot system according to claim 39, wherein the sensing unit is configured to determine the temperature of the tool based on the drive oscillation frequency of the tool, and the drive oscillation frequency is continuously adapted to the actual resonance frequency of the tool.

41. The robot system according to any one of claims 29 to 30, configured to control the coolant flowing to the tool according to the actual operating frequency of the ultrasonic driver.

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