Distal node grounding feature for acoustic waveguides

Abstract

The apparatus comprises a shaft assembly and an end effector. The shaft assembly includes an acoustic waveguide configured to transmit ultrasonic vibrations. The acoustic waveguide has a distal node flange. The shaft assembly further includes a distal portion that pushes the distal node flange radially inward. The distal portion cooperates with the distal node flange to prevent rotational movement of the distal node flange relative to the distal portion and to prevent longitudinal movement of the distal node flange relative to the distal portion. The end effector is located at the distal end of the shaft assembly. The end effector includes an ultrasonic blade and a clamp arm. The ultrasonic blade is positioned at the distal end of the acoustic waveguide. The clamp arm is operable to pivot toward and away from the ultrasonic blade.

Description

Technical Field

[0001] (Priority) This application claims the priority of U.S. Provisional Patent Application No. 63 / 463,944, entitled "Articulating Acoustic Blade Distal Node Grounding", filed on May 4, 2023, the entire disclosure of which is incorporated herein by reference.

Background Art

[0002] Various surgical instruments include an end effector having a blade element that vibrates at ultrasonic frequencies to cut and / or seal tissue (e.g., by denaturing proteins within tissue cells). These instruments include one or more piezoelectric elements that convert electrical power into ultrasonic vibrations, which are transmitted along an acoustic waveguide to the blade element. The accuracy of cutting and coagulation may be controlled by the operator's skill and by adjusting power levels, the angle of the blade tip, tissue traction, blade pressure, and / or other conditions. The power level used to drive the blade element may be varied (e.g., in real time) based on sensed parameters such as tissue impedance, tissue temperature, tissue thickness, and / or other factors. Some ultrasonic instruments have clamp arms and clamp pads for gripping tissue with the blade element.

[0003] Surgical instruments may be directly grasped and manipulated by the surgeon, or they may be incorporated into a robotic surgical system. During robot-assisted surgery, the surgeon can operate a controller to remotely control the movement of such surgical instruments at the surgical site. The controller may be located at a considerable distance from the patient (e.g., across operating rooms, in different rooms, or in a building completely separate from the patient). Alternatively, the controller may be located very close to the patient within the operating room. The controller may include one or more hand input devices (such as a joystick, exoskeleton glove, or master manipulator) coupled to the surgical instrument by a servo mechanism. In some modifications, a servo motor moves a manipulator supporting the surgical instrument based on the surgeon's operation of the hand input device. During surgery, the surgeon may employ a variety of surgical instruments via the robotic surgical system, including ultrasonic blades, tissue graspers, needle holders, and electrosurgical cauterization probes. Each of these structures performs a function for the surgeon, such as cutting tissue, coagulating tissue, holding or driving a needle, grasping a blood vessel, incising tissue, or cauterizing tissue.

[0004] Examples of ultrasonic surgical instruments and related concepts are incorporated herein by reference in their entirety by reference in U.S. Patent No. 5,322,055, issued June 21, 1994, entitled "Clamp Coagulator / Cutting System for Ultrasonic Surgical Instruments"; U.S. Patent No. 6,325,811, issued December 4, 2001, entitled "Blades with Functional Balance Asymmetries for use with Ultrasonic Surgical Instruments"; U.S. Patent No. 6,773,444, issued August 10, 2004, entitled "Blades with Functional Balance Asymmetries for Use with Ultrasonic Surgical Instruments"; and "Rotating Transducer Mount for Ultrasonic Surgical Instruments," issued June 11, 2013, entitled "Rotating Transducer Mount for Ultrasonic Surgical Instruments" Disclosed in U.S. Patent No. 8,461,744, entitled “Instruments”, U.S. Patent No. 8,591,536, entitled “Ultrasonic Surgical Instrument Blades”, issued November 26, 2013, whose entire disclosure is incorporated herein by reference, and U.S. Patent No. 8,911,460, entitled “Ultrasonic Surgical Instruments”, issued December 16, 2014, whose entire disclosure is incorporated herein by reference.

[0005] Some ultrasonic surgical instruments may include an articulation shaft portion. Examples of such ultrasonic surgical instruments are U.S. Patent No. 9,393,037, issued July 19, 2016, entitled “Surgical Instruments with Articulating Shafts,” which is incorporated herein by reference in its entirety; U.S. Patent No. 9,095,367, issued August 4, 2015, entitled “Flexible Harmonic Waveguides / Blades for Surgical Instruments,” which is incorporated herein by reference in its entirety; U.S. Patent No. 10,034,683, issued July 31, 2018, entitled “Ultrasonic Surgical Instrument with Rigidizing Articulation Drive Members,” which is incorporated herein by reference in its entirety; and “Articulation Joint for Surgical Instruments,” issued August 21, 2019, which is incorporated herein by reference in its entirety. Disclosed in U.S. Patent No. 10,405,876, titled “Instrument”, and U.S. Patent No. 11,678,903, issued May 31, 2023, titled “Ultrasonic Surgical Instrument with Articulating End Effector having a Curved Blade”, the entirety of which is incorporated herein by reference.

[0006] Examples of robotic surgical systems and instruments that may be used in such systems are U.S. Patent No. 8,820,605, issued September 2, 2014, entitled "Robotically-Controlled Surgical Instruments," whose entire disclosure is incorporated herein by reference; U.S. Patent No. 9,301,759, issued April 5, 2016, entitled "Robotically-Controlled Surgical Instrument with Selectively Articulatable End Effector," whose entire disclosure is incorporated herein by reference; U.S. Patent No. 8,783,541, issued July 22, 2014, entitled "Robotically-Controlled Surgical End Effector System," whose entire disclosure is incorporated herein by reference; and "Drive Interface for Operably Coupling a Manipulatable Surgical Tool to a This is described in U.S. Patent No. 8,479,969, entitled "Robot," U.S. Patent No. 8,800,838, entitled "Robotically-Controlled Cable-Based Surgical End Effectors," issued on 12 August 2014, whose entire disclosure is incorporated herein by reference, U.S. Patent No. 10,166,082, entitled "System and Method for Controlling a Robotic Wrist," issued on 1 January 2019, whose entire disclosure is incorporated herein by reference, and U.S. Patent No. 11,457,945, entitled "Ultrasonic Blade and Clamp Arm Alignment Features," issued on 4 October 2022, whose entire disclosure is incorporated herein by reference.

[0007] Although several surgical instruments and systems have been manufactured and used, it is believed that no one manufactured or used the present invention as described in the appended claims prior to the present inventors. [Brief explanation of the drawing]

[0008] This specification is concluded by the claims, which specifically point to and clearly claim the present technology. However, the present technology is best understood by reading the following description of a particular embodiment in conjunction with the accompanying drawings, where similar reference numerals in the drawings identify the same elements. [Figure 1] A first perspective view is shown of an example of an ultrasonic surgical instrument having an end effector, a shaft assembly, and a base assembly configured to connect to a robotic drive interface. [Figure 2] Figure 1 shows a second perspective view of the ultrasonic surgical instrument. [Figure 3A] Figure 1 shows an enlarged perspective view of the distal portion of the ultrasonic surgical instrument, where the end effector is in an open configuration and the shaft assembly is in a linear configuration. [Figure 3B] Figure 3A shows an enlarged perspective view of the distal portion, where the end effector is in a closed configuration and the shaft assembly is in a linear configuration. [Figure 4] Figure 3A shows a top view of the distal portion, where the end effector is in an open configuration and the shaft assembly is in a linear configuration. [Figure 5] Figure 3A shows a cross-sectional side view of the distal portion, where the end effector is in an open configuration and the shaft assembly is in a linear configuration. [Figure 6] Figure 3A shows a partially exploded perspective view of the distal portion, with the clamp arm and closing sleeve of the end effector separated from the other components of the shaft assembly. [Figure 7] Another partially exploded perspective view of the distal portion of Figure 3A is shown, with the clamp arm and closing sleeve omitted, the acoustic waveguide separated from the other components of the shaft assembly, and the elastomer sleeve separated from the other components of the shaft assembly. [Figure 8] Figure 1 shows a perspective view of the frame sleeve of an ultrasonic surgical instrument. [Figure 9] Figure 1 shows a perspective view of the distal portion of the acoustic waveguide of the ultrasonic surgical instrument. [Figure 10] Figure 9 shows a side view of the distal node portion of the acoustic waveguide. [Figure 11] Figure 10 shows a cross-sectional view of the acoustic waveguide shown in Figure 9, cut along line 11-11. [Figure 12] Figure 1 shows a perspective view of the distal portion of another example of an acoustic waveguide that can be incorporated into an ultrasonic surgical instrument. [Figure 13] Figure 12 shows a side view of the distal node portion of the acoustic waveguide. [Figure 14] Figure 13 shows a cross-sectional view of the acoustic waveguide shown in Figure 12, cut along line 14-14. [Figure 15] Figure 1 shows a perspective view of the distal portion of another example of an acoustic waveguide that can be incorporated into an ultrasonic surgical instrument. [Figure 16] Figure 1 shows a distal perspective view of another example of an acoustic waveguide, elastomer sleeve, and crimped collet that can be incorporated into an ultrasonic surgical instrument. [Figure 17] Figure 16 shows a perspective view of the crimp collet. [Figure 18] Figure 16 shows a perspective cross-sectional view of the assembly with an additional outer sleeve.

[0009] The drawings are not intended to limit the manner in which the various embodiments of the Art can be carried out, and it is intended that various other manners may be used, including those not necessarily depicted in the drawings. The accompanying drawings incorporated herein and forming part of this specification illustrate some aspects of the Art and are useful together with the specification to illustrate the principles of the Art, but it should be understood that the Art is not limited to the exact arrangements shown. [Modes for carrying out the invention]

[0010] The following description of a particular example of this technology should not be used to limit its scope. Other examples, features, aspects, embodiments, and advantages of this technology will become apparent to those skilled in the art through the following description, which, as an example, represents one of the best modes intended for carrying out this technology. As will be understood, no other different and obvious modes of the technology described herein are possible without departing from the technology. Accordingly, the drawings and descriptions should be considered illustrative and not restrictive.

[0011] It should be further understood that one or more of the teachings, expressions, embodiments, examples, etc. described herein may be combined with one or more of the other teachings, expressions, embodiments, examples, etc. described herein. Therefore, the teachings, expressions, embodiments, examples, etc. described below should not be considered in isolation from one another. Various preferred ways in which the teachings herein can be combined will be readily apparent to those skilled in the art by considering the teachings herein. Such modifications and variations are intended to be included within the scope of the claims.

[0012] For clarity of this disclosure, the terms “proximal” and “distal” are defined herein with respect to the operator of the surgical instrument, whether human or robotic. “Proximal” refers to the location of an element closer to the operator of the surgical instrument, whether human or robotic, and further away from the surgical end effector of the surgical instrument. “Distal” refers to the location of an element closer to the surgical end effector of the surgical instrument and further away from the operator of the surgical instrument, whether human or robotic. For convenience and clarity of explanation, it will also be understood that spatial terms such as “anterior,” “posterior,” “clockwise,” “counterclockwise,” “longitudinal,” and “lateral” are used herein to refer to relative location and relative direction. Such terms are used below with reference to the diagrams illustrated for clarity and are not intended to limit the inventions described herein.

[0013] I. Examples of Ultrasonic Surgical Instruments A. Overview Figures 1-2 show an example of an ultrasonic surgical instrument (10). At least a part of the ultrasonic surgical instrument (10) can be configured and operable according to at least a part of the teachings of any of the various patents cited herein. As described in these documents and in more detail below, the ultrasonic surgical instrument (10) is operable to cut tissue and at the same time seal or join tissue (e.g., blood vessels, etc.). This embodiment incorporates various ultrasonic features as the ultrasonic surgical instrument (10), but the present invention is not intended to be unnecessarily limited to the ultrasonic features described herein.

[0014] The ultrasonic surgical instrument (10) of this embodiment includes a body assembly such as a base assembly (12), a shaft assembly (14), and an end effector (16). The base assembly (12) includes a housing (18), a button (22), and a pair of latch fasteners (24). The button (22) is operably connected to an electrical base power controller (not shown) and is configured to selectively supply power to the ultrasonic surgical instrument (10) for use. In addition, the housing (18) of this embodiment includes a front housing cover (26) and a rear housing cover (28) that are removably fixed together via the latch fasteners (24). More specifically, the latch fasteners (24) removably fix the front housing cover (26) to the rear housing cover (28), whereby the front housing cover (26) can be removed to access an internal space (not shown) within the base assembly (12).

[0015] The shaft assembly (14) extends distally from the base assembly (12) to the end effector (16). As shown in this embodiment, the base assembly (12) is configured to be operably connected to a robotic drive unit (not shown) for driving various features of the shaft assembly (14) and / or the end effector (16). However, in another example, the body assembly (12) may alternatively include a handle assembly (not shown), and the handle assembly may include a pistol grip and / or other structural features configured to be directly grasped and operated by a surgeon to drive various features of the shaft assembly (14) and / or the end effector (16). Thus, the present invention is not intended to be unnecessarily limited to use with the base assembly (12) and a robotic drive unit (not shown). In other words, some variations of the ultrasonic surgical instrument (10) may be handheld and manually operated, some variations of the ultrasonic surgical instrument (10) may be supported and operated by robotic control, and still other variations may receive a combination of hand and robotic holding / support and / or hand and robotic operation.

[0016] As shown in FIG. 2, the base assembly (12) of this embodiment includes a robotic drive interface (32) configured to extend through the base plate (34) of the rear housing cover (28) and to be mechanically coupled to a robotic drive unit (not shown). The robotic drive interface (32) of this embodiment includes a plurality of instrument actuators (36) each having a respective input body (38). Each input body (38), which may also be referred to herein as a "pack", is configured to be removably connected to the robotic drive unit and is, in this embodiment, generally cylindrical and rotatable about its respective axis. The input body (38) has a plurality of slots and / or other features configured to engage corresponding portions of the robotic drive unit, thereby providing robotic drive to the input body (38) and thereby instructing the operation of the shaft assembly (14) and / or the end effector (16).

[0017] The base assembly (12) in this embodiment also includes an electrical cable (42), which is operably connected to a power source (not shown) to supply power to an electric base power controller (not shown), providing power to the base assembly (12) for desired operation, such as guiding electrical energy to various feature parts of a shaft assembly (14) or end effector (16) related to tissue cutting, sealing, or welding. In some modifications, an ultrasonic transducer (not shown) is housed within the base assembly (12), and power supplied via the cable (42) operates the ultrasonic transducer, thereby generating ultrasonic vibrations. The ultrasonic vibrations generated by the transducer can be transmitted to the end effector (16) as described below.

[0018] B. Example of a shaft assembly As shown in Figures 1 to 4, the shaft assembly (14) of this embodiment includes a proximal shaft portion (60) that extends directly from the base assembly (12) along the longitudinal axis (LA). The distal shaft portion (62) is fixedly coupled to the proximal shaft portion (60). The articular movement section (80) is coupled to the distal shaft portion (62). The articular movement section (80) includes a plurality of segments (82). Each segment (82) includes a proximal-oriented tab (84) and a distal-facing recess (86). Each tab (84) of each segment is pivotably fixed within the corresponding recess (86), so that the segments (82) can pivot relative to each other. The tab (84) of the nearest segment (82) is pivotably coupled to the distal shaft portion (62). The frame sleeve (200) is positioned distal to the joint movement section (80) and includes a proximal-oriented tab (207) that is pivotably fixed within a recess (86) of the most distal segment (82).

[0019] Pivot joints at each end of the articular movement section (80), along the articular movement section (80), allow for lateral deflection of the end effector (16) relative to the longitudinal axis (LA), thereby positioning the end effector (16) at a selected articular movement angle (θ), as shown in Figure 4. Such articular movement is driven by articular movement bands (88) that extend through the segment (82) and are fixed distally within the proximal portion (208) of the frame sleeve (200). The articular movement bands (88) are angularly offset from each other by 180° about the longitudinal axis (LA). The first articular movement band (88) can be advanced distally while the second articular movement band (88) can be retracted proximally, thereby causing the end effector (16) to articulate in a first lateral direction, or the first articular movement band (88) can be retracted proximally while the second articular movement band (88) can be advanced distally, thereby causing the end effector (16) to articulate in a second lateral direction. The articular movement bands (88) are coupled to corresponding actuation features in the base assembly (12), thereby driving such opposing longitudinal movements of the articular movement bands (88). Such actuation features can be driven via corresponding input bodies (38) as described above.

[0020] As merely a further example, the articulation section (80) may be configured alternatively or additionally in accordance with one or more teachings of one or more of the following patents: U.S. Patent No. 9,402,682, issued August 2, 2016, “Articulation Joint Features for Articulating Surgical Device,” which is incorporated herein by reference in its entirety; U.S. Patent No. 9,393,037, issued July 19, 2016, “Surgical Instruments with Articulating Shafts,” which is incorporated herein by reference in its entirety; U.S. Patent No. 9,095,367, issued August 4, 2015, “Flexible Harmonic Waveguides / Blades for Surgical Instruments,” which is incorporated herein by reference in its entirety; and / or any other patents cited herein. Alternatively, the articulation section (80) may be configured and / or operable in any other suitable manner.

[0021] The shaft assembly (14) of this embodiment further includes a closing sleeve (90) slidably disposed along the frame sleeve (200). The closing sleeve (90) is operable to move between a distal position along the frame sleeve (200) (Figure 3A) and a proximal position along the frame sleeve (200) (Figure 3B), thereby driving the end effector (16) between an open configuration (Figure 3A) and a closed configuration (Figure 3B), as will be described in more detail below. Such longitudinal movement of the closing sleeve (90) is driven by a pair of closing beams (70) shown in Figures 4 to 7. The closing beams (70) are angularly offset from each other by 180° about the longitudinal axis (LA). In this embodiment, the closing beams (70) are angularly offset by 90° from the articulation band (88) about the longitudinal axis (LA). Each closing beam (70) has a distal head (72) fixed within the proximal portion (96) of the closing sleeve (90), and the closing beam (70) is firmly fixed to the closing sleeve (90) via the head (72). The closing beam (70) is slidably disposed within a corresponding channel (209) in the frame sleeve (200). The channel (209) is best shown in Figure 8. The closing beam (70) is coupled with a corresponding actuation feature in the base assembly (12), thereby driving the coordinated longitudinal movement of the closing beam (70). Such actuation features may be driven via a corresponding input body (38) as described above.

[0022] The shaft assembly (12) further includes an acoustic waveguide (100) and an elastomer sleeve (300). As best shown in Figures 7 and 9, the acoustic waveguide (100) includes a cylindrical shaft (102), a distal blade (110), a distal node flange (120), and a proximal node flange (130). Each flange (120, 130) is enlarged relative to the rest of the shaft (102) such that each flange (120, 130) has a larger diameter than the rest of the shaft (102). A ribbon portion (104) is interposed longitudinally between the flanges (120, 130). The ribbon portion (104) is substantially flat and planar, particularly in this example, compared to the cylindrical shaft (102). The ribbon portion (104) is positioned longitudinally along the articulated section (80) of the shaft assembly (12), and as a result, the ribbon portion (104) is configured to bend so as to allow the end effector (16) to be deflected to the articulated position. The distal blade (110) provides part of the end effector (16), as will be described in more detail below. The flanges (120, 130) are configured to provide structural support to the acoustic waveguide (100) within the shaft assembly (12), as will also be described in more detail below. Although only two flanges (120, 130) are shown, the acoustic waveguide (100) may further include one or more additional flanges in the nodal region along the shaft (102) at a position proximal to the proximal nodal flange (130).

[0023] By being "nodes," the flanges (120, 130) are positioned along the length of the acoustic waveguide (100) corresponding to the nodes of the vibrational waves when the acoustic waveguide (100) vibrates at the resonant ultrasonic frequency. Thus, such nodes represent positions along the length of the acoustic waveguide (100) that have the smallest vibrational motion when the acoustic waveguide (100) vibrates at the resonant ultrasonic frequency. The ultrasonic vibrations of the acoustic waveguide (100) can be driven by an ultrasonic transducer in the base assembly (12), as described above. Thus, the proximal portion of the acoustic waveguide (100) may be acoustically coupled to the ultrasonic transducer, and the ultrasonic vibrations are transmitted to the blade (110) via the shaft (102) along the shaft assembly (14).

[0024] The distal end of the blade (110) is positioned at a location corresponding to an abdominal node related to resonant ultrasonic vibrations transmitted through the acoustic waveguide (100). In some modifications, when the transducer assembly is energized, the distal end of the blade (110) is at a predetermined vibration frequency f of approximately 10 to 500 microns between peaks, and in some examples, for example, 55.5 kHz. o It is configured to move longitudinally in a range of approximately 20 to 200 microns. Alternatively, any other suitable range of displacement and / or frequency may be provided.

[0025] In some modifications, the acoustic waveguide (100) may be configured to amplify mechanical vibrations transmitted through the acoustic waveguide (100). Furthermore, the acoustic waveguide (100) may include features that allow it to control the gain of vibrations along the acoustic waveguide (100) and / or features that allow it to tune to the resonant frequency of an acoustic system. Various suitable ways in which the acoustic waveguide (100) may be mechanically and acoustically coupled to an ultrasonic transducer and / or otherwise configured will be apparent to those skilled in the art in view of the teachings herein.

[0026] The elastomer sleeve (300) is radially interposed between the acoustic waveguide (100) and the other components of the shaft assembly (12). The elastomer sleeve (300) may include silicone, PEBAX, and / or any other suitable material (one or more). The elastomer sleeve (300) in this embodiment includes a cylindrical body (302) having a corrugated portion (304). The corrugated portion (304) is positioned longitudinally along the articulated section (80) of the shaft assembly (12) and is configured to facilitate the effective extension of the elastomer sleeve (300) when the articulated section (80) is bent to laterally deflect the end effector (16) to the articulated position.

[0027] C. Exemplary End Effector As best seen in Figures 3A-3B and 5, the end effector (16) in this example includes a clamp arm (40) and a blade (110). A clamp pad (44) is fixed to the underside of the clamp arm (40) and faces the blade (110). As a mere example, the clamp pad (48) may include polytetrafluoroethylene (PTFE) and / or any other suitable material (one or more). A pair of lugs (42) project downward from the proximal end of the clamp arm (40). The clamp arm (40) is pivotally coupled to a frame sleeve (200) and a closing sleeve (90). Specifically, as best shown in Figure 5, a first pivot pin (202) is disposed through a tongue (204) that passes through the proximal end of the clamp arm (40) and projecting distally to the frame sleeve (200). The second pivot pin (92) is positioned through both lugs (42) of the clamp arm (40) and through a tongue (94) projecting distally from the closing sleeve (90). As described above, the closing sleeve (90) can be translated longitudinally while the frame sleeve (200) remains stationary in the longitudinal direction. Given the nature of the coupling via the pins (92, 202), this longitudinal movement of the closing sleeve (90) relative to the frame sleeve (200) will cause the end effector (16) to transition between an open configuration (Figure 3A) and a closed configuration (Figure 3B).

[0028] As an example, when the end effector (16) is in the open position (Figure 3A), a tissue structure (e.g., a blood vessel) can be positioned between the clamp pad (44) and the blade (110) while the blade (110) is in a non-operating state (e.g., so that the blade (110) does not vibrate ultrasonically). With the tissue structure suitably positioned between the clamp pad (44) and the blade (110), the end effector (16) can be driven to the closed position (Figure 3B), thereby compressing the tissue structure between the clamp pad (44) and the blade (110). In some cases, such operation may be used simply to grasp and stabilize, move, or otherwise manipulate the tissue structure, which can then be released. In some other cases, the blade (110) can be actuated ultrasonically while the tissue structure is compressed between the clamp pad (44) and the blade (110). In some such cases, the combination of compression and ultrasonic vibration can seal tissue structures (for example, by denaturing proteins within the tissue). In addition, or alternatively, the combination of compression and ultrasonic vibration can cleave tissue structures. Alternatively, the end effector (16) may be used in any other suitable manner.

[0029] In some modifications, the end effector (16) is rotatable relative to the base assembly (12) about the longitudinal axis (LA) with respect to at least a portion of the shaft assembly (14). In some other modifications, all or part of the shaft assembly (14) is rotatable relative to the base assembly (12) about the longitudinal axis (LA) together with the end effector (16). In any case, such rotation may be driven via an operating feature in the base assembly (12), which may be driven via the corresponding input body (38) as described above.

[0030] II. Examples of features for grounding the nodes of an acoustic waveguide As described above, the acoustic waveguide (100) has at least two node flanges, including a distal node flange (120) and a proximal node flange (130), the distal node flange (120) being positioned distal to the articular movement section (80) and the proximal node flange (130) being positioned proximal to the articular movement section (80). It may be desirable to mechanically ground or fix the distal node flange (120) to another part of the shaft assembly (14). In particular, it may be desirable to mechanically ground or fix the distal node flange (120) to the frame sleeve (200).

[0031] In some cases, mechanically grounding or fixing the distal node flange (120) to another part of the shaft assembly (14) (e.g., to the frame sleeve (200)) may facilitate consistent alignment between the distal blade (110) and the clamp arm (40). This may facilitate a consistent clamp pressure profile for tissue trapped within the end effector (16). In addition, or alternatively, mechanically grounding or fixing the distal node flange (120) to another part of the shaft assembly (14) (e.g., to the frame sleeve (200)) may minimize ultrasonic impedance within the acoustic waveguide (100) and / or provide other results. The advantage of firmly grounding the distal node flange (120) to another part of the shaft assembly (14) may be particularly enhanced in ultrasonic surgical instruments that include articulation sections (e.g., articulation section (80)), because the bending of the acoustic waveguide in the articulation section may substantially impair the performance of the acoustic waveguide if the distal portion of the acoustic waveguide is not sufficiently fixed to the distal portion of the shaft assembly.

[0032] The following describes examples of features and arrangements that may be used to firmly ground the distal node flange (e.g., distal node flange (120)) of an acoustic waveguide (e.g., acoustic waveguide (100)) against another part of a shaft assembly (e.g., shaft assembly (14)). In some scenarios, these features and arrangements may provide a combination of axial and rotational constraints on relative movement between the acoustic waveguide and the other part of the shaft assembly. In other words, these features and arrangements can substantially or completely prevent relative axial and / or rotational movement between the acoustic waveguide and the other part of the shaft assembly. Furthermore, by firmly grounding the distal node flange against another part of the shaft assembly, the features and arrangements described below may provide a local reaction force against bending loads encountered by the distal blade (e.g., distal blade (110)) when the tissue is clamped against the distal blade (e.g., by a clamping arm (40)) and / or when other laterally oriented forces are applied to the distal blade. Such local reaction forces may then transmit bending stress from the acoustic waveguide to other parts of the shaft assembly to which the acoustic waveguide is firmly grounded. This stress transmission may reduce stress and deflection in portions of the acoustic waveguide extending along the articulated sections of the shaft assembly (e.g., ribbon portion (104)).

[0033] Figures 10-11 show the distal node flange (120) in more detail. As shown, the distal node flange (120) in this example includes an enlarged cylindrical central region (122). A tapered proximal region (121) provides a proximal transition from the shaft (102) to the central region (122), while a tapered distal region (123) provides a distal transition from the central region (122) to the shaft (102). In some modifications, the proximal region (121) provides a single taper angle along a flat surface. In some other modifications, the proximal region (121) provides a composite taper having two or more taper angles along two or more flat surfaces. In yet another modification, at least a portion of the proximal region (121) has a concave curvature. Some such variations of the proximal region (121) may provide a combination of concave curved surfaces (one or more) and flat tapered surfaces (one or more). Similarly, some variations of the distal region (123) may provide a single taper angle along a flat surface. In some other variations, the distal region (123) may provide a composite taper having two or more taper angles along two or more flat surfaces. In yet another variation, at least a portion of the distal region (123) may have a concave curvature. Some such variations of the distal region (123) may provide a combination of concave curved surfaces (one or more) and flat tapered surfaces (one or more). Alternatively, either region (121, 123) may have any other suitable configuration.

[0034] The distal node flange (120) of this embodiment further includes a pair of recesses (124) formed along the central region (122). The recesses (124) extend longitudinally over a substantial portion of the length of the central region (122) (including the midpoint of the length of the central region (122)) and are angularly spaced equidistant from each other about the longitudinal axis (LA). In this embodiment, a total of six recesses (124) are provided, but any other preferred number of recesses (124) may be provided. If the number of recesses (124) is even and the angular spacing of the recesses (124) about the longitudinal axis (LA) is equidistant, then each recess (124) has a corresponding other recess (124) located 180° opposite from the recess (124). In other words, the recesses (124) are aligned in pairs facing each other in the diametrical direction. This alignment is best seen in Figure 11.

[0035] Furthermore, as is most commonly seen in Figure 11, each recess (124) includes a flat concave surface (126), although some other modifications may include concave surfaces (126) having any other preferred profile (e.g., concave curved, roughened, etc.). Each recess (124) also includes a curved transition surface (128) at each longitudinal end of the flat concave surface (126) in this embodiment, but other configurations may be used. As an example only, the curved transition surface (128) may instead be flat but angled.

[0036] In this embodiment, the distal node flange (120) is mechanically grounded or fixed to the frame sleeve (200) by crimping the crimp region (206) of the frame sleeve (200) around the distal node flange (120). This crimping is performed while the distal portion of the cylindrical body (302) of the elastomer sleeve (300) is radially interposed between the frame sleeve (200) and the distal node flange (120), and the cylindrical body (302) is compressed between the crimp region (206) and the distal node flange (120) as the crimp region (206) is crimped around the distal node flange (120).

[0037] The crimping of the crimping region (206) around the distal node flange (120) can be carried out in many ways. As merely one example, the crimping region (206) and the distal node flange (120) may be positioned within a chuck or other clamping device that applies radially inward forces simultaneously along several different radii extending from the longitudinal axis (LA). In some other variations, the clamping member may apply clamping forces simultaneously along two diametrically opposed radii, be repositioned to different angular positions, and then apply clamping forces again simultaneously along two other diametrically opposed radii, and this process may be repeated until diametrically opposed clamping forces are applied at a desired number of angular positions. Alternatively, the crimping of the crimping region (206) around the distal node flange (120) may be carried out in any other suitable way using any other suitable technique and / or equipment.

[0038] The frame sleeve (200) in this embodiment comprises a malleable material (e.g., steel, titanium, polyetheretherketone, etc.). Therefore, when the crimped region (206) is crimped around the distal node flange (120), the material of the crimped region (206) deforms inward, firmly pressing the cylindrical body (302) of the elastomer sleeve (300) around the distal node flange (120) and maintaining the deformed configuration. Thus, the deformed crimped region (206) provides a firm grip on the distal node flange (120), thereby mechanically grounding or fixing the distal node flange (120) to the frame sleeve (200).

[0039] In this example, the deformed portion of the cylindrical body (302) of the elastomer sleeve (300) is received within the recess (124) when the crimped region (206) is crimped around the distal node flange (120), and the crimped region (206) is crimped around the distal node flange (120) when the cylindrical body (302) of the elastomer sleeve (300) comes into contact with the surfaces (126, 128) of the recess (124). In some modifications, at least a portion of the crimped region (206) is also received within the recess (124) when it is crimped around the distal node flange (120). The reception of the cylindrical body (302) (and, optionally, at least a portion of the crimped region (206)) within the recess (124) can provide a firm gripping relationship between the distal node flange (120) and the frame sleeve (200). In other words, the presence of the recess (124) can enhance the gripping strength compared to the gripping strength that can be provided in a modified distal node flange (120) lacking the recess (124). It should also be understood that the flat concave surface (126) can provide enhanced fixation of the acoustic waveguide (100) to the frame sleeve (200) about the longitudinal axis (LA), while the curved transition surface (128) can provide enhanced fixation of the acoustic waveguide (100) to the frame sleeve (200) along the longitudinal axis (LA).

[0040] In some cases, the presence of an elastomer sleeve (300) between the frame sleeve (200) and the distal node flange (120) can provide a damper that minimizes the transmission of vibrations from the acoustic waveguide (100) to the frame sleeve (200). In addition, or alternatively, the presence of an elastomer sleeve (300) between the frame sleeve (200) and the distal node flange (120) can enhance the grip between the crimped region (206) and the distal node flange (120). In addition, or alternatively, the presence of an elastomer sleeve (300) between the frame sleeve (200) and the distal node flange (120) can provide an enhanced fluid seal between the inner surface of the frame sleeve (200) and the distal node flange (120).

[0041] Figure 12 shows an example of another acoustic waveguide (400) that can be incorporated into an ultrasonic surgical instrument (10) instead of the acoustic waveguide (100). The acoustic waveguide (400) in this example may be configured and operable in the same way as the acoustic waveguide (100), except for the differences described below. The acoustic waveguide (400) in this example includes a cylindrical shaft (402), a distal blade (410), a distal node flange (420), and a proximal node flange (430). Each flange (420, 430) is enlarged relative to the rest of the shaft (402), so that each flange (420, 430) has a larger diameter than the rest of the shaft (402). A ribbon portion (404) is interposed longitudinally between the flanges (420, 430). The ribbon portion (404) is substantially flat and planar, particularly in this example, compared to the cylindrical shaft (402). The ribbon portion (404) is configured to be positioned longitudinally along the articulated section (80) of the shaft assembly (12), and as a result, the ribbon portion (404) is configured to bend so as to allow the end effector (16) to be deflected to the articulated position. The distal blade (410) is configured to provide a portion of the end effector (16) as described above. The flanges (420, 430) are configured to provide structural support to the acoustic waveguide (400) within the shaft assembly (12), also as described above. Although only two flanges (420, 430) are shown, the acoustic waveguide (400) may further include one or more additional flanges in the nodal region along the shaft (402) at a position proximal to the proximal nodal flange (430).

[0042] Figures 13-14 show the distal node flange (420) in more detail. As shown, the distal node flange (420) in this example includes an enlarged cylindrical central region (422). A tapered proximal region (421) provides a proximal transition from the shaft (402) to the central region (422), while a tapered distal region (423) provides a distal transition from the central region (422) to the shaft (402). In some modifications, the proximal region (421) provides a single taper angle along a flat surface. In some other modifications, the proximal region (421) provides a composite taper having two or more taper angles along two or more flat surfaces. In yet another modification, at least a portion of the proximal region (421) has a concave curvature. Some such variations of the proximal region (421) may provide a combination of concave curved surfaces (one or more) and flat tapered surfaces (one or more). Similarly, some variations of the distal region (423) may provide a single taper angle along a flat surface. In some other variations, the distal region (423) may provide a composite taper having two or more taper angles along two or more flat surfaces. In yet another variation, at least a portion of the distal region (423) has a concave curvature. Some such variations of the distal region (423) may provide a combination of concave curved surfaces (one or more) and flat tapered surfaces (one or more). Alternatively, either region (421, 423) may have any other suitable configuration.

[0043] The distal node flange (420) of this embodiment further includes a set of recesses (424) formed along the central region (422). The proximal recess set (424) extends longitudinally along the proximal portion of the central region (422), while the distal recess set (424) extends longitudinally along the distal portion of the central region (422). Thus, the longitudinal middle portion of the central region (422) provides a structural interruption between the proximal recess set (424) and the distal recess set (424). In some modifications, the diameter of the longitudinal middle portion of the central region (422) is greater than the diameter of the rest of the longitudinal middle portion of the central region (422).

[0044] All recesses (424) in the proximal recess set (424) are angularly spaced equidistant from each other about the longitudinal axis (LA). Similarly, all recesses (424) in the distal recess set (424) are angularly spaced equidistant from each other about the longitudinal axis (LA). In this example, a total of six distal recesses (424) and six proximal recesses (424) are provided, but any other suitable number of recesses (424) may be provided. If the number of recess sets (424) is even and the angular spacing of each recess set (424) about the longitudinal axis (LA) is equidistant, then each recess (424) in each set has a corresponding other recess (424) in the same set located 180° opposite from the recess (424). In other words, each recess set (424) is aligned in pairs facing each other in the diametrical direction. This alignment is most commonly seen in Figure 14. In this example, there are an even number of recesses (424), but other variations may have an odd number of recesses (424).

[0045] Furthermore, as is most commonly seen in Figure 14, each recess (424) includes a flat concave surface (426), although some other modifications may include a concave surface (426) having any other preferred profile (e.g., concave curved, roughened, etc.). Each recess (424) also includes a curved transition surface (428) at one longitudinal end of the flat concave surface (426) in this embodiment, but other configurations may be used. As an example only, the curved transition surface (428) may instead be flat but angled.

[0046] In this embodiment, the distal node flange (420) may be mechanically grounded or fixed to the frame sleeve (200) by crimping the crimped region (206) of the frame sleeve (200) around the distal node flange (420). This crimping may be performed while the distal portion of the cylindrical body (302) of the elastomer sleeve (300) is radially interposed between the frame sleeve (200) and the distal node flange (420), and the cylindrical body (302) is compressed between the crimped region (206) and the distal node flange (420) when the crimped region (206) is crimped around the distal node flange (420). This crimping may be performed according to the teachings provided above in the context of crimping the crimped region (206) of the frame sleeve (200) around the distal node flange (120). As described above, the deformed crimped region (206) provides a firm grip on the distal node flange (420), thereby allowing the distal node flange (420) to be mechanically grounded or fixed to the frame sleeve (200). Also as described above, the presence of the recess (424) can enhance the gripping strength compared to the gripping strength that may be provided in a modified distal node flange (420) lacking the recess (424). It should also be understood that the flat concave surface (426) can provide enhanced fixation against rotation of the acoustic waveguide (400) relative to the frame sleeve (200) about the longitudinal axis (LA), while the curved transition surface (428) can provide enhanced fixation against translation of the acoustic waveguide (400) relative to the frame sleeve (200) along the longitudinal axis (LA).

[0047] In some cases, the presence of an elastomer sleeve (300) between the frame sleeve (200) and the distal node flange (420) can provide a damper that minimizes the transmission of vibrations from the acoustic waveguide (400) to the frame sleeve (200). In addition, or alternatively, the presence of an elastomer sleeve (300) between the frame sleeve (200) and the distal node flange (420) can enhance the grip between the crimped region (206) and the distal node flange (420). In addition, or alternatively, the presence of an elastomer sleeve (300) between the frame sleeve (200) and the distal node flange (420) can provide an enhanced fluid seal between the inner surface of the frame sleeve (200) and the distal node flange (420).

[0048] Figure 15 shows an example of another acoustic waveguide (500) that can be incorporated into an ultrasonic surgical instrument (10) instead of the acoustic waveguide (100). The acoustic waveguide (500) in this example may be configured and operable in the same way as the acoustic waveguide (100), except for the differences described below. The acoustic waveguide (500) in this example includes a cylindrical shaft (402), a distal blade (510), and a distal node flange (520). The distal node flange (520) is enlarged relative to the other part of the shaft (502) such that the distal node flange (520) has a larger diameter than the other part of the shaft (502). The acoustic waveguide (500) may also include a proximal node flange (not shown), a ribbon portion (not shown), other node flanges (not shown), and / or other structural features. The distal blade (510) is configured to provide part of the end effector (16) as described above. The distal node flange (520) is configured, as also described above, to provide structural support for the acoustic waveguide (500) within the shaft assembly (12).

[0049] As shown in the figure, the distal node flange (520) in this example includes an enlarged cylindrical central region (522). A tapered proximal region (521) provides a proximal transition from the shaft (502) to the central region (522), while a tapered distal region (523) provides a distal transition from the central region (522) to the shaft (502). In some modifications, the proximal region (521) provides a single taper angle along a flat surface. In some other modifications, the proximal region (521) provides a composite taper having two or more taper angles along two or more flat surfaces. In yet another modification, at least a portion of the proximal region (521) has a concave curvature. Some such modifications of the proximal region (521) may provide a combination of one or more concave curved surfaces and one or more flat tapered surfaces. Similarly, several variations of the distal region (523) provide a single taper angle along a flat surface. In some other variations, the distal region (523) provides a composite taper having two or more taper angles along two or more flat surfaces. In yet another variation, at least a portion of the distal region (523) has a concave curvature. Some such variations of the distal region (523) may provide a combination of one or more concave curved surfaces and one or more flat tapered surfaces. Alternatively, either region (521, 523) may have any other suitable configuration.

[0050] The distal node flange (520) of this embodiment further includes a pair of recesses (524) formed along a central region (522). In this example, the recesses (524) are centrally located longitudinally along the length of the central region (522). The recesses (524) are angularly spaced equidistant from each other about the longitudinal axis (LA). In this example, a total of six recesses (524) are provided, but any other preferred number of recesses (524) may be provided. If the number of recesses (524) is even and the angular spacing of the recesses (524) about the longitudinal axis (LA) is equidistant, each recess (524) has a corresponding other recess (524) located 180° opposite from the recess (524). In other words, the recesses (524) are aligned in pairs facing each other in the diametrical direction. In this example, an even number of recesses (524) are present, but other modifications may have an odd number of recesses (524).

[0051] Each recess (524) in this embodiment includes a concave concave surface (526). In some variations, each concave surface (526) is curved, and this curvature is defined by one or more radii. In some other variations, each concave surface (526) has a negative conical shape. Alternatively, each concave surface (526) may have any other suitable configuration.

[0052] In this embodiment, the distal node flange (520) may be mechanically grounded or fixed to the frame sleeve (200) by crimping the crimp region (206) of the frame sleeve (200) around the distal node flange (520). This crimping may be performed while the cylindrical body (302) of the elastomer sleeve (300) is radially interposed between the frame sleeve (200) and the distal node flange (520), and as a result, the cylindrical body (302) is positioned around the distal node flange (520) such that the distal portion is compressed between the crimp region (206) and the distal node flange (520) when the crimp region (206) is crimped around the distal node flange (520). This crimping may be performed according to the teachings provided above in the context of crimping the crimp region (206) of the frame sleeve (200) around the distal node flange (120). As described above, the deformed crimped region (206) provides a firm grip on the distal node flange (520), thereby allowing the distal node flange (520) to be mechanically grounded or fixed to the frame sleeve (200). Also as described above, the presence of the recess (524) can enhance the grip strength compared to the grip strength that may be provided in a modified version of the distal node flange (520) lacking the recess (524). It should also be understood that the concave surface (526) can provide enhanced fixation against both rotation of the acoustic waveguide (500) relative to the frame sleeve (200) about the longitudinal axis (LA) and rotation of the acoustic waveguide (500) relative to the frame sleeve (200) about the longitudinal axis (LA), and can also provide translation of the acoustic waveguide (500) relative to the frame sleeve (200) along the longitudinal axis (LA).

[0053] In some cases, the presence of an elastomer sleeve (300) between the frame sleeve (200) and the distal node flange (520) can provide a damper that minimizes the transmission of vibrations from the acoustic waveguide (500) to the frame sleeve (200). In addition, or alternatively, the presence of an elastomer sleeve (300) between the frame sleeve (200) and the distal node flange (520) can enhance the grip between the crimped region (206) and the distal node flange (520). In addition, or alternatively, the presence of an elastomer sleeve (300) between the frame sleeve (200) and the distal node flange (520) can provide an enhanced fluid seal between the inner surface of the frame sleeve (200) and the distal node flange (520).

[0054] Figures 16 and 18 show an example of another acoustic waveguide (600) that may be incorporated into an ultrasonic surgical instrument (10) instead of the acoustic waveguide (100). The acoustic waveguide (600) in this example may be configured and operable in the same way as the acoustic waveguide (100), except for the differences described below. The acoustic waveguide (600) in this example includes a cylindrical shaft (602), a distal blade (610), and a distal node flange (620). The acoustic waveguide (600) may also include a proximal node flange (not shown), a ribbon portion (not shown), other node flanges (not shown), and / or other structural features. The distal blade (610) is configured to provide part of the end effector (16) as described above. The distal node flange (620) is configured to provide structural support for the acoustic waveguide (600) within the shaft assembly (12), also as described above. The distal node flange (620) is enlarged relative to the rest of the shaft (602) such that the distal node flange (620) has a larger diameter than the rest of the shaft (602). Although not shown in Figure 16 or Figure 18, the distal node flange (620) may include recesses similar to any of the recesses (124, 424, 524) described herein, or may have any other suitable structural features.

[0055] As also shown in Figures 16 and 18, the elastomer sleeve (700), collet (800), and outer sleeve (900) may also be combined with the acoustic waveguide (600) to form part of a modified shaft assembly (14). The elastomer sleeve (700) may include silicone, PEBAX, and / or any other suitable material (one or more). The elastomer sleeve (700) in this example includes a cylindrical body (702) having a corrugated portion (704) so ​​that the elastomer sleeve (700) in this example is configured and operable as the elastomer sleeve (300) described above. The collet (800) is configured to crimp against the distal node flange (620), similar to the crimped region (206) of the frame sleeve (200) described above. The collet (800) may include a malleable material (e.g., steel, titanium, polyetheretherketone, etc.).

[0056] As is most clearly shown in Figure 17, the collet (800) includes a hollow frustoconical body (802) having a set of distal-proximal slits (804) and a set of distal slits (806). The proximal slits (804) extend longitudinally from the proximal edge of the body (802) and terminate just before the distal edge of the body (802). The proximal slits (804) are spaced equiangled from each other. The distal slits (806) extend longitudinally from the distal edge of the body (802) and terminate just before the proximal edge of the body (802). The distal slits (806) are spaced equiangled from each other. The distal slits (806) are angularly offset from the proximal slits (804) such that the slits (804, 806) interlock. In this embodiment, the slits (804, 806) are configured to facilitate uniform deformation of the collet (800) around the distal node flange (620) during crimping of the collet (800) around the distal node flange (620).

[0057] As shown in Figure 18, the outer sleeve (900) includes a tapered inner distal surface (902) that terminates proximal to the shelf (904). During the assembly process, the tapered inner distal surface (902) abuts radially inward against the collet (800), thereby causing the collet (800) to crimp / deform radially inward against the distal node flange (620), and the cylindrical body (702) of the elastomer sleeve (700) is trapped / compressed between the collet (800) and the distal node flange (620). The proximal edge of the body (802) engages with the shelf (904). This relative positioning is then maintained to form the distal portion of the shaft assembly. In some modifications, the collet (800) is merely flexible and does not necessarily need to be malleable. In such modifications, the outer sleeve (900) can still compress the collet (800) radially inward relative to the distal node flange (620) and maintain such compression. Whether the collet (800) is malleable or simply flexible, when the collet (800) is in the configuration shown in Figure 18, the distal node flange (620) can be mechanically grounded or fixed to the outer sleeve (900).

[0058] In some cases, the presence of an elastomer sleeve (700) between the collet (800) and the distal node flange (620) can provide a damper that minimizes the transmission of vibrations from the acoustic waveguide (600) to the collet (800). In addition, or alternatively, the presence of an elastomer sleeve (300) between the collet (800) and the distal node flange (620) can enhance the grip between the collet 800 and the distal node flange (620). In addition, or alternatively, the presence of an elastomer sleeve 300 between the collet (800) and the distal node flange (620) can provide an enhanced fluid seal between the inner surface of the collet (800) and the distal node flange (620).

[0059] IV. Exemplary Combinations The following examples relate to various non-exclusive ways in which the teachings herein may be combined or applied. It should be understood that the following examples are not intended to limit any claims that may be presented at any point in this application or any subsequent application. No waiver of rights is intended. The following examples are provided solely for illustrative purposes. Various teachings herein are intended to be arranged and applied in many other ways. Furthermore, some modifications may omit certain features mentioned in the following examples. Therefore, none of the aspects or features mentioned below should be considered important unless they are subsequently explicitly indicated as such by the inventors or their heirs. If claims presented in this application or any subsequent application relating to this application include additional features other than those mentioned below, those additional features should not be considered added for any patentability reason. [Examples]

[0060] Apparatus, comprising (a) a shaft assembly, (i) an acoustic waveguide configured to transmit ultrasonic vibrations and having a distal node flange, and (ii) a distal portion that pushes the distal node flange radially inward, the distal portion cooperating with the distal node flange to prevent rotational movement of the distal node flange relative to the distal portion and to prevent longitudinal movement of the distal node flange relative to the distal portion, and (b) an end effector at the distal end of the shaft assembly, the end effector comprising (i) an ultrasonic blade positioned at the distal end of the acoustic waveguide, and (ii) a clamp arm operable to pivot toward and away from the ultrasonic blade. [Examples]

[0061] The distal node flange includes a plurality of recesses, as described in Example 1. [Examples]

[0062] The apparatus according to Example 2, wherein the recess extends longitudinally across the center of the central region along the length of the distal node flange. [Examples]

[0063] The apparatus according to Embodiment 2, wherein the recess includes a distal recess set and a proximal recess set, the distal recess set is positioned distal to the longitudinal midpoint of the central region along the length of the distal node flange, and the proximal recess set is positioned proximal to the longitudinal midpoint of the central region, the longitudinal midpoint of the central region providing a structural interruption between the distal recess set and the proximal recess set. [Examples]

[0064] The apparatus according to any one of Examples 2 to 4, wherein each of the multiple recesses is at least partially defined by a first concave surface and a second concave surface, and the second concave surface provides a transition from the rest of the distal node flange to the first concave surface. [Examples]

[0065] The apparatus according to Example 5, wherein the first concave surface is flat. [Examples]

[0066] The apparatus according to Example 5 or 6, wherein the second concave surface is curved. [Examples]

[0067] The apparatus according to Example 2, wherein each recess has a concave shape. [Examples]

[0068] The apparatus according to Example 8, wherein each recess has a curved surface that defines the concave shape. [Examples]

[0069] The apparatus according to Example 8, wherein each recess has a negative conical surface that defines the concave shape. [Examples]

[0070] The apparatus according to any one of Examples 1 to 10, wherein the distal portion includes a frame sleeve coaxially positioned around the distal node flange. [Examples]

[0071] The apparatus according to Example 11, wherein the frame sleeve has a crimped section, the crimped section is crimped around the distal node flange, thereby pushing the distal node flange radially inward. [Examples]

[0072] The apparatus according to Example 12, wherein the crimped section is malleable. [Examples]

[0073] The apparatus according to Example 12 or 13, wherein the clamp arm is pivotably coupled to the frame sleeve. [Examples]

[0074] The apparatus according to any one of Examples 1 to 14, wherein the shaft assembly further includes an articulated section, the articulated section being operable to laterally deflect an end effector away from the central longitudinal axis of the shaft assembly. [Examples]

[0075] The apparatus according to Example 15, wherein the acoustic waveguide further comprises a flexible region extending along the joint movement section. [Examples]

[0076] The apparatus according to Example 16, wherein the distal node flange is located distal to the flexible region. [Examples]

[0077] The apparatus according to any one of Examples 1 to 17, wherein the shaft assembly further comprises an elastomer member interposed between the distal node flange and the distal portion of the shaft assembly, the elastomer member being compressed against the distal node flange by the distal portion of the shaft assembly. [Examples]

[0078] (a) A shaft assembly comprising (i) an acoustic waveguide configured to transmit ultrasonic vibrations, the acoustic waveguide having a distal node flange, (ii) an articulated section, the articulated section having the distal node flange positioned distal to the articulated section, and (ii) a distal sleeve crimped radially inward with respect to the distal node flange, the distal sleeve cooperating with the distal node flange to prevent rotational movement of the distal node flange relative to the distal sleeve and to prevent longitudinal movement of the distal node flange relative to the distal sleeve, and (b) an end effector at the distal end of the shaft assembly, the end effector comprising (i) an ultrasonic blade positioned at the distal end of the acoustic waveguide, and (ii) a clamp arm operable to pivot toward and away from the ultrasonic blade, the articulated section operable to deflect the end effector laterally away from the central longitudinal axis of the shaft assembly. [Examples]

[0079] A method comprising: (a) positioning an elastomer feature around the distal node flange of an acoustic waveguide; (b) positioning a malleable sleeve around the distal node flange such that the elastomer feature is radially interposed between the malleable sleeve and the distal node flange; and (c) compressing the malleable sleeve radially inward, thereby crimping the malleable sleeve against the distal node flange, thereby compressing the elastomer feature against the distal node flange, wherein the malleability of the sleeve is configured to maintain the crimp and compression, thereby firmly fixing the malleable sleeve against the distal node flange.

[0080] IV. Others Any patent, publication, or other disclosure material that is said to be incorporated herein by reference will be incorporated herein only to the extent that the incorporated material, in whole or in part, does not contradict any existing definitions, views, or other disclosure material contained herein. Any disclosure expressly contained herein, either by itself or to the extent necessary, shall take precedence over any conflicting statements incorporated herein by reference. Any material, or any part thereof, that is said to be incorporated herein by reference but contradicts any existing definitions, views, or other disclosure material contained herein will be incorporated only to the extent that there is no conflict between the incorporated material and the existing disclosure material.

[0081] The modifications of the devices described above are applicable not only to conventional medical procedures and surgeries performed by medical professionals, but also to robot-assisted medical procedures and surgeries. For example, various teachings herein can be readily combined with various teachings in any of the references cited herein relating to robotic surgical systems.

[0082] The above-described modifications may be designed to be discarded after a single use, or they may be designed to be used multiple times. In either case or both, the modifications may be readjusted for reuse after at least one use. Readjustment may include any combination of a device disassembly step, a subsequent cleaning or replacement step of specific parts, and a subsequent reassembly step. Specifically, some modifications of the device may be disassembled, and any number of specific parts or components of the device may be selectively replaced or removed in any combination. During cleaning and / or replacement of specific parts, some modifications of the device may be reassembled for subsequent use, either in a readjustment facility or by an operator immediately before the procedure. Those skilled in the art will understand that various techniques for disassembly, cleaning / replacement, and reassembly may be used in the readjustment of the device. The use of such techniques and the resulting readjusted devices are all within the scope of this application.

[0083] For illustrative purposes only, the modifications described herein may be sterilized before and / or after treatment. In one sterilization technique, the device is placed in a sealed container, such as a plastic or TYVEK bag. The container and device may then be placed in a radiation field that can penetrate the container, such as gamma rays, X-rays, or high-energy electron beams. The radiation may kill bacteria on the device and inside the container. The sterilized device may then be stored in the sterilized container for later use. The device may also be sterilized using any other technique known in the art, including but not limited to beta or gamma rays, ethylene oxide, or vapor.

[0084] While various embodiments of the present invention have been illustrated and described, further adaptations of the methods and systems described herein can be achieved without departing from the scope of the invention by appropriate modifications by those skilled in the art. Some of these possible modifications have been mentioned, but others will be obvious to those skilled in the art. For example, the examples, embodiments, geometric shapes, materials, dimensions, proportions, processes, etc., discussed above are illustrative and not essential. Therefore, it should be understood that the scope of the present invention should be considered with respect to the following claims and is not limited to the structural and operational details shown and described herein and in the drawings.

[0085] [Implementation Method] (1) A device, (a) A shaft assembly, (i) an acoustic waveguide, wherein the acoustic waveguide is configured to transmit ultrasonic vibrations, and the acoustic waveguide has a distal node flange, (ii) A shaft assembly comprising: a distal portion that pushes the distal node flange radially inward, wherein the distal portion cooperates with the distal node flange to prevent rotational movement of the distal node flange relative to the distal portion and to prevent longitudinal movement of the distal node flange relative to the distal portion; (b) comprising an end effector at the distal end of the shaft assembly, wherein the end effector is (i) an ultrasonic blade positioned at the distal end of the acoustic waveguide, (ii) a device comprising a clamp arm that is operable to pivot toward and away from the ultrasonic blade. (2) The apparatus according to Embodiment 1, wherein the distal node flange includes a plurality of recesses. (3) The apparatus according to Embodiment 2, wherein the recess extends longitudinally across the center of the central region along the length of the distal node flange. (4) The apparatus according to Embodiment 2 or 3, wherein the recess includes a distal recess set and a proximal recess set, the distal recess set is positioned distal to the longitudinal midpoint of the central region along the length of the distal node flange, the proximal recess set is positioned proximal to the longitudinal midpoint of the central region, and the longitudinal midpoint of the central region provides a structural interruption between the distal recess set and the proximal recess set. (5) The apparatus according to any one of embodiments 2 to 4, wherein each of the plurality of recesses is at least partially defined by a first concave surface and a second concave surface, and the second concave surface provides a transition from the other portion of the distal node flange to the first concave surface.

[0086] (6) The apparatus according to Embodiment 5, wherein the first concave surface is flat. (7) The apparatus according to embodiment 5 or 6, wherein the second concave surface is curved. (8) The apparatus according to any one of embodiments 2 to 7, wherein each recess has a concave shape. (9) The apparatus according to Embodiment 8, wherein each recess has a curved surface that defines the concave shape. (10) The apparatus according to embodiment 8 or 9, wherein each recess has a negative conical surface defining the concave shape.

[0087] (11) The apparatus according to any one of embodiments 1 to 10, wherein the distal portion includes a frame sleeve coaxially positioned around the distal node flange. (12) The apparatus according to embodiment 11, wherein the frame sleeve has a crimped section, the crimped section is crimped around the distal node flange, thereby pushing the distal node flange radially inward. (13) The apparatus according to embodiment 12, wherein the crimped section is malleable. (14) The apparatus according to any one of embodiments 11 to 13, wherein the clamp arm is pivotably coupled to the frame sleeve. (15) The apparatus according to any one of embodiments 1 to 14, wherein the shaft assembly further includes an articulated section, the articulated section being operable to deflect the end effector laterally away from the central longitudinal axis of the shaft assembly.

[0088] (16) The apparatus according to embodiment 15, wherein the acoustic waveguide further comprises a flexible region extending along the joint movement section. (17) The apparatus according to embodiment 16, wherein the distal node flange is located distal to the flexible region. (18) The apparatus according to any one of embodiments 1 to 17, wherein the shaft assembly further comprises an elastomer member interposed between the distal node flange and the distal portion of the shaft assembly, the elastomer member being compressed against the distal node flange by the distal portion of the shaft assembly. (19) A device, (a) A shaft assembly, (i) an acoustic waveguide, wherein the acoustic waveguide is configured to transmit ultrasonic vibrations, and the acoustic waveguide has a distal node flange, (ii) A joint movement section wherein the distal node flange is located distal to the joint movement section, (ii) A shaft assembly comprising: a distal sleeve crimped radially inward with respect to the distal node flange, wherein the distal sleeve cooperates with the distal node flange to prevent rotational movement of the distal node flange relative to the distal sleeve and to prevent longitudinal movement of the distal node flange relative to the distal sleeve; (b) comprising an end effector at the distal end of the shaft assembly, wherein the end effector is (i) an ultrasonic blade positioned at the distal end of the acoustic waveguide, (ii) A clamp arm that is operable to pivot toward and away from the ultrasonic blade, The joint movement section is operable to deflect the end effector laterally away from the central longitudinal axis of the shaft assembly. (20) A method, (a) Positioning elastomer features around the distal node flange of the acoustic waveguide, (b) Positioning the malleable sleeve around the distal node flange such that the elastomer feature is interposed radially between the malleable sleeve and the distal node flange, (c) A method comprising compressing the malleable sleeve radially inward, thereby crimping the malleable sleeve with respect to the distal node flange, thereby compressing the elastomer feature with respect to the distal node flange, wherein the malleability of the sleeve is configured to maintain the crimp and the compression, thereby firmly securing the malleable sleeve with respect to the distal node flange.

Claims

1. It is a device, (a) A shaft assembly, (i) an acoustic waveguide, wherein the acoustic waveguide is configured to transmit ultrasonic vibrations, and the acoustic waveguide has a distal node flange, (ii) A shaft assembly comprising: a distal portion that pushes the distal node flange radially inward, wherein the distal portion cooperates with the distal node flange to prevent rotational movement of the distal node flange relative to the distal portion and to prevent longitudinal movement of the distal node flange relative to the distal portion; (b) an end effector located at the distal end of the shaft assembly, wherein the end effector is (i) an ultrasonic blade positioned at the distal end of the acoustic waveguide, (ii) A device comprising a clamp arm that is operable to pivot toward and away from the ultrasonic blade.

2. The apparatus according to claim 1, wherein the distal node flange includes a plurality of recesses.

3. The apparatus according to claim 2, wherein the recess extends longitudinally across the center of the central region along the length of the distal node flange.

4. The apparatus according to claim 2 or 3, wherein the recess includes a distal recess set and a proximal recess set, the distal recess set is positioned distal to the longitudinal midpoint of the central region along the length of the distal node flange, the proximal recess set is positioned proximal to the longitudinal midpoint of the central region, and the longitudinal midpoint of the central region provides a structural interruption between the distal recess set and the proximal recess set.

5. The apparatus according to claim 2, wherein each of the plurality of recesses is at least partially defined by a first concave surface and a second concave surface, and the second concave surface provides a transition from the other portion of the distal node flange to the first concave surface.

6. The apparatus according to claim 5, wherein the first concave surface is flat.

7. The apparatus according to claim 5 or 6, wherein the second concave surface is curved.

8. The apparatus according to claim 2, wherein each recess has a concave shape.

9. The apparatus according to claim 8, wherein each recess has a curved surface that defines the concave shape.

10. The apparatus according to claim 8 or 9, wherein each recess has a negative conical surface defining the concave shape.

11. The apparatus according to claim 1, wherein the distal portion includes a frame sleeve coaxially positioned around the distal node flange.

12. The apparatus according to claim 11, wherein the frame sleeve has a crimped section, the crimped section is crimped around the distal node flange, thereby pushing the distal node flange radially inward.

13. The apparatus according to claim 12, wherein the crimped section is malleable.

14. The apparatus according to any one of claims 11 to 13, wherein the clamp arm is pivotably coupled to the frame sleeve.

15. The apparatus according to claim 1, wherein the shaft assembly further includes an articulated section, the articulated section being operable to deflect the end effector laterally away from the central longitudinal axis of the shaft assembly.

16. The apparatus according to claim 15, wherein the acoustic waveguide further comprises a flexible region extending along the joint movement section.

17. The apparatus according to claim 16, wherein the distal node flange is located distal to the flexible region.

18. The apparatus according to claim 1, wherein the shaft assembly further comprises an elastomer member interposed between the distal node flange and the distal portion of the shaft assembly, the elastomer member being compressed against the distal node flange by the distal portion of the shaft assembly.

19. It is a device, (a) A shaft assembly, (i) an acoustic waveguide, wherein the acoustic waveguide is configured to transmit ultrasonic vibrations, and the acoustic waveguide has a distal node flange, (ii) A joint movement section wherein the distal node flange is located distal to the joint movement section, (ii) A shaft assembly comprising: a distal sleeve crimped radially inward with respect to the distal node flange, wherein the distal sleeve cooperates with the distal node flange to prevent rotational movement of the distal node flange relative to the distal sleeve and to prevent longitudinal movement of the distal node flange relative to the distal sleeve; (b) an end effector located at the distal end of the shaft assembly, wherein the end effector is (i) an ultrasonic blade positioned at the distal end of the acoustic waveguide, (ii) A clamp arm that is operable to pivot toward and away from the ultrasonic blade, The joint movement section is operable to deflect the end effector laterally away from the central longitudinal axis of the shaft assembly.

20. It is a method, (a) Positioning elastomer features around the distal node flange of the acoustic waveguide, (b) Positioning the malleable sleeve around the distal node flange such that the elastomer feature is interposed radially between the malleable sleeve and the distal node flange, (c) A method comprising compressing the malleable sleeve radially inward, thereby crimping the malleable sleeve with respect to the distal node flange, thereby compressing the elastomer feature with respect to the distal node flange, wherein the malleability of the sleeve is configured to maintain the crimp and the compression, thereby firmly fixing the malleable sleeve with respect to the distal node flange.

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