Ultrasonic tools and methods for manufacturing the tools

Abstract

An ultrasonic cutting tool is designed for use in an ultrasonic instrument. The tool is a blade (10) including a flat portion (11) fabricated from at least a first blade layer (112) and a second blade layer (113), each of which is a flat metal plate arranged parallel to and bonded to one another.

Description

[Technical Field]

[0001] The present invention relates to the field of ultrasonic instruments.The present invention relates to an ultrasonic tool for use in ultrasonic instruments, in particular for cutting or abrasive machining, and to a method for manufacturing said tool. [Background technology]

[0002] An ultrasonic instrument has a generator of ultrasonic energy and an elongated tip or tool or blade whose proximal end receives ultrasonic energy from the generator and transmits it to the distal end of the tip. Depending on the application, the distal end can be used as a probe and / or shaped for instruments to penetrate soft tissue, cut, process bone tissue, etc.

[0003] It is known to provide ultrasonic tools with a conduit for a cooling fluid. The fluid can be water or a mixture of water with ethanol and / or a disinfectant. The fluid is used to cool the blade and flush away the cut material. As shown in U.S. Patent Nos. 4,515,583 and 6,165,150, the conduit can be double-walled to provide an additional conduit for aspirating the fluid material. Furthermore, it is known that the conduit has multiple branching cooling water channels as it exits the opening, as in U.S. Patent No. 5,188,102, or is made of a porous sintered material that allows water to exit through the surface of the ultrasonic cutting blade, as in U.S. Patent Application Publication No. 2015 / 0005774. Achieving efficient cooling of the blade during bone cutting remains a challenge today.

[0004] EP3061415 discloses a blade that is manufactured and attached to a waveguide by manufacturing two halves of the blade separated along the longitudinal axis of the blade, cutting a portion of a conduit in each half of the blade, welding the two halves of the blade together into one blade, and welding the blade to the distal end of the waveguide.

[0005] US Patent Application Publication No. 2005 / 165345 shows a three-layer electrode (two conductors separated by an insulator) used for electrocautery in a fat removal device. The electrode can replace a rotating blade.

[0006] US Patent No. 5,695,510 shows the attachment of blades by means of a bayonet joint using threads.

[0007] These devices are typically manufactured by elaborate or time-consuming processes such as machining or sintering, which increases their cost. There is a need for ultrasonic cutting instruments with simple construction that can be manufactured efficiently and economically. Summary of the Invention [Problem to be solved by the invention]

[0008] The object of the present invention is therefore to create an ultrasonic tool of the type initially mentioned, which overcomes the drawbacks mentioned above. A further object is to create a method for manufacturing the tool. [Means for solving the problem]

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

[0010] One advantage is that the coolant and cleaning fluids are supplied from inside the tool, which avoids the generation of large jets of water in the work area and thereby improves visibility in the work area.

[0011] An ultrasonic cutting tool for use in an ultrasonic instrument is a blade and includes a flat portion made from at least a first blade layer and a second blade layer, the first and second blade layers being flat metal plates arranged parallel to each other and bonded to each other, and optionally one or more additional blade layers may be disposed between the first and second blade layers.

[0012] This allows for the creation of thin blades with a high degree of freedom in shaping the blade. The flats can be inexpensively manufactured, for example, by stamping or laser cutting, and / or using photochemical or photoetching. Such operations can also include creating structures on the blade layers that act as channels (inside the blade) and other structures, such as teeth, for tooling (on the outside of the blade) for cutting and polishing operations.

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

[0014] The tool can be used in an ultrasonic instrument coupled to an ultrasonic vibration generator as a blade for cutting or abrasive machining. The tool can be cooled internally by flowing a coolant through the tool along its length. Conversely, material can be suctioned from the vicinity of the tool. The flat portion can be manufactured to form a cutting tool. In particular, the flat surface can be shaped to form a file or rasp, and / or the edge of the flat portion can be shaped to form a file or rasp or knife.

[0015] In embodiments, the flattened portion forms one or more channels suitable for directing a fluid along the interior of the blade, the channels being capable of transporting a coolant to the end of the blade and / or of drawing liquid or particles through the blade.

[0016] This allows the coolant to be guided through and along the interior of the blade, especially the flattened portion, which serves to cool the blade and its surroundings. Compared to external cooling, there is better visibility in the working area.

[0017] Having the fluid directed through the interior of the mounting area and flat makes the tool particularly suitable for use in conjunction with a robot that holds and moves the tool, since there are no external tubes or hoses to provide coolant.

[0018] In an embodiment, the first blade layer or the second blade layer or both comprise, on the side facing the other blade layer, recesses defining channels suitable for directing a fluid along the blade, in particular the recesses being made by a subtractive method, in particular by machining or photoetching.

[0019] This allows for a high degree of freedom in shaping the channels. They can be easily created by creating recesses inside one or both layers. The shape of the channels, especially their width, can be adapted to the cooling requirements, allowing for high cooling and cleaning efficiency. The location where the channel exits the flattened section can be defined by shaping the recess accordingly.

[0020] Etching, and particularly photoetching, has the advantage that it can be easily scaled for manufacturing. For example, etching can be performed as a roll-to-roll process. The recesses or notches that define the channels can be created simultaneously with the contours of each layer. This is precise and cost-effective for mass production.

[0021] In an embodiment, the first braid layer and the second braid layer are welded together. In an embodiment, the flat portion includes one or more weld lines by which the first blade layer and the second blade layer are welded to each other at the surfaces where the first blade layer and the second blade layer abut each other.

[0022] In other words, the two blade layers are not welded to each other at their longitudinal edges, such as the first edge and the second edge.

[0023] In an embodiment, the weld lines extend along the longitudinal direction of the flat portion, and in particular, one weld line extends adjacent to a first longitudinal edge of the flat portion and another weld line extends adjacent to a second longitudinal edge.

[0024] In other embodiments, the weld line extends adjacent two sides of the channel. In an embodiment, the weld line is interrupted where the weld line intersects a portion of the channel.

[0025] In an embodiment, the flat part is joined to a mounting part for attaching the blade to an ultrasonic generator, in particular the mounting part has a rotationally symmetrical body.

[0026] Such a body simplifies the construction of the mounting part, especially when the rotationally symmetric body is a mounting body around which a ring is arranged, as will be explained below.

[0027] In an embodiment, the flat part is held in the clamping slit of the attachment part, in particular by a press fit.

[0028] In an embodiment, the flat portion is bonded in the fastening slit by, for example, welding, soldering or adhesive.

[0029] In an embodiment, the flat portion includes a hole in at least one of the first braid layer and the second braid layer in the area where the flat portion is held within the fastening slit, the hole defining a braid inlet that is in fluid communication with the channel.

[0030] This creates a conduit from the attachment to the channel that directs fluid into (or out of) the channel through the face of one of the braid layers.

[0031] In an embodiment, the holes are present in only one of the braid layers and not the other, thereby closing off the conduit in the opposite direction to the radial conduit.

[0032] In an embodiment, the attachment comprises a radial conduit in fluid communication with the blade inlet, in particular the radial conduit in fluid communication with the longitudinal conduit.

[0033] Thus, fluid can be directed from the longitudinal conduits through the radial conduits and blade inlets into the channels and in the opposite direction.

[0034] In an embodiment, the mounting part comprises a mounting body in which the clamping slits are arranged, and the ring is arranged around the mounting body, in particular to compress the mounting body.

[0035] In an embodiment, the ring acts as a seal for the radial conduit. In embodiments, a hollow conduit or needle is disposed within the channel and extends longitudinally from the flat portion into the mounting portion with a fluid-tight connection between the hollow needle and the mounting portion, within the flat portion the hollow needle can extend to the distal end of the flat portion or at least half or three-quarters the distance from the mounting portion to the distal end.

[0036] In an embodiment, the attachment portion includes internal or external threads. In an embodiment, the flat portion includes one or more holes in fluid communication with one or more channels.

[0037] In an embodiment, one or more edges of the flat portion include teeth. In an embodiment, one or more edges of the flat portion are machined to define a cutting edge.

[0038] In embodiments, one or more edges of the flat portion include one or more notches that define openings in liquid communication with one or more channels.

[0039] In embodiments, the outer surface of the flat portion is molded to include a structured surface, particularly having teeth or grooves, which can function as a file.

[0040] The presence of teeth and / or cutting edges and / or notches and / or structured surfaces and / or holes can improve the efficiency of cutting and / or polishing. In particular, the edges of the holes can participate in cutting and / or polishing. The holes and / or notches in liquid communication with the channels serve to direct the liquid to the areas where cutting and / or polishing takes place and where the cooling effect may be most needed.

[0041] The method for manufacturing the blade comprises: providing a first braid layer and a second braid layer, at least one of which includes a recess that serves as a channel in the braid; bonding the first braid layer and the second braid layer together with a recess disposed therebetween, thereby forming a blade flat; joining the flat portion to the mounting part by clamping the flat portion in a clamping slit in the mounting part; Includes.

[0042] Alternatively, the method comprises: providing a first braid layer, a second braid layer, and one or more further braid layers, at least one of which includes recesses or notches that act as channels in the braid; bonding the first and second braid layers and one or more additional braid layers together with a recess or notch disposed between the first and second braid layers, thereby forming a blade flat; joining the flat portion to the mounting part by clamping the flat portion in a clamping slit in the mounting part; Includes.

[0043] In an embodiment, joining the flat portion to the mounting portion includes heating the mounting portion, inserting the flat portion into a fastening slit in the mounting portion, and cooling the mounting portion.

[0044] In an embodiment, the method includes the further step of machining holes through the attachment portion and at least one of the braid layers, thereby creating radial conduits in fluid communication with the channels.

[0045] In an embodiment, the holes are machined through only one of the blade layers. In an embodiment, the radial conduits and the tapered portions of the longitudinal conduits are machined starting from a circumferential position on the mounting body of the mounting portion and then covered to create a closed conduit between the radial conduits and the tapered portions.

[0046] By machining the radial conduits and ramps from the same circumferential location, they are in fluid communication, and then the openings required and created by the machining process are closed.

[0047] In an embodiment, the radial conduits and the tapered portions of the longitudinal conduits are covered by fitting a ring around the mounting body.

[0048] Such a ring is simple to manufacture and balances the symmetry of the blade, which is advantageous with respect to vibration.

[0049] In other embodiments, the conduit is sealed by threads, by welding, or by another means for closing the opening.

[0050] According to an aspect of the present invention, there is provided a robotic system configured with a cutting tool as described herein, the robotic system being programmed to apply the tool to machine an object or workpiece.

[0051] In an embodiment, the workpiece is a piece of animal or human tissue, particularly bone. In an embodiment, the robotic system is configured to supply fluid coolant to the cutting tool while machining the workpiece.

[0052] By cooling the tool internally, continuous cooling of the tool can be performed in a more efficient manner and with better control of the cooling and therefore the temperature of the tool, which allows for longer machining time windows.

[0053] The longer machining time window then allows the workpiece to be machined without retrieving the tool, which would otherwise require reinsertion and result in loss of precision. Furthermore, different functions can be performed with the same tool without retrieving it: cutting, sawing, filing, cooling and vacuuming material.

[0054] Combining the tool with a robotic manipulator allows for controlled cutting or machining of 3D parts and shapes, respectively.

[0055] In an embodiment, the robotic system comprises a manipulator arm to which a tool is attached and which is capable of moving the tool, and the tool is provided with a coolant through the manipulator arm, and in particular a coolant conduit is disposed within a casing of at least one distal-most link of the manipulator arm.

[0056] In an embodiment, the robotic system is programmed to apply tools to machine the workpiece sequentially without interruption, without withdrawing the tools from the area where they are applied to the workpiece.

[0057] In an embodiment, the robotic system is programmed to apply the tool to machine a workpiece using two or more different functions of the tool without retrieving the tool, in particular the functions are cutting, sawing, filing, and suctioning material.

[0058] In an embodiment, the robot system is programmed to apply tools to machine different sides of the workpiece, particularly surfaces of the workpiece whose surface normals are oriented at angles greater than 45° or greater than 90° to each other.

[0059] That is, the tool is used to machine two or more different sides of the tool. In embodiments, the robotic system is programmed to apply tools to sequentially machine the workpiece for at least 2 minutes, or 3 minutes, or 4 minutes, or 5 minutes, or 6 minutes without interruption.

[0060] In an embodiment, the tool is shaped to include the functions of at least two of a file, a saw, or a knife.

[0061] For example, the tools may include a file and a saw, or a saw and a knife, etc. This allows the tool to be applied without having to interrupt machine operation to retrieve the tool.

[0062] In an embodiment, the tool is shaped to include at least two variations with the same function but different parameters.

[0063] For example, the tools may include a coarse file and a fine file, or a coarse saw and a fine saw.

[0064] In an embodiment, the robot system comprises a sensing unit configured to measure a tool force exerted by the tool on the workpiece, and is configured to control the movement of the tool according to the measured tool force.

[0065] This allows for controlled tool movement to maintain a desired machining force, which can be used to optimize machining speed and / or prevent excessive heating of the tool.

[0066] In an embodiment, the robot system comprises a coolant supply unit configured to provide coolant to the tool intermittently, in particular alternating between a first duration during which coolant is provided and a second duration during which no coolant is provided, in particular the period after which the first duration occurs being between 1 and 10 seconds, in particular between 2 and 5 seconds.

[0067] In other words, the first duration for which coolant is provided corresponds to a pulse of coolant, which pulse may be repeated for a period of length depending on the period.

[0068] The intermittent flow of coolant creates a fluid buffer that is maintained between the tool and workpiece, preventing it from interfering with tool operation. During the coolant pulse, debris from the tool operation can be flushed away.

[0069] In an embodiment, the robot system or coolant supply unit comprises a sensing unit configured to measure a tool temperature and a control unit configured to control a flow of coolant to the tool according to the measured tool temperature.

[0070] This allows the coolant flow to be adapted to the actual cooling requirements, which are dependent on the operating conditions between the tool and the workpiece.

[0071] The flow can be controlled by continuously varying the flow or in discrete steps, particularly by turning the flow on and off, i.e., by pulsating flow. In the latter case, the controller can set the pulse width, or pulse frequency, or coolant pulses.

[0072] In an embodiment, the sensing unit is configured to determine the tool temperature based on a driver vibration frequency of the tool, the driver vibration frequency being continuously adapted to an actual resonant frequency of the tool.

[0073] This is based on the observation that tool temperature affects the tool's mechanical properties, particularly its length, and therefore the tool's actual resonant frequency. The actual resonant frequency can be determined by using an ultrasonic driver that automatically adapts its operating frequency to the tool's actual resonant frequency. This automatic frequency adaptation is a feature of many existing ultrasonic drivers.

[0074] As a result, the coolant flow can be controlled according to the actual operating frequency of the ultrasonic driver.

[0075] As described herein, intermittently providing coolant to the tool and / or controlling fluid flow and / or measuring temperature can also be performed by a coolant supply unit that is part of a setup where a robotic system is not present.

[0076] Further embodiments are evident from the dependent claims. Features of the method claims may be combined with features of the device claims, and vice versa.

[0077] The subject matter of the invention will be explained in more detail in the following text with reference to exemplary embodiments illustrated in the accompanying drawings, in which: FIG. [Brief explanation of the drawings]

[0078] [Figure 1]1A-1C show different views and portions of a blade according to one embodiment. [Figure 2] 1A-1C show different views and portions of a blade according to one embodiment. [Figure 3] 1A-1C show different views and portions of a blade according to one embodiment. [Figure 4] 1A-1C show different views and portions of a blade according to one embodiment. [Figure 5] Blade layers with different channel geometries. [Figure 6] Blade layers with different channel geometries. [Figure 7] Blade layers with different channel geometries. [Figure 8] Blade layers with different channel geometries. [Figure 9] Further embodiments in respective cross-section and elevation views. [Figure 10] Further embodiments in respective cross-section and elevation views. [Figure 11] Further embodiments in respective cross-section and elevation views. [Figure 12] Further embodiments in respective cross-section and elevation views. [Figure 13] Further embodiments in respective cross-section and elevation views. [Figure 14] Further embodiments in respective cross-section and elevation views. [Figure 15] Further embodiment in elevation view. [Figure 16] Further embodiment in elevation view. [Figure 17] For further embodiments, the first braid layer alone and in combination with the second braid layer. [Figure 18] An embodiment having an axial hollow needle for directing fluid into the flat of the tool. [Figure 19] An embodiment having an axial hollow needle for directing fluid into the flat of the tool. DETAILED DESCRIPTION OF THE INVENTION

[0079] As a rule, identical parts are provided with the same reference numbers in the drawings. Figures 1 to 4 show different views and parts of a blade according to one embodiment: Figure 1 shows a perspective view, Figure 2 shows a longitudinal section with a view perpendicular to the plane in which the blade 10 lies, Figure 3 shows a longitudinal section with a view parallel to said plane, and Figure 4 shows an exploded view.

[0080] The blade 10 includes a flat portion 11 held by a mounting portion 14. The flat portion 11 constitutes the working portion, i.e., the portion for cutting or grinding material, particularly bone and / or soft tissue. The flat portion 11 includes a first blade layer 112 and a second blade layer 113, which are preferably flat pieces made of metal. The two layers are joined to each other, for example, by welding. Corresponding weld lines 24 are represented by dotted lines. They extend adjacent to first and second longitudinal edges 25 and 26. At least one of the layers includes a recess that forms a channel 20 along the length of the flat portion 11. The channel 20 can serve to guide, distribute, and dispense coolant provided via the mounting portion 14.

[0081] The mounting portion 14 allows the blade 10 to be attached to the ultrasonic vibration generator, for example, by external threads 15 as shown, or by internal threads.

[0082] The transfer and dispensing of fluids can be enhanced or facilitated by the pumping effect caused by the ultrasonic vibration of the blade 10, particularly the flat portion 11.

[0083] At the proximal end, the flat part 11 is clamped in a clamping slit 135 arranged in a mounting body 131 which is part of the mounting part 14 .

[0084] The flat portion 11 can be clamped in the clamping slit 135 by heating the attachment portion 14, inserting the flat portion 11 while the attachment portion 14 is hot, and again allowing the attachment portion 14 to cool, thereby creating a press fit. Additionally or alternatively, this connection can be made by welding, soldering, gluing, or other bonding.

[0085] A ring 130 fits around the mounting body 131 and can increase the clamping force applied by the mounting body 131 to the flat portion 11. The ring 130 also serves to close the conduit for directing fluid from the longitudinal conduit 32 in the mounting portion 14 to the channel 20 in the flat portion 11 (or in other directions). The conduit is formed by starting from a circumferential point on the mounting body 131 and machining a radial conduit 133 that connects to the flat portion 11 and an angled conduit section 132 that becomes part of the longitudinal conduit 32. After machining, the two conduits are closed by the ring 130.

[0086] The radial conduits 133 direct the fluid into the channel 20 from the side of one of the first braid layer 112 and the second braid layer 113. This is more reliable and easier to achieve than directing the fluid through the relatively thin proximal edge of the flat portion 11.

[0087] The main components of the blade 10, such as the flat section 11, the attachment section 14 and the ring 130, are typically made from titanium and / or medical grade stainless steel. Some parts can be made from an aluminum alloy.

[0088] In an embodiment, the flat portion 11 and ring 130 are made from stainless steel, and the mounting portion 14 is also made from stainless steel. When creating the press fit, the mounting portion 14 is heated, for example, to about 400°-500° Celsius, before inserting the flat portion 11.

[0089] The channel 20 or corresponding recess(es) can be formed by etching, laser engraving, electrochemical machining, and other methods.

[0090] Figures 5-8 show blade layers with different channel and blade shapes. These examples illustrate the variations that can be easily achieved in both the blade 10 shape and the channel 20 shape. The shapes shown represent recesses in the first blade layer 112, the second blade layer 113, or both. The weld line 24 is adapted to the shape of the channel 20 and / or the blade's outer contour. Figure 5 shows a straight channel 20 leading from the blade inlet 134 to the leading edge 27. Figure 6 shows a channel 20 that, in addition to exiting at the leading edge 27, branches off to side channels that lead to the outlet along the first edge 25 and the second edge 26. The weld line 24 is interrupted where it intersects with the side channels. Figure 7 shows a channel 20 leading from the blade inlet 134 to the leading edge 27 and widening toward the leading edge 27. Figure 8 shows a flattened section 11 with a leading edge 27 shaped to provide a cutting action during vibration, with a straight channel 20 leading from the blade inlet 134 to the leading edge 27.

[0091] In embodiments not shown, there are two or more separate channels 20. The separate channels can be used to distribute coolant evenly along the flat portion 11. Alternatively or additionally, they can be used for different purposes. At least one coolant channel can be used to provide coolant to the flat portion 11, and at least one suction channel can be used to suction material from the area surrounding the flat portion 11.

[0092] The two channels 20 are typically laterally displaced relative to each other. There may be two radial conduits 133, each leading to one of the two channels. The two radial conduits 133 may lead into the flattened portion 11 from the same side or from opposite sides. Thus, in the latter case, one of the radial conduits 133 passes through a blade inlet 134 in the first braid layer 112 and the other through a blade inlet 134 in the second braid layer 113. In other embodiments, one of the channels is in liquid communication with an axially oriented (or longitudinal) channel in the mounting body 131.

[0093] 1-8 show the blade edges as blunt in a simplified representation. In actual embodiments, the edges may be sharpened and / or may include serrations or notches, as shown below.

[0094] 9-16 show transverse cross-sections and elevations of the flat portion 11 of the blade 10, typically with a longitudinal weld seam 24 adjacent to a first longitudinal edge 25 and a second longitudinal edge 26. The major planar surface of the flat portion 11 typically includes a structured surface 23, such as teeth or grooves. While the figures show channels 20 formed in only one of the layers, it will be understood that in each instance they may be formed in both.

[0095] Typically, the first longitudinal edge 25, the second longitudinal edge 26 and the leading edge 27 may be shaped differently or in the same way, with notches 21, teeth, serrated edges or as blades, or in combination with these and even other elements, and the shape of the channel or channels 20 will be adapted accordingly.

[0096] 9-10 show transverse cross-sections and elevations of a flattened portion of blade 10 having a single longitudinal channel. The corresponding shape of channel 20 can be as shown in FIG. 5 or FIG.

[0097] 11-12 show transverse cross-sections and elevations of the blade 10 flat section, showing holes 22 that form the openings for a single channel 20 (not shown) or two parallel channels 20. Each channel is molded in one of the two layers. As a result, only a single type of layer needs to be manufactured. The edges of the holes can have a cutting effect. The diameter of the holes 22 varies longitudinally to control the distribution of coolant along the length of the flat section 11. This can help distribute the flow evenly.

[0098] 13-14 show transverse cross-sections and elevations of the flat portion of the blade 10, with the presence of notches 21 in one or more of the first edge 25 and / or second edge 26 and / or leading edge 27. The notches 21 serve on the one hand as serrations for cutting and on the other hand as conduits for the coolant to exit the channels 20. The corresponding shape of the channels 20 can be as shown in FIG.

[0099] 9-14 show elements such as weld line 24, structured surface 23, holes 22, and notches 21 separately. In other embodiments, these are combined. For example, according to FIG. 15, notch 21 is present on first edge 25, and holes 22 are located near second edge 26, which may be shaped as a cutting edge. Correspondingly shaped channels 20 (not shown) are positioned to be in fluid communication with holes 22 and notches 21.

[0100] In further embodiments, there are two or more weld lines 24, depending on the shape of the channel 20 between them. The weld lines 24 can be used to strengthen the structure of the flat portion 11 and thereby modify its natural vibration frequency, particularly by reducing parasitic vibrations in the lateral direction. Figure 16 shows weld lines 24 in a fishbone pattern.

[0101] 17 shows a further embodiment in which a first braided layer 112 and a second braided layer 113 each include a portion of the attachment portion 14, which, when the layers are joined, forms a cylindrical, in particular tubular, attachment portion 14. The tubular portion is in liquid communication with one or more channels 20 (not shown). The two layers can be manufactured by molding or deep drawing.

[0102] 17 and 19 show a further embodiment in which coolant is guided through hollow needles 28 through the flat portion 11. The hollow needles extend longitudinally of the blade 10. In the flat portion 11, the hollow needles are located within channels 20. For illustrative purposes, the figures show gaps between the hollow needles 28 and components of the flat portion 11. However, in practice, the hollow needles 28 may be positioned and / or molded to closely contact the flat portion 11, i.e., the first braid layer 112 and the second braid layer 113, to enable heat transfer. In an embodiment, a filler with good thermal conductivity is positioned between the hollow needles 28 and the flat portion 11. The hollow needles 28 extend from the flat portion 11 into the mounting portion 14 and can be installed in the mounting portion 14, for example, by press fitting. This allows for a fluid-tight conduit from the mounting portion 14 into the flat portion 11.

[0103] Cutouts such as holes 22 and notches 21 can be machined, for example, by punching or laser cutting, particularly at the same time that the shape of the flat 11 or layer is machined. Other smaller structures such as structured surface 23 can be created by laser engraving or etching. Notches and other structures can be created in first blade layer 112 and second blade layer 113 before or after they are welded together.

[0104] The structured surface 23 can be created during the process of flattening the blank to form the flat portion 11 .

[0105] The blade 10 can be operated with an ultrasonic driver having an operating frequency of 26 kHz.

[0106] While the present invention has been described in the present embodiments, it is to be clearly understood that the invention is not limited thereto and may be otherwise embodied and carried out in various forms within the scope of the appended claims.

Claims

1. An ultrasonic cutting tool for use in an ultrasonic instrument, said tool being a blade (10), said blade (10) comprising: It includes a flat portion (11) extending in a longitudinal direction and made from at least a first braid layer (112) and a second braid layer (113), the first and second braid layers are each flat plates arranged parallel to one another and bonded to one another or to one or more further braid layers; the first blade layer (112) or the second blade layer (113) or both include, on the side facing the other blade layer, recesses defining channels (20) suitable for directing a fluid along the blades (10); The flat portion (11) is joined to a mounting portion (14) for mounting the blade (10) to an ultrasonic generator; The tool, wherein the flat portion (11) is held in a fastening slit (135) of the mounting portion (14).

2. The tool of claim 1 , wherein the shapes of the first blade layer (112) and the second blade layer (113) are produced by photochemical etching.

3. 2. The tool of claim 1, wherein the flat portion (11) includes one or more weld lines (24) by which the first blade layer (112) and the second blade layer (113) are welded to each other at surfaces where the first blade layer (112) and the second blade layer (113) abut each other.

4. 4. The tool according to claim 3, wherein the weld seam (24) extends along the longitudinal direction of the flat portion (11).

5. The tool of claim 3 or 4, wherein the weld line (24) is interrupted where the weld line (24) crosses a portion of the channel (20).

6. 2. The tool of claim 1, wherein the mounting part (14) has a rotationally symmetrical body.

7. 2. The tool according to claim 1, wherein the flat part (11) is held in the fastening slit (135) of the mounting part (14) by a press fit.

8. 2. The tool of claim 1, wherein the flat portion (11) includes holes in at least one of the first and second blade layers (112, 113) in the area where the flat portion (11) is held in the fastening slit (135), forming blade inlets (134) in liquid communication with the channel (20).

9. 9. The tool of claim 8, wherein the mounting portion (14) comprises a radial conduit (133) extending radially relative to the longitudinal direction, the radial conduit (133) being in fluid communication with the blade inlet (134).

10. 10. The tool of claim 9, wherein the mounting portion (14) comprises a mounting body (131) in which the fastening slits (135) are arranged, and a ring (130) is arranged around the mounting body (131) to compress the mounting body (131).

11. The tool of claim 10, wherein the ring (130) acts as a seal for the radial conduit (133).

12. 2. The tool of claim 1, wherein a hollow needle (28) is disposed in the channel (20) and extends from the flat portion (11) into the mounting portion (14) with a fluid-tight connection between the hollow needle (28) and the mounting portion (14).

13. The tool according to claim 1, wherein the mounting portion (14) comprises an internal or external thread (15).

14. The tool of claim 1 , wherein the flat portion (11) includes one or more holes (22) in fluid communication with a plurality of the channels (20).

15. 2. The tool according to claim 1, wherein one or more edges (25), (26), (27) of the flat portion (11) comprise teeth.

16. 2. Tool according to claim 1, wherein one or more edges (25), (26), (27) of said flat part (11) are machined to form cutting edges.

17. 2. The tool of claim 1, wherein one or more edges (25, 26, 27) of the flat portion (11) include one or more notches (21) defining openings in liquid communication with a plurality of the channels (20).

18. The tool of claim 1 , wherein the outer surface of the flat portion (11) is machined to include a structured surface (23).

19. 10. A method for manufacturing a blade (10) according to claim 1 for an ultrasonic cutting tool for use in an ultrasonic instrument, the method comprising: providing a first braid layer (112) and a second braid layer (113), each of said first braid layer (112) and said second braid layer (113) being a flat plate, said method further comprising: - bonding the first braid layer (112) and the second braid layer (113) together, thereby forming a flattened portion (11) of the braid (10), the flattened portion (11) extending in a longitudinal direction, the method further comprising: - joining the flat part (11) to the mounting part (14) by clamping the flat part (11) in the clamping slits (135) of the mounting part (14); Including, At least one of the first blade layer (112) and the second blade layer (113) includes a recess or notch that serves as a channel (20) in the blade (10); - The method, wherein the recess or notch is located between the first braid layer (112) and the second braid layer (113) when the first braid layer (112) and the second braid layer (113) are bonded together.

20. 10. A method for manufacturing a blade (10) according to claim 1 for an ultrasonic cutting tool for use in an ultrasonic instrument, the method comprising: providing a first braid layer (112) and a second braid layer (113) and one or more further braid layers, wherein each of said first braid layer (112) and said second braid layer (113) and said one or more further braid layers is a flat plate, said method further comprising: - bonding the first braid layer (112), the second braid layer (113) and the one or more further braid layers together, thereby forming a flattened portion (11) of the blade (10), the flattened portion (11) extending in a longitudinal direction, the method further comprising: - joining the flat part (11) to the mounting part (14) by clamping the flat part (11) in the clamping slits (135) of the mounting part (14); Including, At least one of the first blade layer (112) and the second blade layer (113) includes a recess or notch that serves as a channel (20) in the blade (10); - The method, wherein the recess or notch is located between the first braid layer (112) and the second braid layer (113) when the first braid layer (112) and the second braid layer (113) are bonded together.

21. when said first braid layer (112) and said second braid layer (113) are joined together, at least one hollow needle (28) is disposed between two of said layers; A method according to claim 19 or 20, wherein when joining the flat part (11) to the attachment part (14), the part of the hollow needle (28) extending out from the flat part (11) is inserted into the attachment part (14) so ​​as to establish a fluid-tight connection therebetween.

22. 21. The method according to claim 19 or 20, wherein joining the flat portion (11) to the mounting portion (14) comprises heating the mounting portion (14), inserting the flat portion (11) into a fastening slit (135) of the mounting portion (14), and cooling the mounting portion (14).

23. 21. The method of claim 19 or 20, comprising the further step of machining holes through the attachment portion (14) and at least one of the braid layers, thereby creating radial conduits (133) extending radially relative to the longitudinal direction, the radial conduits (133) being in liquid communication with the channels (20).

24. 21. The method of claim 19 or 20, wherein the step of providing the blade layers (112, 113) comprises creating, by photoetching, recesses in at least one of the layers that define channels (20).

25. 10. A robotic system configured to be equipped with the cutting tool of claim 1, wherein the robotic system is programmed to apply the tool to machine an object or workpiece.

26. 26. The robotic system of claim 25, comprising a manipulator arm to which the tool is attached and capable of moving the tool, the tool being provided with cooling fluid through the manipulator arm.

27. 26. The robotic system of claim 25, programmed to apply the tools to machine the workpiece sequentially without interruption without withdrawing the tools from the area where they are applied to the workpiece.

28. 30. The robotic system of claim 27, programmed to apply the tool to machine the workpiece using two or more different functions of the tool without retrieving the tool.

29. 26. The robotic system of claim 25, programmed to apply tools to machine different sides of the workpiece.

30. 26. The robotic system of claim 25, programmed to apply the tools to sequentially machine the workpiece for at least 2 minutes, or 3 minutes, or 4 minutes, or 5 minutes, or 6 minutes without interruption.

31. 26. The robotic system of claim 25, wherein the tool is shaped to include the functions of at least two of a file, a saw, or a knife.

32. 26. The robotic system of claim 25, further comprising a sensing unit configured to measure a tool force exerted by the tool on the workpiece, and configured to control movement of the tool according to the measured tool force.

33. 26. The robotic system of claim 25, configured to intermittently provide coolant to the tool.

34. 26. The robotic system of claim 25, comprising: a sensing unit configured to determine a tool temperature; and a control unit configured to control a flow of coolant to the tool according to the determined tool temperature.

35. 35. The robotic system of claim 34, wherein the sensing unit is configured to determine the tool temperature based on a drive frequency of the tool, the drive frequency being controlled to match an actual resonant frequency of the tool.

36. A robot system as described in claim 25, configured to control the flow of coolant to the tool in accordance with the actual operating frequency of an ultrasonic driver that operates the blade (10).

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