Thermocouple for ultrasonic instrument

Abstract

An ultrasonic surgical instrument (10) includes a housing (112) having an elongate shaft (150) extending therefrom, the housing having an ultrasonic transducer (140) disposed therein. The ultrasonic transducer (140) is operably coupled to the waveguide (154). An ultrasonic blade (162) made of a first metal is operably coupled to and extends from the waveguide (154). The ultrasonic blade (162) is configured to vibrate to treat tissue upon activation of the ultrasonic transducer (140). A distinct second metal (500) is disposed on the ultrasonic blade. A thermocouple (600) is formed from a first electrical lead (520) extending from the reference bond (153) and a second electrical lead (510) coupled to the distinct second metal (500). The thermocouple (600) is configured to detect a temperature difference between a reference junction (153) and a portion of the blade (162) supporting the dissimilar second metal (500). The thermocouple (600) derives a temperature at the dissimilar second metal (500) from a voltage generated at a junction between the first metal and the dissimilar second metal and a temperature at the reference junction (153).

Description

Technical Field

[0001] The present disclosure relates to surgical instruments and, more particularly, to ultrasonic surgical instruments for performing multiple surgical tasks. Background Art

[0002] Ultrasonic surgical instruments and systems utilize ultrasonic energy (i.e., ultrasonic vibrations) to treat tissue. More specifically, ultrasonic surgical instruments and systems utilize mechanical vibration energy transmitted at ultrasonic frequencies to treat tissue. Ultrasonic surgical devices can include, for example, an ultrasonic blade and a clamping mechanism to enable clamping of tissue on the blade. The ultrasonic energy transmitted to the blade causes the blade to vibrate at a very high frequency, which allows heating of the tissue to treat the tissue clamped on or otherwise in contact with the blade. The ultrasonic blade can also be used to perform other surgical tasks such as, for example, dissection, scoring, incision, etc.

[0003] As mentioned above, during use, the vibration of the blade at ultrasonic frequencies causes the blade and various other elements in its immediate vicinity, such as the waveguide, to heat up to very high temperatures, thus requiring careful observation and placement of the instrument until the components have had a chance to cool. Therefore, the temperature of the blade and its proximal components plays an important role in instrument manipulation during and after activation. Additionally, and due to the particular nature of ultrasonic instruments, conventional temperature measurements of the blade and components in the vicinity of the blade, such as the waveguide, are generally difficult or unreliable due to the high-frequency vibrations. Summary of the Invention

[0004] As used herein, the term "distal" refers to the portion described as being farther from the operator (whether a human surgeon or a surgical robot), while the term "proximal" refers to the portion described as being closer to the operator. As utilized herein, terms including "generally", "about", "substantially", etc. are intended to cover variations up to and including plus or minus 10%, such as manufacturing tolerances, material tolerances, use and environmental tolerances, measurement variations, and / or other variations. Additionally, any or all aspects described herein can be used, to some extent, in combination with any or all other aspects described herein.

[0005] In accordance with aspects of the present disclosure, an ultrasonic surgical instrument is provided that includes a housing having an elongate shaft extending therefrom. An ultrasonic transducer has a waveguide operatively coupled thereto, the waveguide being configured to extend through the elongate shaft, the ultrasonic transducer being adapted to be coupled to an energy source to permit selective activation of the ultrasonic transducer. An ultrasonic blade made of a first metal is operatively coupled to the waveguide and is configured to extend from the waveguide, the ultrasonic blade being configured to vibrate upon activation of the ultrasonic transducer to treat tissue. A dissimilar second metal is disposed on a portion of the ultrasonic blade. A thermocouple is formed by a first electrical lead extending from a reference junction at a proximal end portion of the waveguide and a second electrical lead coupled to the dissimilar second metal, the thermocouple being configured to detect a temperature difference between the proximal end portion of the waveguide and the portion of the blade supporting the dissimilar second metal, the thermocouple deriving the temperature at the dissimilar second metal from a voltage generated at a junction between the first metal and the dissimilar second metal and the temperature at the reference junction.

[0006] In accordance with aspects of the present disclosure, the dissimilar second metal is deposited onto the blade via metal or plasma deposition, chemical vapor deposition, printing, spraying, sintering, curing, high velocity oxy-fuel (HVOF) thermal spraying, 3D printing, screen printing, or application of a metal ink or paint.

[0007] In accordance with aspects of the present disclosure, the ultrasonic instrument includes a handle operatively coupled to the housing and configured to selectively move relative to the housing to pivot jaw members relative to the ultrasonic blade to clamp tissue therebetween.

[0008] In accordance with aspects of the present disclosure, the housing includes a circuit that converts a voltage obtained from the temperature difference to an actual temperature on the blade at the junction with the dissimilar second metal, the circuit communicating with a display panel disposed on the housing for displaying the temperature. In other aspects of the present disclosure, the circuit converts the voltage and communicates with the display panel in real time.

[0009] According to other aspects of the present disclosure, an ultrasonic surgical instrument is provided. The ultrasonic surgical instrument includes a housing having an elongated shaft extending from the housing. An ultrasonic transducer including a waveguide made of a first metal is operably coupled to the waveguide and configured to extend through the elongated shaft. The ultrasonic transducer is adapted to be coupled to an energy source to allow selective activation of the ultrasonic transducer. An ultrasonic blade is operably coupled to the waveguide and configured to extend from the waveguide. The ultrasonic blade is configured to vibrate to treat tissue when the ultrasonic transducer is activated. A plurality of different second metals are disposed along the waveguide and extend proximally from the ultrasonic blade. A thermocouple is formed by a first electrical lead from a reference junction operably coupled to the housing and a second electrical lead coupled to each different second metal. The thermocouple is configured to detect a temperature difference between the reference junction and a portion of the blade supporting each different second metal. The thermocouple derives the temperature at each of the plurality of different second metals from the voltage generated at the junction between the first metal and each of the plurality of different second metals and the temperature at the reference junction.

[0010] In aspects according to the present disclosure, the plurality of different second metals are deposited onto the waveguide via metal or plasma deposition, chemical vapor deposition, printing, spraying, sintering, curing, high velocity oxy-fuel (HVOF) thermal spraying, 3D printing, screen printing, or application of a metal ink or paint.

[0011] In aspects according to the present disclosure, the ultrasonic instrument includes a handle operably coupled to the housing and configured to selectively move relative to the housing to pivot jaw members relative to the ultrasonic blade to clamp tissue therebetween.

[0012] In aspects according to the present disclosure, the housing includes a circuit that converts a voltage obtained from the temperature difference into an actual temperature on the waveguide at each junction supporting the plurality of different second metals on the waveguide. The circuit communicates with a display panel disposed on the housing for displaying the temperature. In other aspects according to the present disclosure, the circuit converts the voltage and communicates with the display panel in real time.

[0013] In aspects according to the present disclosure, one or more of the plurality of different second metals are disposed at nodes of the waveguide.

[0014] In aspects according to the present disclosure, each of the plurality of different second metals is disposed at nodes of the waveguide.

[0015] In other aspects of the present disclosure, a method for determining the temperature of a blade of an ultrasonic surgical instrument is provided. The method includes: electrically coupling a thermocouple across a first electrical lead and a second electrical lead, the first electrical lead extending from a proximal end portion of a waveguide and integrally coupled with an ultrasonic blade, and the second electrical lead being coupled to a different second metal disposed on top of the ultrasonic blade; obtaining a reference temperature at a reference junction; activating a transducer to energize the waveguide so that the ultrasonic blade made of a first metal vibrates to treat tissue proximal to the ultrasonic blade; using the thermocouple to detect a temperature difference between the proximal end portion of the waveguide and a portion of the blade that supports the different second metal on the blade, the thermocouple deriving the temperature at the different second metal from a voltage generated at a junction between the first metal and the different second metal and the temperature at the reference junction; and using the temperature of the portion of the blade that supports the different second metal for safety, storage, and / or manipulation.

[0016] In aspects according to the present disclosure, the method further includes depositing the different second metal on top of the blade via metal or plasma deposition, chemical vapor deposition, printing, spraying, sintering, curing, high-velocity oxy-fuel (HVOF) thermal spraying, 3D printing, screen printing, or applying a metal ink or paint.

[0017] In aspects according to the present disclosure, a housing includes a circuit that includes a thermocouple and is configured to convert a voltage obtained from the temperature difference into an actual temperature on the blade at the portion of the blade that supports the different second metal, and wherein the method further includes: communicating with a display panel disposed on the housing for displaying the temperature. In other aspects according to the present disclosure, the circuit converts the voltage and communicates with the display panel in real time. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The above and other aspects and features of the present disclosure will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings, in which like reference numerals identify similar or identical elements.

[0019] Figure 1 is a side view of a surgical system provided according to the present disclosure, the surgical system including a surgical instrument, a surgical generator, and, in aspects, a return electrode device;

[0020] Figure 2 is a perspective view of another surgical system provided according to the present disclosure, the surgical system including a surgical instrument in which an ultrasonic generator, a power supply, and, in aspects, an electrosurgical generator are incorporated;

[0021] Figure 3 is a schematic diagram of a robotic surgical system provided according to the present disclosure;

[0022] Figure 4 is Figure 1 or Figure 2 A longitudinal cross-sectional view of a distal end portion of any one of surgical instruments, the surgical instrument including a waveguide configured to support an ultrasonic blade at a distal end of the surgical instrument;

[0023] Figure 5A is for use with Figure 1 and Figure 2 A schematic view of a waveguide for use with any one of the instruments, the instrument having a blade extending from the instrument, the blade being made of a first metal and having a dissimilar second metal deposited thereon, the dissimilar second metal and a proximal end of the waveguide forming a thermocouple electrically to identify a voltage when a temperature difference exists therebetween;

[0024] Figure 5B is for use with Figure 1 and Figure 2 A schematic view of a waveguide for use with any one of the instruments, the waveguide being made of a first metal and having a dissimilar second metal deposited near a distal end of the waveguide, the dissimilar second metal and a proximal end of the waveguide forming a thermocouple electrically to identify a voltage when a temperature difference exists therebetween; and

[0025] Figure 6 is for use with Figure 1 and Figure 2 A schematic view of a waveguide for use with any one of the instruments, the waveguide being made of a first metal and having a plurality of dissimilar second metals deposited near a distal end of the waveguide and extending proximally relative to the distal end, each of the plurality of dissimilar second metals and a proximal end of the waveguide forming a thermocouple electrically to identify a voltage when a temperature difference exists therebetween. DETAILED DESCRIPTION

[0026] Referring to Figure 1 , a surgical system provided in accordance with aspects of the present disclosure is shown generally identified by reference numeral 10, the surgical system including a surgical instrument 100, a surgical generator 200. The surgical instrument 100 includes a handle assembly 110, an elongate assembly 150 extending distally from the handle assembly 110, an end effector assembly 160 disposed at a distal end of the elongate assembly 150, and a cable assembly 190 operably coupled to and extending from the handle assembly 110 to connect to the surgical generator 200.

[0027] The surgical generator 200 includes a display 210, a plurality of user interface features 220 (e.g., buttons, touchscreens, switches, etc.), and an ultrasonic plug port 230. As an alternative to the plurality of dedicated ports 230 - 260, one or more common ports (not shown) may be configured to act as any two or more of the ports 230 - 260. The surgical generator 200 is configured to generate an ultrasonic drive signal for output to the surgical instrument 100 through the ultrasonic plug port 230 to activate the surgical instrument 100 in an ultrasonic mode.

[0028] Continuing to refer Figure 1 , the handle assembly 110 includes a housing 112, an activation button 120, and a clamping trigger 130. The housing 112 is configured to support the ultrasonic transducer 140. The ultrasonic transducer 140 may be permanently joined within the housing 112 or removable from the housing. The ultrasonic transducer 140 includes a piezoelectric stack, e.g., other suitable ultrasonic transducer components electrically coupled to the surgical generator 200 via one or more of the first electrical leads 197, such that an ultrasonic drive signal can be transmitted to the ultrasonic transducer 140 to drive the ultrasonic transducer 140 to generate ultrasonic vibration energy, which is transmitted along the waveguide 154 of the elongate assembly 150 to the blade 162 of the end effector assembly 160 of the elongate assembly 150, as detailed below. Feedback and / or control signals may likewise be transmitted between the ultrasonic transducer 140 and the surgical generator 200. More specifically, the ultrasonic transducer 140 may include a stack of piezoelectric elements fixed under pre - compression between a proximal block and a distal block or a proximal block and a horn, where a first electrode and a second electrode are electrically coupled between the piezoelectric elements in the stack of piezoelectric elements to enable it to be energized to generate ultrasonic energy. However, other suitable ultrasonic transducer configurations are also contemplated, including multiple transducers and / or non - longitudinal (e.g., torsional) transducers.

[0029] The activation button 120 is disposed on the housing 112, for example, via one or more of the electrical leads 197, and is coupled to the ultrasonic transducer 140 and / or the surgical generator 200 or coupled between the ultrasonic transducer and the surgical generator such that activation of the ultrasonic transducer 140 can be responsive to pressing the activation button 120. In some configurations, the activation button 120 can include a closed / open switch. In other configurations, the activation button 120 can include multiple actuation switches such that activation can be from an off position to different actuation positions corresponding to different activation settings, for example, a first actuation position corresponding to a first activation setting (e.g., low power or tissue sealing setting) and a second actuation position corresponding to a second activation setting (e.g., high power or tissue transection setting). In still other configurations, separate activation buttons can be provided, for example, a first actuation button for activating the first activation setting and a second activation button for activating the second activation setting. Additional activation buttons, sliders, wheels, etc. are also contemplated to enable control of various different activation settings from the housing 112.

[0030] The elongate assembly 150 of the surgical instrument 100 includes an outer drive sleeve 152, an inner support sleeve 153 disposed within the outer drive sleeve 152 ( Figure 4 ), a waveguide 154 extending through the inner support sleeve 153 ( Figure 4 ), a drive assembly (not shown), a rotary knob 156, and an end effector assembly 160 including a blade 162 and a jaw member 164. The rotary knob 156 is rotatable in either direction to rotate the elongate assembly 150 relative to the handle assembly 110 in either direction. The drive assembly operably couples a proximal portion of the outer drive sleeve 152 to the clamping trigger 130 of the handle assembly 110. A distal portion of the outer drive sleeve 152 is operably coupled to the jaw member 164, and a distal end of the inner support sleeve 153 ( Figure 4 ) pivotally supports the jaw member 164. Thus, the clamping trigger 130 can be selectively actuated to thereby move the outer drive sleeve 152 about the inner support sleeve 153 ( Figure 4 ) to pivot the jaw member 164 relative to the blade 162 of the end effector assembly 160 from a spaced-apart position to a proximate position for clamping tissue between the jaw member 164 and the blade 162. The configurations of the outer sleeve 152 and the inner sleeve 153 ( Figure 4 ) can be reversed, for example, where the outer sleeve 152 is the support sleeve and the inner sleeve 153 ( Figure 4 ) is the drive sleeve. Other suitable drive structures contrary to the sleeves can also be contemplated, such as, for example, drive rods, drive cables, drive screws, etc.

[0031] Still referring to Figure 1, the drive assembly can be adjusted to provide a jaw clamping force or a jaw clamping force within a range of jaw clamping forces to tissue clamped between the jaw members 164 and the blade 162, or the drive assembly can include a force limiting feature whereby the clamping force applied to tissue clamped between the jaw members 164 and the blade 162 is limited to a specific jaw clamping force or a jaw clamping force within a range of jaw clamping forces.

[0032] As described above, the waveguide 154 extends from the handle assembly 110 through the inner sleeve 153( Figure 4 ). The waveguide 154 includes a blade 162 disposed at its distal end. The blade 162 can be integrally formed with the waveguide 154, formed separately and then (permanently or removably) attached to the waveguide 154, or otherwise operably coupled to the waveguide 154. The waveguide 154 and / or the blade 162 can be formed of titanium, a titanium alloy, or other suitable conductive materials, although non-conductive materials can also be considered. The waveguide 154 also includes a proximal connector (not shown), e.g., a threaded male connector, that is configured for engagement (e.g., threaded engagement) within a threaded female receiver of the ultrasonic transducer 140 such that ultrasonic motion generated by the ultrasonic transducer 140 is transmitted along the waveguide 154 to the blade 162 to treat tissue clamped between the blade 162 and the jaw member 164 or positioned adjacent to the blade 162.

[0033] The cable assembly 190 of the surgical instrument 100 includes a cable 192 and an ultrasonic plug 194. The ultrasonic plug 194 is configured for connection to an ultrasonic plug port 230 of the surgical generator 200.

[0034] An electrical lead 197 electrically coupled to the ultrasonic plug 194 extends through the cable 192 and into the handle assembly 110 for electrical connection to the ultrasonic transducer 140 and / or the activation button 120 such that an ultrasonic drive signal can be selectively supplied from the surgical generator 200 to the ultrasonic transducer 140 when the activation button 120 is activated in the ultrasonic mode.

[0035] As an alternative to the remote generator 200, the surgical system 10 can be at least partially cordless since the surgical system incorporates an ultrasonic generator and / or a power source, such as a battery, thereon or therein. In this way, the connection from the surgical instrument 100 to an external device (e.g., a generator and / or a power source) is reduced or eliminated. More specifically, reference Figure 2 , another surgical system according to the present disclosure is shown as a surgical instrument 20 that supports an ultrasonic generator 310, a power source (e.g., a battery assembly 400), and in all respects, thereon or therein. The surgical instrument 20 is similar to the surgical instrument 100( Figure 1), and may include any of its features, unless explicitly contradicted hereinafter. Accordingly, only the differences between the surgical instrument 20 and the surgical instrument 100 ( Figure 1 ) are described in detail hereinafter, while similarities are omitted or described in general terms.

[0036] The housing 112 of the surgical instrument 20 includes a body portion 113 and a fixed handle portion 114 that depends from the body portion 113. The body portion 113 of the housing 112 is configured to support an ultrasonic transducer and generator assembly (“TAG”) 300 that includes an ultrasonic generator 310 and an ultrasonic transducer 140. The TAG 300 may be permanently joined to or removable from the body portion 113 of the housing 112.

[0037] The fixed handle portion 114 of the housing 112 defines a compartment 116 configured to receive a battery assembly 400 and a door 118 configured to enclose the compartment 116. An electrical connection component (not shown) is disposed within the housing 112 and is operative to electrically couple the activation button 120, the ultrasonic generator 310 of the TAG 300, and the battery assembly 400 to one another when the TAG 300 is supported on or within the body portion 113 of the housing 112 and the battery assembly 400 is disposed within the compartment 116 of the fixed handle portion 114 of the housing 112, such that the surgical instrument 20 can be activated in response to appropriate actuation of the activation button 120.

[0038] Steering Figure 3 , a robotic surgical system in accordance with aspects and features of the present disclosure is generally identified by the reference numeral 1000. For purposes herein, the robotic surgical system 1000 is generally described. Aspects and features of the robotic surgical system 1000 that are not closely related to an understanding of the present disclosure are omitted to avoid obscuring aspects and features of the present disclosure with unnecessary detail.

[0039] The robotic surgical system 1000 generally includes a plurality of robotic arms 1002, 1003; a control device 1004; and an operating console 1005 coupled to the control device 1004. The operating console 1005 may include: a display device 1006 that may be particularly configured to display three-dimensional images; and manual input devices 1007, 1008 by which a person such as a surgeon (not shown) can remotely manipulate the robotic arms 1002, 1003 in a first operating mode. The robotic surgical system 1000 may be configured for a patient 1013 lying on a patient table 1012 for minimally invasive treatment. The robotic surgical system 1000 may additionally include a database 1014, particularly a database coupled to the control device 1004, in which preoperative data and / or anatomical maps from the patient 1013 are stored, for example.

[0040] Each of the robotic arms 1002, 1003 can include a plurality of members connected by joints, and attachment devices 1009, 1011 to which, for example, a surgical tool "ST" supporting the end effectors 1050, 1060 can be attached. One of the surgical tools "ST" can be a surgical instrument 100( Figure 1 ), surgical instrument 20( Figure 2 ), or any other suitable surgical instrument 20 configured for use in an ultrasonic mode, where manual actuation features (e.g., an actuation button 120( Figure 1 ), a clamping lever 130( Figure 1 ), etc.) are replaced by robotic inputs. In such a configuration, the robotic surgical system 1000 can include or be configured to connect to an ultrasonic generator and / or a power source. The other surgical tool "ST" can include any other suitable surgical instrument, such as an endoscopic camera, other surgical tools, etc. The robotic arms 1002, 1003 can be driven by electric drives (e.g., motors) connected to the control device 1004. The control device 1004 (e.g., a computer) can be configured to specifically start the motors in such a way that, through a computer program, the robotic arms 1002, 1003, their attachment devices 1009, 1011, and thus the surgical tool "ST" perform desired movements and / or functions respectively according to corresponding inputs from the manual input devices 1007, 1008. The control device 1004 can also be configured in such a way that the control device adjusts the movements of the robotic arms 1002, 1003 and / or the motors.

[0041] Referring again Figure 4 , the end effector assembly 160 as described above includes a blade 162 and a jaw member 164. The blade 162 generally defines a linear configuration, but in some cases, can define a curved configuration, or can define any other suitable configuration, such as straight and / or curved surfaces, portions, and / or sections; one or more convex and / or concave surfaces, portions, and / or sections, etc. Regarding the curved configuration, the blade 162 can bend in any direction relative to the jaw member 164 such that the distal tip of the blade 162 faces the jaw member 164, faces away from the jaw member 164, or bends laterally (in either direction) relative to the jaw member 164. Additionally, the blade 162 can be formed to include multiple curves in a similar direction, multiple curves in different directions within a single plane, and / or multiple curves in different directions in different planes. Further, the blade 162 can alternatively or additionally be formed to include any suitable features, such as a tapered configuration, various different cross-sectional configurations along its length, incisions, indentations, edges, protrusions, straight surfaces, curved surfaces, angled surfaces, wide edges, narrow edges, and / or other features.

[0042] The blade 162 can define a polygon, a rounded polygon, or any other suitable cross-sectional configuration. The waveguide 154 or at least a portion of the waveguide 154 adjacent to the blade 162 proximally can define a cylindrical configuration. A plurality of tapered surfaces (not shown) can interconnect the cylindrical waveguide 154 with the polygon (or rounded-edge polygon or other suitable shape) configuration of the blade 162 to define a smooth transition between the body of the waveguide 154 and the blade 162.

[0043] The blade 162 can be wholly or selectively coated with a suitable material, e.g., a non-stick material, an electrical insulating material, a conductive material, combinations thereof, etc. Suitable coatings and / or methods of applying coatings include, but are not limited to polyphenylene oxide (PPO), deposited liquid ceramic insulating coatings; thermal spray coatings, such as thermal spray ceramics; plasma electrolytic oxidation (PEO) coatings; anodized coatings; sputter coatings, e.g., silica; coatings available from the Surface Solutions Group of Chicago, IL, USA; or other suitable coatings and / or methods of applying coatings.

[0044] The jaw members 164 of the end effector assembly 160 include a more rigid structural body 182 and can include a more compliant jaw lining 184. The structural body 182 can be formed of various materials, conductive materials, thermally conductive materials, electrically insulating materials, or combinations thereof depending on its desired purpose.

[0045] The structural body 182 includes a pair of proximal flanges 183a that are pivotally coupled to the inner support sleeve 153 by receiving pivot bosses (not shown) of the proximal flanges 183a within corresponding openings (not shown) defined within the inner support sleeve 153, and is operatively coupled to the outer drive sleeve 152 by a drive pin 155 that is fixed relative to the outer drive sleeve 152 and pivotally received within a bore 183b defined within the proximal flange 183a. Accordingly, sliding of the outer drive sleeve 152 around the inner support sleeve 153 pivots the jaw members 164 from a spaced-apart position to a closer position relative to the blade 162 to clamp tissue between the jaw lining 184 of the jaw members 164 and the blade 162.

[0046] Reference Figure 5A, during dissection (or other tissue treatment such as coagulation or tissue sealing) using the ultrasonic instrument 100, the blade 162 vibrates with sufficient energy such that when the energy is delivered to the tissue pressed against the blade 162, the blade can reach a temperature exceeding 300 °C. It can be appreciated that measuring the temperature of the blade 162 before, during, and after activation provides important feedback to the surgeon when using and manipulating the ultrasonic instrument 10. Due to the vibrating characteristics of the blade 162, adding a conventional temperature probe (to monitor the temperature) to the blade 162 in this case would be unreliable.

[0047] Figure 5A An example of the blade 162 according to the present disclosure is shown, the blade including a layer of metal 500 that is dissimilar to the metal of the blade 162 disposed at point 162a along its length. A first lead 510 is electrically attached to the metal 500 at one end and extends to a first potential of the thermocouple junction 600 at its opposite end. A second lead 520 is electrically attached to the reference junction 153 and extends to a second potential of the thermocouple junction 600. Generally, the reference junction 153 (or another point within the housing 12) is maintained at a constant or reliable temperature to generate a constant voltage that is later used to derive the temperature at the metal 500 at the blade 162 after activation or during cooling (in real time), as explained below.

[0048] The metal 500 can be disposed on the blade 162 in any manner known in the art. In an embodiment, the metal 500 is deposited via metal or plasma deposition, chemical vapor deposition, printing, spraying, sintering, curing, high velocity oxy-fuel (HVOF) thermal spraying, 3D printing, screen printing, applying a metal ink or paint, or similar such processes to form a thin layer of metal 500 on top of the blade 162 that is electrically coupled to the first lead 510. By coupling a thermocouple 600 between two dissimilar metals (e.g., the type of metal 500 deposited on top of the blade 162), the temperature difference between the two metals can be measured via the Seebeck effect.

[0049] The Seebeck effect is a phenomenon in which a temperature difference between two dissimilar electrical conductors (i.e., metals) creates a voltage difference between the two substances. Accordingly, the temperature difference at any point 162a along the blade 162 can be measured and compared to the known constant temperature of the reference junction 153. Other known or thermostatic junctions on the instrument 10 can be coupled to the thermocouple 600 and used for this purpose. Even if the temperature difference is small, such as fractions of a degree, a small voltage difference is obtained at the thermocouple 600 and it is readily observable. Monitoring the temperature of the portion of the blade 162 at the metal 500 allows the surgeon to more safely manipulate the instrument 10 around delicate tissue, deactivate the instrument 10 between activations, and / or store the instrument 10 while using other instruments. Additionally, the ultrasonic vibrations will not affect the ability of the thermocouple 600 to measure the voltage difference across the two dissimilar metals (the blade 162 and the metal 500).

[0050] The selected metal 500 has a Seebeck coefficient that is different from that of the ultrasonic blade 162. By joining these dissimilar metals, a thermocouple is formed at that point 162a. The thermocouple generates a voltage that is related to the temperature difference between a) the junction between the two metals and b) the connection of these metals to the sensing circuit or thermocouple junction 600. The measurement of the temperature of the blade 162 is calculated or otherwise derived from the generated voltage and the known temperature at the reference junction.

[0051] Using the Seebeck effect, the surgeon can determine the temperature of the blade 162 before, during, and after activation and when the blade 162 is cooling. Additionally, applying the metal 500 to the blade and simply measuring the voltage will remain reliable during activation of the blade 162 and ultrasonic vibrations.

[0052] Now referring Figure 5B and Figure 6 , as mentioned above, during dissection (or other tissue treatment, such as coagulation or tissue sealing) using the ultrasonic instrument 100, the blade 162 vibrates with sufficient energy such that when the energy is delivered to the tissue pressed against the blade 162, the blade can reach a temperature in excess of 300°C. Accordingly, other components that are integrally coupled to the blade 162 (e.g., the waveguide 154) or other components proximal to the blade 162 can also reach significantly high temperatures during tissue treatment, especially under long surgical conditions. Since various factors can contribute to residual heat conduction to certain components under different conditions, in some cases the surgeon may not be aware of the given temperature of a particular component.

[0053] For example, ultrasonic surgical instruments typically transfer residual heat along waveguide 154, which in some cases can come into contact with tissue and organs when the surgeon manipulates instrument 100 between uses to perform dissections around a surgical cavity. Although blade 162 can cool rapidly, this may not be the case for waveguide 154. Due to the vibrational characteristics of waveguide 154, adding a conventional temperature probe (to monitor temperature) to the waveguide 154 in this scenario would be unreliable. Thus, the temperature of waveguide 154 during and after tissue treatment can be a problem when instrument 100 is being manipulated.

[0054] Figure 5B An embodiment of waveguide 154 in accordance with the present disclosure is shown, which includes a layer of metal 500 that is dissimilar to the metal of waveguide 154 at point 154b disposed along its length. First lead 510 is electrically attached at one end to metal 500 and extends at its opposite end to a first potential of thermocouple junction 600. Second lead 520 is electrically attached to a reference point 154c at the proximal end 154a of waveguide 154 and extends to a second potential of thermocouple junction 600. Typically, reference point 154c (or another point within housing 12 or anywhere along waveguide 154) is maintained at a constant or reliable temperature to generate a constant voltage that is later used to derive the temperature at metal 500 after activation or during cooling (in real time), as explained below.

[0055] Metal 500 can be disposed on waveguide 154 in any manner known in the art as described above. By coupling thermocouple 600 between two dissimilar metals (e.g., the type of metal 500 deposited on top of metal waveguide 154), the temperature difference between the two metals can be measured via the Seebeck effect.

[0056] Monitoring the temperature of the portion of waveguide 154 at metal 500 allows the surgeon to more safely manipulate instrument 100 around delicate tissue, put instrument 100 to sleep between activations, and / or store instrument 100 while using other instruments. Additionally, ultrasonic vibrations will not affect the ability of thermocouple 600 to measure the voltage difference across the two dissimilar metals (waveguide 154 and metal 500).

[0057] Figure 6 Another example of waveguide 454 in accordance with the present disclosure is shown, where a series of metals 500a, 500b, and 500c are deposited along the waveguide. Metals 500a, 500b, and 500c are disposed along waveguide 454 at nodes to avoid asymmetry (or unbalanced formation) along waveguide 454 during activation or propagation of ultrasonic waves. If the layer is thin enough, asymmetry can be avoided, and other issues may become relevant, such as contact 510 rubbing through metal 500.

[0058] Return toFigure 6 Metal 500a is deposited across node A, metal 500b is deposited across node B, and metal 500c is deposited across node C. Each of the metals 500a, 500b, and 500c is in turn connected via respective leads 510a, 510b, and 510c to respective potentials of the thermocouple 600. The proximal end 454a of the waveguide 454 is connected via a second lead 520 to a different potential of the thermocouple 600. By virtue of the dissimilar metals 500a, 500b, and 500c deposited on top of the waveguide 454 at the respective nodes A, B, and C (the metals 500a, 500b, and 500c may all be the same or all different depending on the particular purpose) and the unique properties of the Seebeck effect, the respective temperatures at each of the nodes A, B, and C can be reliably measured in comparison to the temperature at the proximal end 454 measured via the lead 520.

[0059] As can be appreciated, this will allow the surgeon to monitor the temperature along the waveguide 454 as the waveguide 454 heats during activation and more importantly cools after activation. Knowing the temperature of the portions of the waveguide 454 at the metals 500a, 500b, and 500c allows the surgeon to monitor safety, storage, or manipulation. Again, the ultrasonic vibrations will not affect the ability of the thermocouple 600 to measure the voltage difference across the dissimilar metals (waveguide 154 and metals 500a, 500b, 500c).

[0060] In various aspects, the thermocouple 600 can be utilized with additional circuitry or algorithms that analyze the energy flow / heat flow along the waveguides 154, 454 as energy / heat propagates proximally from the blade 162 over time by incorporating variables such as the specific heat and mass of the waveguides 154, 454, which are useful for advancements in instrument control.

[0061] In addition, setting one or more of the metals 500a, 500b, and 500c to act as thermocouples at nodes A, B, and C can have additional advantages. For example, placing a metal (metal 500a) to act as a thermocouple at a node (e.g., node A) can be used to monitor frequency changes during activation. Additional metals 500b and 500c acting as thermocouples can be used to track frequency information across several nodes A, B, and C or between nodes.

[0062] In addition, knowing the temperature of the nodes along waveguides 154, 454 can have additional other benefits. For example, by knowing the temperature of each of nodes A, B, and C along waveguides 154, 454 or at any point along the waveguides and knowing the temperature and frequency variations of transducer 140 (along or between nodes A, B, and C), the temperature of blade 162 can be estimated. For precision, additional thermocouples may need to be added. Such an estimate can be used alone to measure the blade temperature or in combination with the above-described embodiments, in which metal is placed directly on blade 162 to measure temperature using the Seebeck effect and serves as a secondary verification for measuring the blade temperature.

[0063] Although several aspects of the present disclosure have been detailed above and shown in the figures, it is not intended to limit the present disclosure thereto, but rather to have the scope of the present disclosure as broad as allowed in the art and to understand the specification in the same manner. For example, surgical instrument 100 can be part of a larger surgical system 10 (see Figure 1 ), which is all configured to be connected directly or wirelessly to a communication hub. Thus, the temperature information of waveguides 154, 454 can be monitored by a surgeon at instrument 100 (e.g., on display panel 185 ( Figure 1 )) or at a point remote from instrument 100 (e.g., panel 240 on generator 200).

[0064] In various aspects, housing 112 can include circuitry 113 that communicates with display panel 185 to convert the voltage obtained from the temperature difference between a first metal and a second metal (waveguides 154, 454 and metal 500 (or metals 500a, 500b, 500c)) into the actual temperature on waveguides 154, 454 proximal to metal 500 (or metals 500a, 500b, 500c), and the circuitry communicates and display panel 240 displays the temperature in real time.

[0065] Other types of systems are envisioned, such as those described in the co-owned U.S. Patent Application Serial No. 63 / 343,231, entitled "SURGICAL SYSTEM INCLUDING A CORDLESS SURGICAL INSTRUMENT COMMUNICATION HUB, AND ONE OR MORE CONNECTED DEVICES," filed on May 18, 2022, the entire content of which is incorporated herein by reference.

[0066] Accordingly, the above description and drawings should not be construed as restrictive, but merely as illustrative of particular aspects. Those skilled in the art can envision other modifications within the scope and spirit of the appended claims herein.

Claims

1. An ultrasonic surgical instrument, the ultrasonic surgical instrument comprising: a housing including a slender shaft extending from the housing; an ultrasonic transducer including a waveguide operably coupled to the ultrasonic transducer and configured to extend through the slender shaft, the ultrasonic transducer being adapted to be coupled to an energy source to allow selective activation of the ultrasonic transducer; an ultrasonic blade made of a first metal, the ultrasonic blade being operably coupled to the waveguide and configured to extend from the waveguide, the ultrasonic blade being configured to vibrate to treat tissue upon activation of the ultrasonic transducer; a different second metal disposed on a portion of the ultrasonic blade; and a thermocouple formed by a first electrical lead and a second electrical lead, the first electrical lead extending from a reference junction at a proximal end portion of the waveguide, the second electrical lead being coupled to the different second metal, the thermocouple being configured to detect a temperature difference between the proximal end portion of the waveguide and the portion of the blade supporting the different second metal, the thermocouple deriving the temperature at the different second metal from the voltage generated at the junction between the first metal and the different second metal and the temperature at the reference junction.

2. The ultrasonic surgical instrument according to claim 1, wherein the different second metal is deposited onto the blade via metal or plasma deposition, chemical vapor deposition, printing, spraying, sintering, curing, high velocity oxy-fuel thermal spraying (HVOF), 3D printing, screen printing, or application of a metal ink or paint.

3. The ultrasonic surgical instrument according to claim 1, wherein the ultrasonic instrument includes a handle operably coupled to the housing and configured to selectively move relative to the housing to pivot a jaw member relative to the ultrasonic blade to clamp tissue between the jaw and the ultrasonic blade.

4. The ultrasonic surgical instrument according to claim 1, wherein the housing includes a circuit that converts the voltage obtained from the temperature difference into an actual temperature on the blade at the junction with the different second metal, the circuit communicating with a display panel disposed on the housing for displaying the temperature.

5. The ultrasonic surgical instrument according to claim 4, wherein the circuit converts the voltage and communicates with the display panel in real time.

6. An ultrasonic surgical instrument, the ultrasonic surgical instrument comprising: a housing including a slender shaft extending from the housing; an ultrasonic transducer including a waveguide made of a first metal, the waveguide operably coupled to the ultrasonic transducer and configured to extend through the slender shaft, the ultrasonic transducer being adapted to be coupled to an energy source to allow selective activation of the ultrasonic transducer; an ultrasonic blade operably coupled to the waveguide and configured to extend from the waveguide, the ultrasonic blade being configured to vibrate to treat tissue upon activation of the ultrasonic transducer; A plurality of different second metals, the plurality of different second metals being disposed along the waveguide and extending proximally from the ultrasonic blade; and A thermocouple formed by a first electrical lead and a second electrical lead, the first electrical lead extending from a reference junction operably coupled to the housing, the second electrical lead being coupled to each different second metal, the thermocouple being configured to detect a temperature difference between the reference junction and a portion of the blade that supports each different second metal, the thermocouple deriving the temperature at each of the plurality of different second metals from the voltage generated at the junction between the first metal and each of the plurality of different second metals and the temperature at the reference junction.

7. The ultrasonic surgical instrument according to claim 6, wherein the plurality of different second metals are deposited onto the waveguide via metal or plasma deposition, chemical vapor deposition, printing, spraying, sintering, curing, high velocity oxy-fuel thermal spraying (HVOF), 3D printing, screen printing, or application of a metal ink or paint.

8. The ultrasonic surgical instrument according to claim 6, wherein the ultrasonic instrument includes a handle operably coupled to the housing and configured to selectively move relative to the housing to pivot a jaw member relative to the ultrasonic blade to clamp tissue between the jaw and the ultrasonic blade.

9. The ultrasonic surgical instrument according to claim 6, wherein the housing includes a circuit that converts the voltage obtained from the temperature difference into the actual temperature on the waveguide at each junction of the waveguide that supports the plurality of different second metals, the circuit communicating with a display panel disposed on the housing for displaying the temperature.

10. The ultrasonic surgical instrument according to claim 9, wherein the circuit converts the voltage and communicates with the display panel in real time.

11. The ultrasonic surgical instrument according to claim 6, wherein at least one of the plurality of different second metals is disposed at a node of the waveguide.

12. The ultrasonic surgical instrument according to claim 6, wherein each of the plurality of different second metals is disposed at a node of the waveguide.

13. A method of determining the temperature of a blade of an ultrasonic surgical instrument, the method comprising: electrically coupling a thermocouple across a first electrical lead and a second electrical lead, the first electrical lead extending from a proximal end portion of a waveguide and integrally coupled with an ultrasonic blade made of a first metal, the second electrical lead being coupled to a different second metal disposed on top of the ultrasonic blade; obtaining a reference temperature at a reference junction; activating a transducer to energize the waveguide, thereby vibrating the ultrasonic blade to treat tissue proximal to the ultrasonic blade; using the thermocouple to detect a temperature difference between the proximal end portion of the waveguide and a portion of the blade that supports the different second metal on the blade, the thermocouple deriving the temperature at the different second metal from the voltage generated at the junction between the first metal and the different second metal and the reference junction; and Use the temperature of the portion of the blade that supports the different second metal for at least one of safety, storage, or manipulation.

14. The method of determining the temperature of a blade of an ultrasonic surgical instrument according to claim 13, the method further comprises: Depositing the different second metal on top of the blade via metal or plasma deposition, chemical vapor deposition, printing, spraying, sintering, curing, high velocity oxy-fuel (HVOF) thermal spraying, 3D printing, screen printing, or applying a metal ink or paint.

15. The method of determining the temperature of a blade of an ultrasonic surgical instrument according to claim 13, wherein the housing includes a circuit that includes the thermocouple, the circuit being configured to convert the voltage obtained from the temperature difference into the actual temperature on the blade at the portion of the blade that supports the different second metal, and wherein the method further comprises: Communicating with a display panel disposed on the housing for displaying the temperature.

16. The method of determining the temperature of a blade of an ultrasonic surgical instrument according to claim 15, wherein the circuit converts the voltage and communicates with the display panel in real time.

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