Mechanical Lockout for Ultrasonic Surgical Instruments

Abstract

To provide an ultrasonic surgical instrument.SOLUTION: The ultrasonic surgical instrument includes: an ultrasonic transducer supported by a first modular assembly including an operator input feature; and a second modular assembly configured to be removably coupled with the first modular assembly. The second modular assembly includes an end effector extending distally from a distal end portion. The instrument includes a mechanical lockout assembly configured to switch between an unlocked configuration and a locked configuration. In the locked configuration, the first modular assembly and the second modular assembly are partially coupled together to physically prevent an operator from activating the instrument. In the unlocked configuration, the first modular assembly and the second modular assembly are fully coupled together to allow an operator to activate the instrument by using the operator input feature.SELECTED DRAWING: Figure 1A

Description

[Background technology]

[0001] Various surgical instruments include end effectors with blade elements that vibrate at ultrasonic frequencies to cut and / or seal tissue (e.g., by denaturing proteins within tissue cells). These instruments contain piezoelectric elements that convert electrical power into ultrasonic vibrations, which are transmitted to the blade element along an acoustic waveguide. The precision of cutting and coagulation can be controlled by the surgeon's technique and by adjusting the power level, blade edge, tissue tension, and blade pressure.

[0002] Examples of ultrasonic surgical instruments include HARMONIC ACE® Ultrasonic Shears, HARMONIC WAVE® Ultrasonic Shears, HARMONIC FOCUS® Ultrasonic Shears, and HARMONIC SYNERGY® Ultrasonic Blades, all manufactured by Ethicon Endo-Surgery, Inc. (Cincinnati, Ohio).Further examples of such devices and related concepts are described in U.S. Pat. No. 5,322,055, entitled "Clamp Coagulator / Cutting System for Ultrasonic Surgical Instruments," issued June 21, 1994, the disclosure of which is incorporated herein by reference; U.S. Pat. No. 5,873,873, entitled "Ultrasonic Clamp Coagulator Apparatus Having Improved Clamp Mechanism," issued February 23, 1999, the disclosure of which is incorporated herein by reference; U.S. Pat. No. 5,980,510, entitled "Ultrasonic Clamp Coagulator Apparatus Having Improved Clamp Arm Pivot Mount," filed October 10, 1997, the disclosure of which is incorporated herein by reference; and U.S. Pat. No. 6,325,811, entitled "Blades with Functional Balance Asymmetries for use with Ultrasonic Surgical Instruments," the disclosure of which is incorporated herein by reference. No. 6,773,444, entitled "Blades with Functional Balance Asymmetries for Use with Ultrasonic Surgical Instruments," issued on August 10, 2004, the disclosure of which is incorporated herein by reference; and U.S. Pat. No. 6,783,524, entitled "Robotic Surgical Tool with Ultrasound Cauterizing and Cutting Instrument," issued on August 31, 2004, the disclosure of which is incorporated herein by reference.

[0003] Still further examples of ultrasonic surgical instruments include U.S. Patent Publication No. 2006 / 0079874, entitled "Tissue Pad for Use with an Ultrasonic Surgical Instrument," published April 13, 2006, the disclosure of which is incorporated herein by reference; U.S. Patent Application Publication No. 2007 / 0191713, entitled "Ultrasonic Device for Cutting and Coagulating," published August 16, 2007, the disclosure of which is incorporated herein by reference; U.S. Patent Application Publication No. 2007 / 0282333, entitled "Ultrasonic Waveguide and Blade," published December 6, 2007, the disclosure of which is incorporated herein by reference; and U.S. Patent Application Publication No. 2008 / 0200940, entitled "Ultrasonic Device for Cutting and Coagulating" (published August 21, 2008); U.S. Patent Application Publication No. 2009 / 0105750, entitled "Ergonomic Surgical Instruments" (published April 23, 2009), the disclosure of which is incorporated herein by reference; U.S. Patent Application Publication No. 2010 / 0069940, entitled "Ultrasonic Device for Fingertip Control" (published March 18, 2010), the disclosure of which is incorporated herein by reference; U.S. Patent Application Publication No. 2011 / 0015660, entitled "Rotating Transducer Mount for Ultrasonic Surgical Instruments" (published January 20, 2011), the disclosure of which is incorporated herein by reference; and U.S. Patent Application Publication No. 2012 / 0029546, entitled "Ultrasonic Surgical Instrument Blades" (published February 2, 2012), the disclosure of which is incorporated herein by reference.

[0004] Some ultrasonic surgical instruments may include a cordless transducer such as those disclosed in the following patent documents: U.S. Patent Publication No. 2012 / 0112687, entitled "Recharge System for Medical Devices," published May 10, 2012, the disclosure of which is incorporated herein by reference; U.S. Patent Application Publication No. 2012 / 0116265, entitled "Surgical Instrument with Charging Devices," published May 10, 2012, the disclosure of which is incorporated herein by reference; and / or U.S. Patent Application No. 61 / 410,603, entitled "Energy-Based Surgical Instruments," filed November 5, 2010, the disclosure of which is incorporated herein by reference.

[0005] Additionally, some ultrasonic surgical instruments may include an articulating shaft portion. Examples of such ultrasonic surgical instruments are disclosed in U.S. Patent Application Publication No. 2014 / 0005701, entitled "Surgical Instruments with Articulating Shafts," published January 2, 2014, the disclosure of which is incorporated herein by reference, and U.S. Patent Application Publication No. 2014 / 0114334, entitled "Flexible Harmonic Waveguides / Blades for Surgical Instruments," published April 24, 2014, the disclosure of which is incorporated herein by reference.

[0006] While several surgical instruments and systems have been made and used, it is believed that no one prior to the present inventors has made or used the invention as set forth in the appended claims. [Brief explanation of the drawings]

[0007] While this specification concludes with claims particularly pointing out and distinctly claiming the present technology, it is believed that the present technology will be better understood from the following description of certain specific embodiments read in conjunction with the accompanying drawings, in which like reference numerals identify the same elements. [Figure 1A] 1 illustrates a perspective view of a first exemplary surgical instrument with an end effector of the instrument in an open configuration; [Figure 1B] 1B illustrates a perspective view of the instrument of FIG. 1A with the end effector in a closed configuration. [Figure 2] 1B illustrates an exploded perspective view of the device of FIG. 1A. [Figure 3] 1 illustrates a side view of a second exemplary ultrasonic surgical instrument having a handle assembly and a shaft assembly with an end effector. [Figure 4A] FIG. 4 illustrates an enlarged side view of the end effector of FIG. 3 in an open configuration. [Figure 4B] FIG. 4B illustrates an enlarged side view of the end effector similar to FIG. 4A, but with the end effector in a closed configuration. [Figure 5] FIG. 4 illustrates a partially exploded side view of the ultrasonic surgical instrument of FIG. [Figure 6] 4 illustrates a partially schematic enlarged side view of the ultrasonic transducer, waveguide, and rotation knob of the ultrasonic surgical instrument of FIG. 3, showing the attachment of the waveguide to the ultrasonic transducer. [Figure 7] 7 illustrates a partially schematic enlarged cross-sectional side view of the threaded connection between the ultrasonic transducer and the waveguide of FIG. 6. [Figure 8] 1 illustrates a schematic side view of a third exemplary ultrasonic surgical instrument. [Figure 9] 9 illustrates a schematic, partially exploded perspective view of a portion of the instrument of FIG. 8, including a first exemplary mechanical lockout assembly. [Figure 10A] FIG. 10 illustrates a schematic cross-sectional view similar to FIG. 9 of the device in a locked configuration. [Figure 10B] FIG. 10 illustrates a schematic cross-sectional view of the device similar to FIG. 9 but moving from a locked configuration to an unlocked configuration. [Figure 10C] FIG. 10 illustrates a schematic cross-sectional view of the device similar to FIG. 9 but in an unlocked configuration. [Figure 11] 10B illustrates a schematic perspective view of the device similar to FIG. 10A but in a locked configuration. [Figure 12] 10C illustrates a schematic perspective view of an instrument similar to FIG. 10B, still in a locked configuration but having been moved to an unlocked configuration. [Figure 13] 1 illustrates a schematic side view of a fourth exemplary ultrasonic surgical instrument in an unlocked configuration, with a portion of the outer sheath cut away to illustrate the second exemplary mechanical lockout assembly. [Figure 14A] FIG. 14 illustrates a schematic side view of the device similar to FIG. 13 but in a locked configuration with a notch in the outer sheath. [Figure 14B] FIG. 14B illustrates a schematic side view of the device in an unlocked configuration similar to FIG. 14A but with a notch in the outer sheath. [Figure 15] 14 illustrates a schematic top view of the outer sheath and associated cutouts of FIG. 13. [Figure 16A] FIG. 10 illustrates a schematic side view of a fifth exemplary ultrasonic surgical instrument including a third exemplary mechanical lockout assembly in a locked configuration. [Figure 16B] FIG. 16B illustrates a schematic side view of the instrument similar to FIG. 16A but in an unlocked configuration. [Figure 17] 16B illustrates a schematic cross-sectional side view of a portion of an instrument including a fourth exemplary mechanical lockout assembly similar to FIG. 16A but in an unlocked configuration. [Figure 18A] FIG. 18 illustrates a schematic cross-sectional top view of a portion of the instrument similar to FIG. 17 and in a locked configuration. [Figure 18B] FIG. 18 illustrates a schematic cross-sectional top view of the device similar to FIG. 17 but in an unlocked configuration. [Figure 19] 1 illustrates a schematic side view of a sixth exemplary ultrasonic surgical instrument. [Figure 20A]FIG. 20 illustrates a schematic cross-sectional side view of an instrument similar to FIG. 19, including a fifth exemplary mechanical lockout assembly in a locked configuration. [Figure 20B] FIG. 20 illustrates a schematic cross-sectional side view of the instrument similar to FIG. 19 but in an unlocked configuration. [Figure 21A] 20B illustrates a schematic cross-sectional side view of an instrument similar to FIG. 20A, including a sixth exemplary mechanical lockout assembly in a locked configuration. [Figure 21B] FIG. 20C illustrates a schematic cross-sectional side view of the device similar to FIG. 20B but in an unlocked configuration. [Figure 22A] FIG. 10 illustrates a schematic side view of a seventh exemplary ultrasonic surgical instrument including a seventh exemplary mechanical lockout assembly in a locked configuration. [Figure 22B] FIG. 22B illustrates a schematic side view of the instrument similar to FIG. 22A but in an unlocked configuration. [Figure 23] 10 illustrates a schematic side view of an eighth exemplary ultrasonic surgical instrument. [Figure 24A] FIG. 24 illustrates a schematic cross-sectional side view of an instrument similar to FIG. 23, including an eighth exemplary mechanical lockout assembly in a locked configuration. [Figure 24B] FIG. 24B illustrates a schematic cross-sectional side view of the device similar to FIG. 24A but in an unlocked configuration. [Figure 25] 25 is a schematic cross-sectional view of FIG. 24A taken along section line 25-25 of FIG. 24A in a locked configuration. [Figure 26A] FIG. 10 illustrates a schematic side view of a ninth exemplary ultrasonic surgical instrument including a ninth exemplary mechanical lockout assembly in a locked configuration. [Figure 26B] FIG. 26B illustrates a schematic side view of the instrument similar to FIG. 26A but in an unlocked configuration. [Figure 27A] FIG. 14 illustrates a schematic cross-sectional side view of a tenth exemplary ultrasonic surgical instrument including a tenth exemplary mechanical lockout assembly in an unlocked configuration. [Figure 27B] FIG. 27B illustrates a schematic cross-sectional side view of the device similar to FIG. 27A but in a locked configuration. [Figure 27C] 27B illustrates a schematic cross-sectional side view of the device, similar to FIG. 27B, but in a second, locked configuration. [Figure 27D] 27B illustrates a schematic cross-sectional side view of the instrument similar to FIG. 27C but in an unlocked configuration similar to FIG. 27A. [Figure 28A] 27B illustrates a schematic cross-sectional side view of an enlarged portion of an instrument similar to that of FIG. 27A in the unlocked configuration of FIG. 27A. [Figure 28B] 28B illustrates a schematic cross-sectional side view of an enlarged portion of the instrument, similar to FIG. 28A, in the locked configuration of FIG. 27B when the shaft assembly is inserted. [Figure 28C] 28B illustrates a schematic cross-sectional side view of the enlarged portion of the instrument as the shaft assembly is inserted, similar to FIG. 28B but in the locked configuration of FIG. 27C. [Figure 28D] 28D illustrates a schematic cross-sectional side view of an enlarged portion of the instrument similar to FIG. 28C but in the unlocked configuration of FIG. 27D. [Figure 29] 13 illustrates a schematic, partially exploded side view of an eleventh exemplary ultrasonic surgical instrument. [Figure 30A] FIG. 30 illustrates a schematic cross-sectional view of an instrument similar to FIG. 29, including an eleventh exemplary mechanical lockout assembly in a locked configuration. [Figure 30B] FIG. 30B illustrates a schematic cross-sectional view of the device similar to FIG. 30A but moving from a locked configuration to an unlocked configuration. [Figure 30C] FIG. 30C illustrates a schematic cross-sectional view of the device similar to FIG. 30B but in an unlocked configuration. [Figure 31A] FIG. 30B illustrates a schematic enlarged cross-sectional side view of a mechanical lockout assembly similar to FIG. 30A but in a locked configuration. [Figure 31B] FIG. 30C illustrates a schematic enlarged cross-sectional side view of a mechanical lockout assembly similar to FIG. 30B transitioning from a locked configuration to an unlocked configuration. [Figure 31C] FIG. 30D illustrates a schematic enlarged cross-sectional side view of a mechanical lockout assembly similar to FIG. 30C but in an unlocked configuration. [Figure 32]12 illustrates a schematic side view of a twelfth exemplary ultrasonic surgical instrument. [Figure 33] 33 illustrates a schematic cross-sectional side view of the instrument of FIG. 32 including a twelfth exemplary mechanical lockout assembly in a locked configuration. [Figure 34A] 33 illustrates a schematic perspective view of a first alternative embodiment of a coupling device configured for use with the instrument of FIG. 32; [Figure 34B] 33 illustrates a schematic perspective view of a second alternative embodiment of a coupling device configured for use with the instrument of FIG. 32; [Figure 34C] 33 illustrates a schematic perspective view of a third alternative embodiment of a coupling device configured for use with the instrument of FIG. 32; [Figure 34D] 33 illustrates a schematic perspective view of a fourth alternative embodiment of a coupling device configured for use with the instrument of FIG. 32; [Figure 35] A schematic perspective view of a thirteenth exemplary ultrasonic surgical instrument is illustrated. [Figure 36] FIG. 36 illustrates a schematic, partially exploded perspective view of the device of FIG. 35 including a thirteenth exemplary mechanical lockout assembly. [Figure 37] 37 illustrates a schematic enlarged perspective view of the outer tube collar of the mechanical lockout assembly of FIG. 36; [Figure 38] FIG. 37 illustrates a schematic enlarged perspective view of a bayonet collar of the mechanical lockout assembly of FIG. 36; [Figure 39A] FIG. 37 illustrates a schematic perspective view of the mechanical lockout assembly of FIG. 36 including an outer tube collar coupled with a bayonet collar in a locked configuration. [Figure 39B] FIG. 39B illustrates a schematic perspective view of a mechanical lockout assembly similar to FIG. 39A moving from a locked configuration toward an unlocked configuration. [Figure 39C] FIG. 39C illustrates a schematic perspective view of the mechanical lockout assembly similar to FIG. 39B but in an unlocked configuration. [Figure 40A] 40A illustrates a schematic enlarged cross-sectional view of FIG. 39A taken along section line 40A-40A of FIG. 39A. [Figure 40B] 40B illustrates a schematic enlarged cross-sectional view of FIG. 39B taken along section line 40B-40B of FIG. 39B. [Figure 40C] 40C illustrates a schematic enlarged cross-sectional view of FIG. 39C taken along section line 40C-40C of FIG. 39C. [Figure 41] 10 illustrates a schematic cross-sectional view of an outer tube collar coupled with a rotating collar in a locking configuration.

[0008] The drawings are not intended to be limiting in any way, and it is contemplated that various embodiments of the technology may be embodied in a variety of other ways, including those not necessarily depicted in the drawings. The accompanying drawings, which are incorporated in and form a part of this specification, illustrate several aspects of the technology and, together with the description, serve to explain the principles of the technology, although it is understood that the technology is not limited to the precise arrangements shown. DETAILED DESCRIPTION OF THE INVENTION

[0009] The following description of specific examples of the present technology should not be used to limit its scope. Other examples, features, aspects, embodiments, and advantages of the present technology will become apparent to those skilled in the art from the following description, which is, by way of example, one of the best modes contemplated for carrying out the present technology. As will be understood, the technology described herein is capable of other different and obvious aspects, all without departing from the technology. Therefore, the drawings and description should be regarded as illustrative in nature, and not as restrictive.

[0010] It will be further understood that any one or more of the teachings, expressions, embodiments, examples, etc. described herein can be combined with any one or more of the other teachings, expressions, embodiments, examples, etc. described herein. Accordingly, the teachings, expressions, embodiments, examples, etc. described below should not be considered in isolation from one another. In view of the teachings herein, various suitable ways in which the teachings herein can be combined will be readily apparent to those skilled in the art. Such modifications and variations are intended to be within the scope of the following claims.

[0011] For clarity of this disclosure, the terms "proximal" and "distal" are defined herein relative to a human or robotic surgical instrument operator. The term "proximal" refers to the location of an element closer to a human or robotic surgical instrument operator and further from the surgical end effector of the surgical instrument. The term "distal" refers to the location of an element closer to a surgical end effector of the surgical instrument and further from the human or robotic surgical instrument operator. Additionally, the terms "upper," "lower," "lateral," "transverse," "bottom," and "top" are relative terms to provide further clarity in the description of the figures provided below. The terms "upper," "lower," "lateral," "transverse," "bottom," and "top," therefore, are not intended to unnecessarily limit the invention(s) described herein.

[0012] Additionally, the terms "first" and "second" are used herein to distinguish between one or more portions of a surgical instrument. For example, a first assembly and a second assembly may alternatively be described as a second assembly and a first assembly, respectively. The terms "first" and "second" and other numerical designations are merely illustrative of such terms and are not intended to unnecessarily limit the invention(s) described herein.

[0013] I. A First Exemplary Ultrasonic Surgical Instrument for Surgical Procedures 1A-2 illustrate a first exemplary ultrasonic surgical instrument (10). At least a portion of the instrument (10) may be constructed and operative in accordance with at least a portion of the teachings of U.S. Patent Nos. 5,322,055; 5,873,873; 5,980,510; 6,325,811; 6,773,444; 6,783,524; U.S. Patent Application Publication Nos. 2006 / 0079874; 2007 / 0191713; and 200 Nos. 7 / 0282333, 2008 / 0200940, 2009 / 0105750, 2010 / 0069940, 2011 / 0015660, 2012 / 0112687, 2012 / 0116265, 2014 / 0005701, 2014 / 0114334, U.S. Patent Application Nos. 61 / 410,603 and / or 14 / 028,717, the disclosures of each of the foregoing patents, patent publications, and patent applications are incorporated herein by reference. Additionally, or alternatively, at least a portion of instrument (10) may be constructed and operative in accordance with at least a portion of the teachings of the following patent applications: U.S. Patent Application Publication No. 15 / 284,837, filed October 4, 2016, entitled "Surgical Instrument with Dual Mode End Effector and Compound Lever with Detents," the disclosure of which is incorporated herein by reference; and / or U.S. Patent Application Publication No. 62 / 363,411, filed July 18, 2016, entitled "Surgical Instrument with Dual Mode End Effector," the disclosure of which is incorporated herein by reference.

[0014] As described in further detail below, instrument 10 is operable to substantially simultaneously cut tissue and seal or join tissue (e.g., blood vessels, etc.). It should also be understood that instrument 10 may bear various structural and functional similarities to HARMONIC ACE® Ultrasonic Shears, HARMONIC WAVE® Ultrasonic Shears, HARMONIC FOCUS® Ultrasonic Shears, and / or HARMONIC SYNERGY® Ultrasonic Blades. Furthermore, instrument 10 may bear various structural and functional similarities to devices taught in any of the other references cited herein and incorporated by reference.

[0015] The instrument (10) of this example includes a first modular assembly (12), a second modular assembly (14), and a connecting member (16). As described in more detail below, the connecting member (16) may selectively attach the first modular assembly (12) to the second modular assembly (14) to form the instrument (10) having an end effector (18). As best seen in Figures 1A and 1B, the end effector (18) includes an ultrasonic blade (20) and a clamp pad (22) of a clamp pad assembly (24).

[0016] Additionally, as described in more detail below, selected portions of the second modular assembly (14) may be actuated relative to the first modular assembly (12) when properly attached to one another to actuate the end effector (18) from an open configuration ( FIG. 1A ) to a closed configuration ( FIG. 1B ). The ability to selectively attach and detach the second modular assembly (14) from the first modular assembly (12) may provide the additional benefit of allowing reuse of either of the modular assemblies (12, 14). For example, different types of first modular assemblies (12) may be used with the second modular assembly (14) to provide different types of surgical instruments. Similarly, different types of second modular assemblies (14) may be used with the first modular assembly (12) to provide different types of surgical instruments. Additionally, the moving components of the second modular assembly (14) may be housed within the stationary components of the second modular assembly (14), which may provide additional advantages, some of which are described below, while others will be apparent to those skilled in the art in view of the teachings herein.

[0017] The first modular assembly (12) includes a handle assembly (26), a shaft assembly (28) extending distally from the handle assembly (26), and an ultrasonic blade (20) extending distally from the shaft assembly (28). The handle assembly (26) includes a body (30), a finger grip ring (32), a pair of buttons (34) distal to the finger grip ring (32), and an ultrasonic transducer assembly (36) housed within the body (30).

[0018] The shaft assembly (28) includes a proximal outer sheath (38) extending distally from the body (30), a tube (40) extending distally from the proximal outer sheath (38), and a waveguide (42) extending within and through both the proximal outer sheath (38) and the tube (40). The proximal outer sheath (38) includes a pair of projections (44). In addition, the proximal outer sheath (38) defines a pair of recesses (46). As described in more detail below, the recesses (46) are sized to mate with a portion of the distal outer sheath (48), while the projections (44) are configured to pivotally couple the proximal outer sheath (38) to the coupling member (16). Both the projections (44) and the recesses (46) may aid in coupling the first modular assembly (12) to the second modular assembly (14).

[0019] The proximal outer sheath (38) may be fixed relative to the body (30), and the tube (40) may be fixed relative to the proximal outer sheath (38). As described in more detail below, the waveguide (42) may be attached to the transducer assembly (36) and supported by portions of the proximal outer sheath (38) and the tube (40). The ultrasonic blade (20) may be integrally connected to the waveguide (42) or may extend distally from the waveguide (42). As described in more detail below, the waveguide (42) is operable to connect to the ultrasonic transducer assembly (36) to provide acoustic communication between the ultrasonic blade (20) and the transducer assembly (36).

[0020] The transducer assembly (36) is housed within the body (30) of the handle assembly (26). As can be seen in FIGS. 1A and 1B, the transducer assembly (36) is coupled to the generator (50) via a plug (52). The transducer assembly (36) receives power from the generator (50) and converts the power into ultrasonic vibrations using piezoelectric principles. The generator (50) may include a power source and a control module configured to provide the transducer assembly (36) with a power profile particularly suited for generating ultrasonic vibrations by the transducer assembly (36). The generator (50) may also be configured to provide a power profile that enables the end effector (18) to apply RF electrosurgical energy to tissue.

[0021] By way of example only, generator 50 may include the GEN300 sold by Ethicon Endo-Surgery, Inc. (Cincinnati, Ohio). Additionally, or alternatively, generator 50 (not shown) may be constructed in accordance with at least some of the teachings of U.S. Patent Application Publication No. 2011 / 0087212, entitled "Surgical Generator for Ultrasonic and Electrosurgical Devices," published April 14, 2011, the disclosure of which is incorporated herein by reference. It should also be understood that at least a portion of the functionality of generator 50 may be incorporated into handle assembly 26, which may further include a battery or other internal power source, thereby eliminating plug 52. Still other suitable forms that generator 50 may take, as well as various features and operability that generator 50 may provide, will be apparent to those skilled in the art in view of the teachings herein.

[0022] When properly coupled, ultrasonic vibrations generated by the transducer assembly 36 are transmitted along the sonic waveguide 42. The waveguide 42 is mechanically and acoustically coupled to the transducer assembly 36. The waveguide 42 extends through the shaft assembly 28 to the ultrasonic blade 20. The waveguide 42 may be secured to the proximal outer sheath 38 and / or the body 30 via a pin (not shown) that extends through the waveguide 42 and the proximal outer sheath 38. The pin may help ensure that the waveguide 42 remains longitudinally and rotationally fixed relative to the rest of the shaft assembly 28 when the waveguide 42 is at rest (i.e., not ultrasonically vibrating).

[0023] Additionally, waveguide 42 may be supported by tube 40 via a seal 54 located between the interior of tube 40 and the exterior of waveguide 42. Seal 54 may also prevent undesirable materials and fluids from entering the portion of tube 40 that houses waveguide 42. Pins (not shown) and seals 54 are located at locations along the length of waveguide 42 that correspond to nodes associated with resonant ultrasonic vibrations transmitted through waveguide 42. Therefore, contact between waveguide 42 and pins (not shown) and between waveguide 42 and seals 54 may not affect the ultrasonic vibrations transmitted through waveguide 42.

[0024] When the ultrasonic blade 20 is activated (i.e., ultrasonically vibrating), the ultrasonic blade 20 is operable to effectively cut and seal tissue, particularly when tissue is clamped between the clamp pad 22 and the ultrasonic blade 20. It should be appreciated that the waveguide 42 may be configured to amplify the mechanical vibrations transmitted through the waveguide 42. Additionally, the waveguide 42 may include features operable to control the gain of the longitudinal vibrations along the waveguide 42 and / or to tune the waveguide 42 to a resonant frequency of the system.

[0025] In this embodiment, when no tissue load is applied to the acoustic assembly, the preferred resonant frequency f o To tune the acoustic assembly to a predetermined vibration frequency f, the distal end of the ultrasonic blade 20 is positioned at a location corresponding to an antinode associated with a resonant ultrasonic vibration transmitted through the waveguide 42. When the transducer assembly 36 is energized, the distal end of the ultrasonic blade 20 vibrates at a predetermined vibration frequency f, for example, in the range of about 10 to 500 micrometers peak-to-peak, in some cases, for example, 55.5 kHz. o The transducer assembly 36 is configured to move longitudinally at a frequency ranging from about 20 to about 200 micrometers. When the transducer assembly 36 of this embodiment is activated, these mechanical vibrations are transmitted through the waveguide 42 to the ultrasonic blade 20, thereby causing the blade 20 to vibrate at a resonant ultrasonic frequency. Thus, when tissue is clamped between the ultrasonic blade 20 and the clamp pad 22, the ultrasonic vibrations of the ultrasonic blade 20 can cut the tissue and simultaneously denature proteins within adjacent tissue cells, resulting in a coagulation effect with relatively little heat dissipation.

[0026] In some variations, current may also be provided through the ultrasonic blade 20 and / or clamp pad 22 to seal tissue. Accordingly, it should be understood that the instrument 10 may also be configured to provide radiofrequency (RF) energy to the surgical site via the end effector 18. By way of example only, an operator may primarily rely on the use of ultrasonic energy from the blade 20 to cut tissue trapped between the ultrasonic blade 20 and the clamp pad 22. The operator may further rely on the use of RF energy from the end effector 18 to seal the cut tissue. Of course, it will be understood that the ultrasonic energy from the blade 20 will seal the tissue to some extent, and thus the RF energy from the end effector 18 may supplement the seal that may already have been provided by the ultrasonic energy. It will also be understood that there may be times when an operator simply desires to use the end effector 18 to apply only RF energy to tissue, without applying ultrasonic energy to the tissue. As will be understood from the description herein, several variations of instrument 10 are capable of providing all of the above types of functionality. Various ways in which instrument 10 may be configured and operable to provide both ultrasonic and RF electrosurgical modes of operation are described in the various references cited herein, and other ways in which instrument 10 may be configured and operable to provide both ultrasonic and RF electrosurgical modes of operation will be apparent to those skilled in the art in light of the teachings herein.

[0027] An operator may activate buttons 34 to selectively activate the transducer assembly 36, thereby activating the ultrasonic blade 20. In this embodiment, two buttons 34 are provided. In some variations, one button 34 is provided for activating the ultrasonic blade 20 with a first power profile (e.g., a first frequency and / or a first amplitude), and another button 34 is provided for activating the ultrasonic blade 20 with a second power profile (e.g., a second frequency and / or a second amplitude). In some other variations, one button 34 is provided for activating the ultrasonic blade 20 with ultrasonic energy, and another button 34 is provided for activating the end effector 18 with RF energy. In some other variations, one button 34 is operable to simultaneously activate the ultrasonic blade 20 with ultrasonic energy and the end effector 18 with RF energy, while the other button 34 is operable only to activate the ultrasonic blade 20 with ultrasonic energy. In some other variations, at least one button 34 is operable to first activate the ultrasonic blade 20 with ultrasonic energy, and then, based on one or more other conditions (e.g., time, measured impedance, etc.), ultimately activate the end effector 18 with RF energy while still activating the ultrasonic blade 20 with ultrasonic energy, with the button 34 still activated. In some other variations, at least one button (34) is operable to initially activate the ultrasonic blade (20) with ultrasonic energy, and then, based on one or more other conditions (e.g., time, measured impedance, etc.), ultimately activate the end effector (18) with RF energy while terminating activation of the ultrasonic blade (20) with ultrasonic energy while the button (34) remains activated.In some other variations, at least one button (34) is operable to initially activate the end effector (18) with RF energy, and then, based on one or more other conditions (e.g., time, measured impedance, etc.), ultimately activate the ultrasonic blade (20) with ultrasonic energy while terminating activation of the end effector (18) with RF energy while the button (34) remains activated.

[0028] It should be understood that any other suitable number of buttons and / or selectable power levels and / or power styles may be provided. For example, a foot pedal may be provided for selectively activating the transducer assembly 36.

[0029] In this example, button 34 is positioned so that an operator can easily and completely operate instrument 10 with one hand. For example, when first and second modular assemblies 12, 14 are coupled, an operator may position their thumb within thumb grip ring 56, their ring finger within finger grip ring 32, their middle finger around body 30, and their index finger to operate button 34. Of course, instrument 10 may be grasped and operated using any other suitable technique, and button 34 may be located in any other suitable location.

[0030] As mentioned above and described below, the connecting member (16) is configured to selectively connect the first modular assembly (12) with the second modular assembly (14). As best seen in FIG. 2, the connecting member (16) includes a body (58) and a pair of resilient arms (60) and a pair of grips (62) extending from the body (58). The resilient arms (60) each define a respective pivot hole (64) and a locking assembly (66). The resilient arms (60) are spaced apart from one another to receive the proximal outer sheath (38) and to snap-fit ​​the pivot holes (64) with the respective projections (44). The connecting member (16) is configured to pivotally connect to the proximal outer sheath (38) via the pivot holes (64) and the projections (44). In this embodiment, connecting member 16 and proximal outer sheath 38 are pivotally coupled via a snap fit, although any other type of suitable connection may be used, as will be apparent to one of ordinary skill in the art in view of the teachings herein. For example, protrusion 44 may be extendable relative to proximal outer sheath 38 for pivotally coupling with pivot hole 64 of connecting member 16. Grip 62 may be positioned on body 58 to allow an operator to easily rotate connecting member 16 relative to proximal outer sheath 38 via grip 62. As described in more detail below, locking assembly 66 is configured to rotate about pivot hole 64 and protrusion 44 to selectively couple with portions of first modular assembly 14.

[0031] While the coupling member (16) in this example is used to connect the first modular assembly (12) to the second modular assembly (14), it should be understood that the coupling member (16) may be incorporated into any suitable type of modular assembly, as would be apparent to one of ordinary skill in the art in view of the teachings herein. For example, the coupling member (16) may be modified to couple a different modular clamp arm assembly with the first modular assembly (12), including a clamp arm assembly such as those taught in U.S. Patent Application Publication No. 15 / 284,855, filed October 4, 2016, entitled "Surgical Instrument with Dual Mode End Effector and Modular Clamp Arm Assembly," the disclosure of which is incorporated herein by reference. Thus, one modular clamp arm assembly that may be coupled to the first modular assembly (12) may provide pivotal movement of the clamp arm on one side of the ultrasonic blade (20), while another modular clamp arm assembly that may be coupled to the first modular assembly (12) may provide pivotal movement of the clamp arm on the other side of the ultrasonic blade (20). Other suitable types of clamp arm assemblies that may be used to provide different types of second modular assemblies (14) will be apparent to those skilled in the art in view of the teachings herein.

[0032] The second modular assembly (14) includes a clamp arm assembly (68), a clamp pad assembly (24), and a distal outer sheath (48). As described in more detail below, the distal outer sheath (48) is configured to couple with both the coupling member (16) and the proximal outer sheath (38) to selectively couple the first modular assembly (12) with the second modular assembly (14). In other words, when properly coupled, the proximal outer sheath (38) and the distal outer sheath (48) can be fixed relative to one another. As described in more detail below, the clamp arm assembly (68) and the clamp pad assembly (24) are both pivotally coupled to the distal outer sheath (48). Additionally, the clamp arm assembly (68) and the clamp pad assembly (24) are sized to interlock with one another such that rotation of one assembly (24, 68) relative to the distal outer sheath (48) causes rotation of the other assembly (24, 68) relative to the distal outer sheath (48). In other words, the clamp arm assembly (24) and the clamp pad assembly (68) can rotate relative to one another relative to the distal outer sheath (48).

[0033] The distal outer sheath (48) includes a U-shaped body (70) extending from a distal face (72) and terminating in a pair of proximally presented projections (74). The proximally presented projections (74) each include a lateral projection (76) extending away from the U-shaped body (70). The U-shaped body (70) defines a longitudinal passage (78) and a plurality of holes (80). The U-shaped body (70) and longitudinal passage (78) are dimensioned to receive the tube (40) and rotatably accommodate a portion of the clamp arm assembly (68) and clamp pad assembly (24). Specifically, the U-shaped body (70) can be inserted over the ultrasonic blade (20) and tube (40) such that the tube (40) is positioned below the clamp arm assembly (68) and clamp pad assembly (24). The tube (40) may protect the waveguide (42) from contacting adjacent portions of the waveguide (42) with the clamp arm assembly (68) and the clamp pad assembly (24).

[0034] As shown in FIG. 2, the proximally presented projections (74) are configured to be inserted into recesses (46) defined by the proximal outer sheath (38). When the proximally presented projections (74) are inserted into the recesses (46), the distal outer sheath (48) may not rotate relative to the proximal outer sheath (38) about the longitudinal axis defined by the tube (40). Thus, the proximally presented projections (74) may mate with the recesses (46) to rotatably secure the distal outer sheath (48) relative to the proximal outer sheath (38).

[0035] Once the distal outer sheath (48) is rotatably secured relative to the proximal outer sheath (38), the operator may rotate the coupling member (16) so that the locking assembly (66) snaps into engagement with the lateral projections (76). Specifically, the operator may rotate the coupling member (16) about the projections (44) so ​​that the lateral projections (76) cam against the resilient arms (60). As a result, the resilient arms (60) flex outwardly and away from the proximally presented projections (74). The operator may further rotate the coupling member (16) about the projections (44). The resilient nature of the resilient arms (60) allows the resilient arms (60) to return to a relaxed position so that the lateral projections (76) rest within the locking assembly (66). With the locking assembly (66) of the connecting member (16) fully attached, the distal outer sheath (48) is longitudinally fixed relative to the proximal outer sheath (38), thereby connecting the first modular assembly (12) with the second modular assembly (14).

[0036] When an operator desires to decouple the first modular assembly (12) from the second modular assembly (14), the operator can grasp the grip (62) and rotate the coupling member (16) in the opposite direction around the protrusion (44) to bend the resilient arm (60) and pop out the lateral protrusion (76).

[0037] As described above, both the clamp arm assembly (68) and the clamp pad assembly (24) are pivotally coupled to the distal outer sheath (48) such that rotation of one assembly (24, 68) relative to the distal outer sheath (48) causes rotation of the other assembly (24, 68) relative to the distal outer sheath (48).

[0038] As seen in FIG. 1B , clamp arm assembly (68) includes elongated arm (82), thumb grip ring (56), and cam projection (84). Together, thumb grip ring (56) and elongated arm (82), in combination with body (30) and finger grip ring (32), provide a scissors-grip type configuration. A pivot connection pivotally connects clamp arm assembly (68) to distal outer sheath (48) via pin (86). Cam projection (84) interacts with clamp pad assembly (24) to rotate clamp pad assembly (24) in response to rotation of clamp arm assembly (68), as described in more detail below.

[0039] As can be seen in FIG. 1B , the clamp pad assembly (24) includes a clamp pad (24) facing the ultrasonic blade (20), a pair of tissue stops (88) located adjacent the ultrasonic blade (20) and proximal to the clamp pad (22), and an arm (90) defining a cam recess (92). In some variations, the clamp pad assembly (24) further includes one or more electrodes operable to apply RF electrosurgical energy to tissue. While various references herein describe examples of how the clamp pad assembly (24) may incorporate one or more electrodes operable to apply RF electrosurgical energy to tissue, other examples of how the clamp pad assembly (24) may incorporate one or more electrodes operable to apply RF electrosurgical energy to tissue will be apparent to those skilled in the art in view of the teachings herein.

[0040] In this embodiment, when the end effector 18 is in the closed position, the tissue stop 88 is longitudinally aligned with the distal face 72. The tissue stop 88 and the distal face 72 may consistently and simply prevent tissue from unintentionally reaching a proximal location within the end effector 18 where ultrasonic energy from the blade 20 may not adequately cut or seal the tissue. In providing such protection, the tissue stop 88 may eliminate the need for an operator to visualize the proximal region of the end effector 18 to determine whether tissue has reached an undesired proximal location within the end effector 18.

[0041] The cam projections (84) are sized to rotate within the cam recesses (92) while also contacting the cam recesses (92). The cam projections (84) and cam recesses (92) are positioned within the distal outer sheath (48). Thus, as shown in FIGS. 1A and 1B, when an operator rotates the elongated arm (82) toward the distal outer sheath (48), the cam projections (84) rotate away from the distal outer sheath (48). Because the cam projections (84) are housed within the cam recesses (92), upward movement of the cam projections (84) causes upward movement of the cam recesses (92). The upward movement of the cam recesses (92) rotates the arm (90) such that the clamp pad (22) rotates toward the ultrasonic blade (20). Thus, closing of the elongated arms 82 of the clamp arm assembly 68 toward the handle assembly 26 results in closing of the clamp pad 22 toward the ultrasonic blade 20. It should be appreciated, therefore, that when the first modular assembly 12 and the second modular assembly 14 are connected, an operator may clamp tissue between the clamp pad assembly 24 and the ultrasonic blade 20 by squeezing the thumb grip ring 56 toward the body 30, compressing the tissue against the ultrasonic blade 20. Activating the ultrasonic blade 20 during such compression causes the clamp pad assembly 24 and the ultrasonic blade 20 to cooperate to cut and / or seal the compressed tissue.

[0042] In some variations, one or more resilient members are used to bias the clamp pad assembly (24) toward the open position shown in FIG. 1A. Of course, any other suitable type of resilient member, such as a torsion spring, may be used, as would be apparent to one of ordinary skill in the art in view of the teachings herein. Alternatively, the clamp pad assembly (24) need not necessarily be biased toward the open position.

[0043] The foregoing components and operability of instrument 10 are exemplary only. As will be apparent to those skilled in the art in view of the teachings herein, instrument 10 may be configured in a variety of other ways. By way of example only, at least a portion of instrument 10 may be constructed and / or operative in accordance with at least a portion of the teachings of any of the following patent documents, the disclosures of which are incorporated herein by reference in their entireties: U.S. Pat. Nos. 5,322,055; 5,873,873; 5,980,510; 6,325,811; 6,783,524; and U.S. Patent Application Publication No. 2006 / 00798. 74, 2007 / 0191713, 2007 / 0282333, 2008 / 0200940, 2010 / 0069940, 2011 / 0015660, 2012 / 0112687, 2012 / 0116265, 2014 / 0005701, 2014 / 0114334, and / or U.S. Patent Application Publication No. 2015 / 0080925, entitled "Alignment Features for Ultrasonic Surgical Instrument," published on March 19, 2015, the disclosures of which are incorporated herein by reference.

[0044] II. A Second Exemplary Ultrasonic Surgical Instrument for Surgical Procedures 3-4B illustrate an exemplary ultrasonic surgical instrument (110) including a first modular assembly, shown as a handle assembly (112), a second modular assembly, shown as a shaft assembly (114) extending distally from the handle assembly (112), and an end effector (116) disposed at the distal end of the shaft assembly (114). The handle assembly (112) includes a body (118) including a pistol grip (120) and an energy control button (122), the energy control button configured to be manipulated by a surgeon to control various aspects of the tissue treatment energy delivered by the surgical instrument (110). A trigger (124) is coupled to a lower portion of the body (118) and is pivotable toward and away from the pistol grip (120) to selectively actuate the end effector (116). In other suitable variations of the surgical instrument (110), the handle assembly (112) may include, for example, a scissor grip configuration. The body (118) houses an ultrasonic transducer (126), shown schematically in FIG. 3, configured to deliver ultrasonic energy to the end effector (116), as described in more detail below. The body (118) may also be referred to herein as a housing (118), and may include a single component or an assembly of components. Thus, the terms "body" and "housing" are not intended to unnecessarily limit the inventions described herein to any number of separate components.

[0045] As best shown in Figures 4A and 4B, the end effector (116) includes an ultrasonic blade (128) and a clamp arm (130), which is configured to selectively pivot toward and away from the ultrasonic blade (128) to clamp tissue therebetween. The clamp arm (130) includes a clamp pad (132) disposed on the clamping side and is movable from an open position shown in Figure 4A to a closed position shown in Figure 4B. With reference to Figure 3, the ultrasonic blade (128) is acoustically coupled to an ultrasonic transducer (126), which is configured to drive (i.e., vibrate) the ultrasonic blade (128) at ultrasonic frequencies to cut and / or seal tissue positioned in contact with the ultrasonic blade (128). The clamp arm 130 is operably coupled to the trigger 124 such that the clamp arm 130 is configured to pivot toward the ultrasonic blade 128 to a closed position in response to pivoting of the trigger 124 toward the pistol grip 120. Additionally, the clamp arm 130 is configured to pivot away from the ultrasonic blade 128 to an open position in response to pivoting of the trigger 124 away from the pistol grip 120. Various suitable manners by which the clamp arm 130 may be coupled to the trigger 124 will be apparent to those skilled in the art in view of the teachings herein. In some variations, one or more resilient members may be incorporated to bias the clamp arm 130 and / or the trigger 124 toward the open position.

[0046] The shaft assembly (114) of this example extends along a longitudinal axis and includes an outer tube (134), an inner tube (136) received within the outer tube (134), and an ultrasonic waveguide (138) supported within and extending longitudinally therethrough. The ultrasonic blade (128) is integrally formed with and extends distally from the waveguide (138). The proximal end of the clamp arm (130) is pivotally coupled to the distal ends of the outer and inner tubes (134, 136), allowing the clamp arm (130) to pivot relative to the shaft assembly (114) about a pivot axis defined by a pivot pin (140) (see FIGS. 4A and 4B ) extending laterally through the distal end of the inner tube (136).

[0047] In this embodiment, the inner tube (136) is longitudinally fixed relative to the handle assembly (118), and the outer tube (134) is configured to translate relative to the inner tube (136) and the handle assembly (118) along the longitudinal axis of the shaft assembly (114). When the outer tube (134) translates distally, the clamp arm (130) pivots about the pivot axis toward its open position. When the outer tube (134) translates proximally, the clamp arm (130) pivots in the opposite direction about the pivot axis toward its closed position. Although not shown, the proximal end of the outer tube (134) is operably coupled to the trigger (124) such that actuation of the trigger (124) causes translation of the outer tube (134) relative to the inner tube (136), thereby opening or closing the clamp arm (130) as described above. In other suitable configurations not shown herein, outer tube (134) may be longitudinally fixed, and inner tube (136) may be configured to translate to move clamp arm (130) between its open and closed positions. A variety of other suitable mechanisms for actuating clamp arm (130) between its open and closed positions will be apparent to those skilled in the art.

[0048] The shaft assembly (114) and the end effector (116) are configured to rotate together relative to the body (118) about a longitudinal axis defined by the shaft assembly (114). As shown in FIGS. 5-6, the shaft assembly (114) further includes a rotation knob (142) disposed at its proximal end and a shaft coupler (143) configured to mechanically couple to a body coupler (144) of the handle assembly (112). The rotation knob (142) is rotatably coupled to the body (118) of the handle assembly (112) and is rotatably secured to the outer tube (134), inner tube (136), and waveguide (138) by connecting pins (not shown) extending laterally therethrough. The connecting pins (not shown) are positioned at longitudinal locations corresponding to acoustic nodes of the waveguide (138). In other examples, the rotation knob 142 may be rotatably secured to the remaining components of the shaft assembly 114 in a variety of other manners. The rotation knob 142 is configured to be grasped by an operator to selectively manipulate the rotational direction of the shaft assembly 114 and the end effector 116 relative to the handle assembly 112. Various examples of acoustic and mechanical connections between the shaft assembly 114 and the handle assembly 112 are described in further detail in U.S. patent application Ser. No. 15 / 644,930, filed July 10, 2017, entitled "Acoustic Drivetrain with External Collar at Nodal Position," and U.S. patent application Ser. No. 15 / 644,944, filed July 10, 2017, entitled "Features to Couple Acoustic Drivetrain Components in Ultrasonic Surgical Instrument," the disclosures of which are each incorporated herein by reference.

[0049] 3-5 show further details of the ultrasonic transducer 126 and the waveguide 138. Specifically, the ultrasonic transducer 126 and the waveguide 138 are configured to threadably couple to one another. The waveguide 138 is therefore configured to acoustically couple the ultrasonic transducer 126 to the ultrasonic blade 128, thereby transmitting ultrasonic mechanical vibrations from the ultrasonic transducer 126 to the blade 128. In this manner, the ultrasonic transducer 126, the waveguide 138, and the ultrasonic blade 128 together define the acoustic assembly of the ultrasonic surgical instrument 110. The ultrasonic transducer (126) is rotatably supported within the body (118) of the handle assembly (112) and is configured to rotate, together with the shaft assembly (114), including the waveguide (138), and the end effector (116), about the longitudinal axis of the shaft assembly (114).

[0050] The ultrasonic transducer (126) is electrically coupled to a generator (not shown), which may be external to or incorporated within the ultrasonic surgical instrument (110). During use, the generator (not shown) energizes the ultrasonic transducer (126) to generate ultrasonic mechanical vibrations that are transmitted distally through the waveguide (138) to the ultrasonic blade (128). The ultrasonic blade (128) is configured to generate a predetermined vibration frequency f, e.g., about 50 kHz. oThe vibrating ultrasonic blade 128 vibrates longitudinally at a peak-to-peak frequency in the range of approximately 10 to 500 micrometers, and in some cases, in the range of approximately 20 to 200 micrometers. The vibrating ultrasonic blade 128 may be positioned in direct contact with tissue to apply ultrasonic vibrational energy to the tissue, with or without an assisted clamping force applied by the clamp arm 130, thereby cutting and / or sealing the tissue. For example, the blade 128 may cut tissue clamped between the clamp arm 130 and the clamping side of the blade 128, or the blade 128 may cut tissue positioned in contact with the non-clamping side of the blade 128, e.g., during a "reverse cutting" motion. In some variations, the waveguide 138 may be configured to amplify the ultrasonic vibrations delivered to the blade 128. The waveguide (138) may include various features operable to control the gain of the vibrations and / or features suitable for tuning the waveguide (138) to a selected resonant frequency.

[0051] In this embodiment, the ultrasonic transducer 26 includes a first resonator (or "end-bell") 145, a conical-shaped second resonator (or "fore-bell") 146, and a transduction portion disposed between the end-bell 145 and the fore-bell 146, the transduction portion including a plurality of piezoelectric elements 148. A compression bolt (not shown) extends coaxially distally through the end-bell 145 and the piezoelectric elements 148 and is threadably received within the proximal end of the fore-bell 146. A velocity transducer (or "horn") 150 extends distally from the fore-bell 146 and includes an internally threaded bore 152 configured to receive and threadably couple with the externally threaded proximal tip 154 ​​of the waveguide 38, as shown in FIGS. 6-7.

[0052] While the teachings herein are disclosed in the context of ultrasonic surgical instruments, it will be understood that they may also be employed in the context of surgical instruments configured to provide a combination of ultrasonic and radio frequency (RF) energy. Examples of such instruments and related methods and concepts are disclosed in U.S. Patent No. 8,663,220, entitled "Ultrasonic Surgical Instruments," issued March 4, 2014, the disclosure of which is incorporated herein by reference; U.S. Patent Application Publication No. 2015 / 0141981, entitled "Ultrasonic Surgical Instrument with Electrosurgical Feature," published May 21, 2015, the disclosure of which is incorporated herein by reference; and U.S. Patent Application Publication No. 2017 / 0000541, entitled "Surgical Instrument with User Adaptable Techniques," published January 5, 2017, the disclosure of which is incorporated herein by reference.

[0053] III. ALTERNATIVE EXEMPLARY ULTRASONIC SURGICAL INSTRUMENTS AND VARIOUS MECHANICAL LOCKOUT ASSEMBLIES Given that the various portions of the ultrasonic surgical instrument (10, 110) are removably connected to one another, in various instances, it may be desirable to reuse some portions of the ultrasonic surgical instrument (10, 110) and replace other portions, upon reconnection, for further use by the surgeon. For example, while the first modular assembly (12, 112) of the present embodiment is reusable, the second modular assembly (14, 114) may be replaced with an unused replacement second modular assembly (14, 114). Because the first modular assembly (12, 112) is separable from the second modular assembly (14, 114), it may be beneficial to ensure that the first modular assembly (12, 112) and the second modular assembly (14, 114) are properly and completely assembled prior to use to prevent failure of the first modular assembly (12, 112) or unintentional separation from the second modular assembly (14, 114). For at least this reason, it may be desirable to incorporate a lockout assembly that prevents use of the instrument (10, 110) unless the first modular assembly (12, 112) and the second modular assembly (14, 114) are correctly and completely assembled together.

[0054] The following mechanical lockout assemblies (216, 316, 416, 416', 544, 544', 644, 744, 844, 944, 1044, 1144, 1244) are reusable and interchangeable features for removably connecting any of the following mechanical lockout assemblies (216, 316, 416, 416', 544, 544', 644, 744, 844, 944, 1044, 1144, 1244) While shown in a unique location between , it will be understood that the mechanical lockout assembly (216, 316, 416, 416′, 544, 544′, 644, 744, 844, 944, 1044, 1144, 1244) may be incorporated into, replaced with, or moved around any of the surgical instruments described herein to allow one or more portions of the surgical instrument to be detachable from the remainder of the surgical instrument. Two common forms of mechanical lockout varieties are shown and described below. The first is a mechanical lockout assembly that effectively locks the clamp arms, thereby preventing the operator from clamping tissue with the end effector. The second is a mechanical lockout assembly that effectively locks the energy control button, thereby preventing the operator from activating the ultrasonic blade. Thus, the mechanical lockout assemblies (216, 316, 416, 416', 544, 544', 644, 744, 844, 944, 1044, 1144, 1244) are intended to encompass both an energy control button lockout that prevents activation of the ultrasonic blade, and a trigger lockout that prevents closure of the clamp arm assembly toward the ultrasonic blade. It will also be understood that one or more of these mechanical lockout assemblies (216, 316, 416, 416', 544, 544', 644, 744, 844, 944, 1044, 1144, 1244) may be used in combination with another mechanical lockout assembly (216, 316, 416, 416', 544, 544', 644, 744, 844, 944, 1044, 1144, 1244).

[0055] The following description provides various examples of mechanical lockout assemblies. Such mechanical lockout assemblies (216, 316, 416, 416', 544, 544', 644, 744, 844, 944, 1044, 1144, 1244) described below may be used with any of the ultrasonic surgical instruments described above and below, and in any of the various procedures described in the various patent references cited herein. To this end, like numbers below indicate like features described above. Except as otherwise described below, the ultrasonic surgical instruments (210, 310, 410, 510, 610, 710, 810, 910, 1010, 1110, 1210) described below may be constructed and operative like the instruments (10, 110) described above. Accordingly, specific details of ultrasonic surgical instruments (210, 310, 410, 510, 610, 710, 810, 910, 1010, 1110, 1210) will be omitted from the following description, it being understood that such details have already been provided above in the description of instruments (10, 110). Other suitable manners in which the various ultrasonic surgical instruments may be used will also be apparent to those skilled in the art in view of the teachings herein.

[0056] Similarly, various electrical lockouts may be incorporated into any surgical instrument in conjunction with the following mechanical lockouts: 216, 316, 416, 416', 544, 544', 644, 744, 844, 944, 1044, 1144, 1244. Such electrical lockouts are disclosed in evenly filed U.S. patent application Ser. No. 09 / 029,148, filed on Oct. 1, 2002, entitled "Electrical Lockout for Ultrasonic Surgical Instrument," the disclosure of which is incorporated herein by reference. Other suitable manners in which various ultrasonic surgical instruments may be used will be apparent to those skilled in the art in view of the teachings herein.

[0057] A. Third exemplary ultrasonic surgical instrument having a first embodiment of a mechanical lockout assembly 8-12 illustrate a third exemplary ultrasonic surgical instrument (210) including a first mechanical lockout assembly (216). As shown in FIGS. 8 and 9, the instrument (210) of this example includes a first modular assembly (212), a second modular assembly (214), an end effector (218), an ultrasonic blade (220), a clamp pad (222), a clamp pad assembly (224), a handle assembly (226), a shaft assembly (228), a body (230), a finger grip ring (232), and a pair of buttons (236). The device includes a tongue (234), an ultrasonic transducer (236), a proximal outer sheath (238), a waveguide (242), a distal outer sheath (248), a plug (252), a thumb grip ring (256), a clamp arm assembly (268), a U-shaped body (270), a distal face (272), a longitudinal passage (278), a plurality of holes (280), an elongated arm (282), a plurality of pins (286), and an arm (290).

[0058] 8, a first modular assembly (212) is configured to be removably coupled to a second modular assembly (214). As shown, the first modular assembly (212) includes a handle assembly (226), an ultrasonic transducer (236), an energy control button (234), and a proximal outer sheath (238), with the ultrasonic transducer (236) supported by the first modular assembly (212). A waveguide (242) is acoustically coupled to the ultrasonic transducer (236). The second modular assembly (214) includes a waveguide (242), a clamp arm assembly (268), a distal outer sheath (248), and at least a portion of an end effector (218), the end effector (218) extending distally from a distal end portion of the second modular assembly (214).

[0059] Figure 9 also illustrates an ultrasonic surgical instrument (210) that includes at least one mechanical lockout assembly (216). The mechanical lockout assembly (216) is configured to be capable of being switched between at least a locked configuration and an unlocked configuration. While Figure 9 illustrates a mechanical lockout assembly (216) that includes two unique and separate lockout members (240), more or fewer lockout members (240) are also contemplated, including the use of only a single lockout member (240).

[0060] As best seen in FIGS. 9-12, the clamp arm assembly (268) includes an elongated arm (282) and a thumb grip ring (256). As shown, the clamp arm assembly (268) includes at least one cutout portion (244). The lockout member (240) is configured to move from a locked configuration to an unlocked configuration while at least partially contained within the cutout portion (244). As shown in FIGS. 9, 11, and 12, the cutout portions (244) may each include a protrusion (246) to prevent translation of the lockout member (240) while in the locked configuration. As described in more detail below, while in the unlocked configuration, the lockout member (240) is not contained within the cutout portion (244).

[0061] 9 shows a lockout member (240) including a body (250) with lockout features having at least one of a curve (254), an angle change, a slot (258), or a proximal protrusion (260) from the body (250). A pin (286) pivotally couples the distal outer sheath (248) to the clamp arm assembly (268) and the lockout member (240). The proximal outer sheath (238) includes a protrusion (262) that moves the lockout member (240) distally when the proximal outer sheath (238) is coupled with the distal outer sheath (248). As shown, the lockout member (240) uses the same point of rotation as the clamp arm assembly (268).

[0062] 10A illustrates a locked configuration in which the first modular assembly (212) and the second modular assembly (214) are partially coupled together to physically prevent the operator from actuating the clamp arm assembly (268). The mechanical lockout assembly (216) prevents the operator from clamping tissue with the end effector (218). In the locked configuration, the lockout member (240) prevents actuation of the clamp arm assembly (268) due to interference from the elongated arms (282) of both the clamp arm assembly (268) and the distal outer sheath (248). As shown, when the operator attempts to depress the clamp arm assembly (268), the lockout member (240) abuts against the top surface (262) of the protrusion adjacent the top of the distal outer sheath (248). This prevents the end effector (218) from clamping tissue when the instrument (210) is not properly assembled. An operator cannot depress elongated arm (290) while lockout member (240) of mechanical lockout assembly (216) is in place.

[0063] 10B and 12 illustrate an exemplary unlocking of the instrument (210). When the proximal outer sheath (238) is coupled with the distal outer sheath (248), the projection (262) on the proximal outer sheath (238) translates the lockout member (240) past the projection (246) on the elongated arm (282). This effectively unlocks the clamp arm assembly (268). The slot (258) in the lockout member (240) allows proximal displacement of the pin (286) such that the pin (286) slides within the slot (258) and allows the elongated arm (282) to pivot. The lockout member (240) translates distally away from the projection (262) when moving from the locked configuration to the unlocked configuration.

[0064] 10C illustrates the unlocked configuration, in which the proximal outer sheath (238) is fully coupled with the distal outer sheath (230), allowing the operator to activate the instrument (210). In the unlocked configuration, the clamp arm assembly (268) is free to rotate relative to the locking member (264) and is not contained within the notched portion (244). The elongated arm (282) can be further depressed after unlocking the instrument (210). The operator can fully clamp the tissue (218) with the end effector after the instrument (210) is fully assembled.

[0065] Additionally, in the locked configuration, the instrument (210) allows for a method of maintaining the position of the elongated arm (282) relative to the distal outer sheath (248) to improve ease of assembly by the operator. The mechanical lockout assembly (216) holds the elongated arm (282) of the clamp arm assembly (268) in a position that does not interfere with assembly, providing additional benefits.

[0066] B. Fourth Exemplary Ultrasonic Surgical Instrument Having a Second Embodiment of a Mechanical Lockout Assembly Figures 13-15 show a fourth exemplary ultrasonic surgical instrument (310) including a second mechanical lockout assembly (316). Figure 13 of this example shows that the instrument (310) includes a first modular assembly (312), a second modular assembly (314), an end effector (318), an ultrasonic blade (320), a clamp pad (322), a clamp pad assembly (324), a handle assembly (326), a shaft assembly (328), a body (330), a finger grip ring (332), a pair of buttons (334), and an ultrasonic transducer. 3 shows a clamp arm assembly (368) including a clamping arm (370), a proximal outer sheath (338), a waveguide (342), a distal outer sheath (348), a plug (352), a thumb grip ring (356), a clamp arm assembly (368), a U-shaped body (370), a distal face (372), a longitudinal passage (378), a plurality of holes (380), an elongated arm (382), a camming projection (384), a plurality of pins (386), an arm (390), and a camming recess (392).

[0067] 13 illustrates a first modular assembly (312) configured to be removably coupled to a second modular assembly (314). The first modular assembly (312) includes a handle assembly (326), an ultrasonic transducer (336), and a proximal outer sheath (338), with the ultrasonic transducer (336) supported by the first modular assembly (312). A waveguide (342) is acoustically coupled to the ultrasonic transducer (336). The second modular assembly (314) includes the waveguide (342), a clamp arm assembly (368), a distal outer sheath (348), and at least a portion of an end effector (318). The end effector (318) extends distally from the distal end portion of the second modular assembly (214).

[0068] With continued reference to FIG. 13, the mechanical lockout assembly (316) allows for at least switching between an unlocked configuration and a locked configuration. The mechanical lockout assembly (316) includes at least one protrusion (340) operably coupled to a clamp arm assembly (368). The protrusion (346), coupled to an arm (390), is configured to engage the clamp arm assembly (368) with at least one recess (350) in the distal outer sheath (348) to ensure proper alignment throughout closure. FIG. 15 shows a top view of the recess (350) in the distal outer sheath (348). The protrusion (346) and recess (350) are shown as curved, although other shapes are contemplated.

[0069] FIG. 14A shows the instrument 310 in a locked configuration, with the first modular assembly 312 and the second modular assembly 314 partially coupled together to physically prevent the operator from activating the instrument 310. More specifically, FIG. 14A shows the arms 390 pivoted apart such that the clamp pads 322 are spaced apart from the ultrasonic blade 320. The distal outer sheath 348 is hidden in FIGS. 14A-14B for improved clarity. In the locked configuration, the protrusions 346 are not received by corresponding recesses 350 in the distal outer sheath 348. As a result, the protrusions 346 prevent the operator from clamping tissue with the end effector 318. In other words, in the locked configuration, when the protrusions 346 are not aligned with the recesses 350, the ultrasonic blade 320 and the clamp pad 322 cannot move toward one another. Unless the protrusions 346 are aligned with the recesses 350, the protrusions 346 provide a hard stop that prevents the clamp arm assembly 368 from pivoting toward the ultrasonic blade 320. While two recesses 350 are shown capturing two corresponding protrusions 346, more or fewer protrusions 346 and corresponding recesses 350 are also envisioned.

[0070] 14B shows the instrument (310) in an unlocked configuration, with the first modular assembly (212) and the second modular assembly (314) fully coupled together, allowing an operator to actuate the instrument (310) using the clamp arm assembly (368). In the unlocked configuration, the protrusions (340) are received by corresponding recesses (350) in the distal outer sheath (348), allowing the instrument (10) to be actuated. In the unlocked configuration, the protrusions (346) no longer provide a hard stop, thereby allowing the clamp arm assembly (368) to pivot toward the ultrasonic blade (320). It is beneficial to precisely longitudinally align the clamp arm assembly (368) with the ultrasonic blade (320).

[0071] C. Fifth Exemplary Ultrasonic Surgical Instrument Having a Third Embodiment of a Mechanical Lockout Assembly 16A-16B illustrate a fifth exemplary ultrasonic surgical instrument (410) including a third mechanical lockout assembly (416). FIG. 16A of this example illustrates that the instrument (410) includes a first modular assembly (412), a second modular assembly (414), an end effector (418), an ultrasonic blade (420), a clamp pad (422), a clamp pad assembly (424), a handle assembly (426), a shaft assembly (428), a body (430), a finger grip ring (432), and one or two The device is shown to include one or more energy control buttons (434), an ultrasonic transducer (436), a proximal outer sheath (438), a waveguide (442), a distal outer sheath (448), a plug (452), a thumb grip ring (456), a clamp arm assembly (468), a distal face (472), a longitudinal path (478), an elongated arm (482), a plurality of pins (486), and an arm (490).

[0072] 16A-16B illustrate a first modular assembly (412) configured to be removably coupled to a second modular assembly (414). As shown, the first modular assembly (412) includes a handle assembly (426), an ultrasonic transducer (436), an energy control button (434), and a proximal outer sheath (438). The ultrasonic transducer (436) is supported by the first modular assembly (412). A waveguide (442) is acoustically coupled to the ultrasonic transducer (436). The second modular assembly (414) includes the waveguide (442), a clamp arm assembly (468), a distal outer sheath (448), and at least a portion of the end effector (418). An end effector (418) extends distally from the distal end portion of the second modular assembly (414).

[0073] 16A-16B illustrate a mechanical lockout assembly (416) configured to at least allow switching between an unlocked configuration and a locked configuration. The mechanical lockout assembly (416) locks out the instrument (410) so that it cannot be activated by the energy control button (434). The mechanical lockout assembly (416) includes a barrier (444) including a body portion (446) and at least one opening (450). The barrier (444) is operably coupled to the shaft assembly (428) using a linkage (453) such that the barrier (444) translates between the locked and unlocked configurations. The barrier (444) may be made from any material that has lateral flexibility yet also has substantial column strength to be biased longitudinally along the instrument (410). The handle assembly 426 includes a passageway 455 extending between the energy control button 434 and the switch 458. Two energy control buttons 434 and two switches 458 are shown, although more or fewer, e.g., one or three, energy control buttons 434 and switches 458 are envisioned. Although not shown, the number of energy control buttons 434 and switches 458 can vary.

[0074] 16A depicts the instrument (410) in a locked configuration, with the first modular assembly (412) and the second modular assembly (414) partially coupled together to physically prevent an operator from activating the instrument (410) using the energy control button (434). As shown, the mechanical lockout assembly (416) prevents activation of the energy control button (434) by preventing completion of an electrical circuit until the shaft assembly (428) is fully seated. The body portion (446) is disposed between the energy control button (434) and the switch (458), thereby providing a physical barrier that prevents the energy control button (434) from actuating the switch (458). The mechanical lockout assembly (416) also includes a resilient element, shown as a spring (460), for returning the mechanical lockout assembly (416) to the locked configuration upon subsequent removal of the shaft assembly (428). When the second modular assembly (412), which may be the disposable portion of the instrument (410), is inserted along with the first modular assembly (412), which may be the reusable portion of the instrument (410), the barrier (444) translates proximally. As shown, the entire barrier (444) translates proximally. This translation of the barrier (444) allows the energy control button (434) to mechanically actuate the switch (458) and activate the instrument (410). At least one of the energy control button (434) or the switch (458) may enter the passageway (455).

[0075] 16B illustrates an unlocked configuration in which first modular assembly (412) and second modular assembly (414) are fully coupled together, allowing an operator to activate instrument (410) using energy control button (434). In the unlocked configuration, aperture (450) is disposed between energy control button (434) and switch (458), allowing button (434) to actuate switch (458).

[0076] D. Fifth Exemplary Ultrasonic Surgical Instrument Having a Fourth Embodiment of a Mechanical Lockout Assembly 17-18B show various cross-sectional views of another exemplary embodiment of the fourth mechanical lockout assembly 416'. Figure 17 shows a barrier 444' passing under the acoustic drive train 462 and between the energy control button 434' and the switch 458' of the handle assembly 426'.

[0077] 18A shows that first modular assembly 412' can be the reusable part, second modular assembly 414 can be the disposable part, and that when in the locked configuration, spring 460' presses against barrier 444' to prevent activation of instrument 410. Switch 458' is blocked by barrier 444' from being pressed by energy control button 434'.

[0078] 18B shows that the mechanical lockout assembly (416') is pressed inward by the disposable second modular assembly (414'). At this point, an opening (450'), shown as a window, is positioned between the switch (458') and the energy control button (434'), allowing the energy control button (434') to press the switch (458') through the barrier (444') to activate the instrument (410') in the unlocked configuration.

[0079] E. Sixth Exemplary Ultrasonic Surgical Instrument Having a Fifth Embodiment of a Mechanical Lockout Assembly Figures 19-20B show a sixth exemplary ultrasonic surgical instrument (510) including a fifth mechanical lockout assembly (544). Figure 19 shows the ultrasonic surgical instrument (510) comprising a first modular assembly shown as a handle assembly (512), a second modular assembly shown as a shaft assembly (514), an end effector (516), a body (518), a pistol grip (520), an energy control button (522), a trigger (524), an ultrasonic transducer (526), ​​an ultrasonic blade (528), a clamp arm (530), a clamp pad (532), an outer tube (534), an inner tube (536), an ultrasonic waveguide (538), and a rotation knob (542).

[0080] Figures 20A and 20B show an instrument (510) including a mechanical lockout assembly (544). The mechanical lockout assembly (544) includes a barrier (546) that translates between a locked configuration and an unlocked configuration. The barrier (546) includes at least one body portion, two body portions (548, 550) are shown in Figures 20A and 20B. The body portion (550) includes at least one opening (552) disposed therein, two openings (552) are shown in Figures 20A and 20B. While the barrier (546) is shown as a resilient elongated member disposed within the handle assembly (512), the barrier (546) may be operably coupled to the shaft assembly (514) and may be of various shapes and forms. The barrier (546) is laterally flexible and has sufficient column strength to actuate the body portion (550) without buckling. The handle assembly (512) includes an energy control button (522) separated from a switch (556) by a passageway (554). It is understood that the opening (550) may not extend completely through the body portion (550) to allow the energy control button (522) to mechanically actuate the switch (556), as shown in FIG. 20A . As previously described in connection with the previous embodiment, two energy control buttons (522) and two switches (556) are shown, but more or fewer energy control buttons (522) and switches (556), e.g., one or three, are envisioned. Although not shown, the number of energy control buttons (522) and switches (556) may vary in some variations.

[0081] 20A shows instrument 510 in a locked configuration, with body portion 548 contacting and translating body portion 550 disposed between energy control button 522 and switch 556, preventing button 522 from activating switch 556, thereby preventing switch 556 from activating instrument 510. When moving to the unlocked configuration, barrier 546 is pushed by body portion 548 and translated into passageway 554 extending between energy control button 522 and switch 556. In other words, the proximal portion of shaft 514 pushes against body portion 548, causing barrier 546 to translate into passageway 554 extending between energy control button 522 and switch 556. As shown, engagement of shaft assembly (514) with handle assembly (512) forces barrier (546) into a position that places opening (550) in barrier (546) between energy control button (522) and switch (556).

[0082] Figure 20B shows instrument 510 in an unlocked configuration, with aperture 552 disposed between energy control button 522 and switch 556, allowing button 522 to activate switch 556, which in turn activates instrument 510. Figure 20B shows that at least one of energy control button 522 or switch 556 extends at least partially into aperture 550 and contacts the other of energy control button 522 or switch 556 through aperture 550. Figure 20B shows that barrier 546 as a whole translates within passage 554 toward energy control button 522 and switch 556. A spring (not shown), similar to spring (664) shown in Figures 22A and 22B or spring (764) shown in Figures 24A and 24B, or another suitable mechanism, may be located at the bottom of barrier (546) to return barrier (546) to the locked configuration when shaft assembly (514) is removed from handle assembly (512).

[0083] F. Sixth Exemplary Ultrasonic Surgical Instrument Having a Sixth Embodiment of a Mechanical Lockout Assembly 21A and 21B show another exemplary embodiment of the sixth mechanical lockout assembly 544' in which the barrier 546' includes a single body portion 558' that includes an opening 560'. Additionally, the opening 560' extends completely through the body portion 558' of the barrier 546' in a generally vertical direction. The shaft assembly 514' includes a protrusion 562' that contacts the barrier 546' and causes translation of the barrier 546' when the shaft assembly 514' is fully coupled with the handle assembly 512', resulting in transition of the instrument 510 to the unlocked configuration.

[0084] G. Seventh Exemplary Ultrasonic Surgical Instrument Having a Seventh Embodiment of a Mechanical Lockout Assembly Figures 22A and 22B show a seventh exemplary ultrasonic surgical instrument (610) including a seventh mechanical lockout assembly (644). The instrument (610) illustrated in Figures 22A and 22B is similar to the instrument (510) illustrated in Figures 21A and 21B, with differences that will be briefly described below and where similarities are omitted. For example, the instrument (610) includes a mechanical lockout assembly (644) that is different from the mechanical lockout assembly (544) of the instrument (510).

[0085] FIG. 22A shows the instrument (610) in a locked configuration, with a first modular assembly shown as the handle assembly (612) and a second modular assembly shown as the shaft assembly (614) not fully coupled together. Consequently, a mechanical lockout assembly (644) physically prevents an operator from using the energy control button (622) to activate the instrument (610). As shown, the mechanical lockout assembly (644) includes a barrier (646), such as a button lockout plate, and an angled slide (648) shaped as a wedge. The barrier (646) includes a body portion (649) and at least one aperture (652), with two apertures (652) shown in FIG. 22A. In the locked configuration shown in FIG. 22A, the barrier (646) is positioned such that the aperture (652) is not interposed between the button (622) and the corresponding switch (656). Thus, the barrier (646) prevents the button (622) from activating the corresponding switch (656), thereby preventing activation of the device (610).

[0086] The angled slide (648) of the mechanical lockout assembly (644) is configured to contact the protrusion (662) of the shaft assembly (614) when the shaft assembly (614) is coupled to the handle assembly (612). Contact with the protrusion (662) results in the angled slide (648) translating proximally and subsequently contacting the barrier (646). The angled proximal end of the slide (648) drives the barrier (646) downward through a cam action. With the barrier (646) in the lowered position, the opening (652) is positioned between the button (622) and the corresponding switch (656), thereby providing a separation distance for the button (622) to activate the corresponding switch (656). Thus, full coupling of the shaft assembly (614) and the handle assembly (612) causes the instrument (610) to move from the locked configuration to the unlocked configuration.

[0087] FIG. 22B shows the instrument 610 in an unlocked configuration, with the handle assembly 612 and shaft assembly 614 fully coupled together, allowing an operator to activate the instrument 610 using the energy-control button 622. Upon removal of the shaft assembly 614, a resilient member, shown as a compression spring 664, urges the barrier 646 back to the locked configuration, blocking actuation of the energy-control button 622 from activating the switch 656 via the body portion 649 of the barrier 646. The switch 656 may include a button dome switch and corresponding printed circuit board ("PCB"). In the unlocked configuration, the compression spring 664 is in a compressed state, while in the locked configuration (shown in FIG. 22A), the compression spring 664 is in an expanded state.

[0088] H. Eighth Exemplary Ultrasonic Surgical Instrument Having an Eighth Embodiment of a Mechanical Lockout Assembly 23-25 ​​illustrate an eighth exemplary ultrasonic surgical instrument (710) including an eighth mechanical lockout assembly (744). The instrument (710) of this example comprises a first modular assembly, designated as a handle assembly (712), a second modular assembly, designated as a shaft assembly (714), an end effector (716), a body (718), a pistol grip (720), an energy control button (722), a trigger (724), an ultrasonic transducer (726), an ultrasonic blade (728), a clamp arm (730), a clamp pad (732), an outer tube (734), an inner tube (736), an ultrasonic waveguide (738), and a rotation knob (742).

[0089] Figures 24A and 24B show an instrument (710) including a mechanical lockout assembly (744). The mechanical lockout assembly (744) includes a barrier (746) that translates between a locked configuration and an unlocked configuration. The barrier (746) may translate within a molded track (747), which may be integrally formed as a single piece with the body (718). The barrier (746) includes at least one body portion (748) with at least one opening (752) disposed within the body portion (748). Figures 24A and 24B show two openings (752). The barrier (746) is shown as a lockout slide disposed within the handle assembly (712). The handle assembly (712) includes an energy control button (722) separated from a switch (756) by a passageway (754).

[0090] FIG. 24A shows the instrument (710) in a locked configuration, with the body portion (748) contacting and translating the body portion (750) disposed between the energy control button (722) and the switch (756). In other words, when the shaft assembly (714), including the outer tube (734) and the clamp arm (730), is not fully coupled with the handle assembly (712), the barrier (746) prevents the energy control button (722) from being depressed. This prevents the switch (756) from activating the instrument (710). In the locked configuration, the compression spring (764) is in an expanded state. In the locked state shown in FIG. 24A, the barrier (746) is positioned such that the opening (752) is not interposed between the button (722) and the corresponding switch (756). Barrier 746 prevents button 722 from activating corresponding switch 756, thereby preventing activation of device 710. Figure 25 depicts a schematic cross-sectional view of Figure 24A in the locked configuration.

[0091] FIG. 24B shows the instrument 710 in the unlocked configuration, with an opening 752 disposed between the energy control button 722 and the switch 756, allowing the switch 756 to activate the instrument 710. When moving to the unlocked configuration, the barrier 746 is pushed downward into a passage 754 extending between the energy control button 722 and the switch 756. With the barrier 746 in the lowered position, the opening 752 is positioned between the button 722 and the corresponding switch 756, thereby providing a separation distance for the button 722 to activate the corresponding switch 756. As shown in FIG. 24B, a tab 758 presses the lockout slide downward, allowing the energy control button 722 to contact the switch 756. The tab 758 may be formed within the outer tube 734 or may be part of the outer tube overmold. Thus, full engagement of the shaft assembly (714) with the handle assembly (712) causes the instrument (710) to move from the locked configuration to the unlocked configuration. In the unlocked configuration, the compression spring (764) is in a compressed state. In other words, the barrier (746) is spring-loaded to return to the initial locked configuration when the shaft assembly (714) is removed.

[0092] I. Ninth Exemplary Ultrasonic Surgical Instrument Having a Ninth Embodiment of a Mechanical Lockout Assembly 26A and 26B illustrate a ninth exemplary ultrasonic surgical instrument (810) including a ninth mechanical lockout assembly (844). The instrument (810) of this example includes a first modular assembly shown as a first portion of a handle assembly (812), a second modular assembly shown as a second portion of a handle assembly and shaft assembly (814), a body (818a, 818b), a pistol grip (820), an energy control button (822), a trigger (824), an ultrasonic transducer (826), an outer tube (834), and a rotation knob (842).

[0093] FIG. 26A illustrates the instrument (810) in a locked configuration, in which a mechanical lockout assembly (844) prevents activation of the instrument (810) when the shaft assembly (814) is not fully coupled with the handle assembly (812). The handle assembly (812) may include at least a portion of the energy control button (822). For example, the energy control button (822) may be separated into shaft and handle portions (846, 848) or may have the energy control button (822) completely comprised of the shaft assembly (814). For example, as shown in FIG. 26A, the shaft portion (846) of the energy control button (822) may be coupled with the shaft assembly (814), while the handle portion (848) of the energy control button (822) may be coupled with the handle assembly (812). Misalignment of the shaft and handle portions (846, 848) of the energy control button (822) prevents the switch (856) from activating the instrument (810).

[0094] FIG. 26B shows the instrument 810 in an unlocked configuration, with the shaft assembly 814 fully coupled to the handle assembly 812. In the unlocked configuration, the mechanical lockout assembly 844 allows the energy control button 822 to contact the switch 856, allowing the operator to activate the instrument 810. Alignment of the shaft of the energy control button 822 and the handle portions 846, 848 allows the switch 856 to activate the instrument 810. The switch 856, which may be a dome switch according to an exemplary embodiment, may be in electrical communication with a printed circuit board (“PCB”) and may remain within the handle assembly 812. Memory, such as an EEPROM, may be disposed within the handle assembly 812, preventing activation of the energy control button 822 unless the shaft assembly 814 is fully inserted. The switch 856 may be recessed within the handle assembly 812 to prevent unintentional activation.

[0095] J. Tenth Exemplary Ultrasonic Surgical Instrument Having a Tenth Embodiment of a Mechanical Lockout Assembly 27A-28D illustrate a tenth exemplary ultrasonic surgical instrument (910) including a tenth mechanical lockout assembly (944). The instrument (910) of this example comprises a first modular assembly shown as a handle assembly (912), a second modular assembly shown as a shaft assembly (914), a body (918), a pistol grip (920), at least one energy control button (922), a trigger (924), an ultrasonic transducer (926), and an outer tube (934).

[0096] As shown in FIGS. 27A-27D, the handle assembly (912) includes a switch (956) configured to be activated by the energy control button (922). The mechanical lockout assembly (944) includes a closure lever link (946) operably coupled to the trigger (924) of the handle assembly (912). The handle assembly (912) includes a stop feature (948) that can limit the movement of the closure lever link (946) as desired. The stop feature (948) can be integrally formed as a single piece with the body (918) of the handle assembly (912) or can be a distinct component coupled to the body (918) of the handle assembly (912). As shown in FIGS. 27A-27D, the closure lever link (946) is coupled at a first end to the body (918) at a first rotation point (950). The closure lever link (946) is coupled at a second end to the trigger (924) at a second pivot point (952). Additionally, the trigger (924) is coupled to the body (918) at a third pivot point (954).

[0097] FIG. 27A shows the instrument (910) in the unlocked configuration, and FIG. 28A shows a detailed view of the handle assembly (912) through which the shaft assembly (914) is subsequently inserted. As shown, in the unlocked configuration, the angle alpha (α) between the first rotation point (950) and a point on the trigger (924) is less than 180 degrees. To switch the instrument (910) to the locked configuration, the trigger (924) is rotated / translated distally as shown by the arrow. It is also envisioned that the instrument (910) may initially be in the locked configuration, as described below in connection with FIG. 28B.

[0098] FIG. 27B shows an operator pulling the closure lever link (946) beyond the unlocked configuration, which serves as the normal operating position, and FIG. 28B shows a detailed view of the shaft assembly (914) being actively inserted into the handle assembly (912). In the locked configuration, when the shaft assembly (914) is partially coupled by the handle assembly (912), the closure lever link (946) is pulled past its center in a first direction. Pulling the closure lever link (946) past its center prevents the closure lever link (946) from rotating closed. As shown in the locked configuration, the angle beta (β) between the first rotation point (950) and a point on the trigger (924) is greater than 180 degrees. When the trigger (924) is effectively locked, it prevents the operator from clamping tissue with an end effector disposed at the distal end of the shaft assembly (914) until the shaft assembly (914) is fully seated in the handle assembly (912).

[0099] 27C and 28C show a second locked configuration in which the shaft assembly (914) is inserted into the instrument (910), pushing the yoke (958) proximally and facilitating the closure lever link (946) to move past the center. The yoke (958) connects the trigger assembly on the handle to the clamp arm closure driver on the shaft assembly (914). As shown in the second locked configuration, the angle theta (θ) between the first rotation point (950) and a point on the trigger (924) is approximately 180 degrees. The mechanical lockout assembly (944) maintains the locked configuration until the shaft assembly (914) is fully seated by the handle assembly (912).

[0100] Figures 27D and 28D show the unlocked configuration when the shaft assembly (914) is fully coupled with the handle assembly (912). Figure 27D shows that actuation of the trigger (924) causes the closure lever link (946) to rotate in a second direction opposite the first direction. When the shaft assembly (914) is fully seated in the handle assembly (912), the trigger (924) transitions to the unlocked configuration. This allows actuation of the trigger (924), thereby actuating the clamp arm of the end effector. The mechanical lockout assembly (944) effectively locks out use of the clamp arm assembly. In the unlocked configuration, the angle alpha (α) between the first rotation point (950) and a point on the trigger (924) is less than 180 degrees.

[0101] K. 11th Exemplary Ultrasonic Surgical Instrument Having an Eleventh Embodiment of a Mechanical Lockout Assembly 29-31C illustrate an eleventh exemplary ultrasonic surgical instrument (1010) including an eleventh mechanical lockout assembly (1044). The instrument (1010) of this example comprises a first modular assembly shown as a handle assembly (1012), a second modular assembly shown as a shaft assembly (1014), an end effector (1016), a body (1018), a pistol grip (1020), an energy control button (1022), a trigger (1024), an ultrasonic transducer (1026), an ultrasonic blade (1028), a clamp arm (1030), a clamp pad (1032), an outer tube (1034), an inner tube (1036), an ultrasonic waveguide (1038), and a rotation knob (1042).

[0102] Figures 30A-30C show an instrument 1010 including a mechanical lockout assembly 1044. The mechanical lockout assembly 1044 includes a one-way door 1046 configured to be opened by coupling the handle assembly 1012 to the shaft assembly 1014. As shown in Figures 30A-30C, the mechanical lockout assembly 1044 is coupled to the shaft assembly 1014 such that the shaft assembly 1014 and the mechanical lockout assembly 1044 are coupled together, although this is not required. Figures 30A and 31A show the shaft assembly 1014 approaching the handle assembly 1012 with the one-way door 1046 blocking access to the threaded bore 1058 at the proximal end of the acoustic waveguide 1038 of the shaft assembly 1014.

[0103] 30B and 31B show the shaft assembly 1014 partially coupled to the handle assembly 1012, with the one-way door 1046 still preventing the threaded stud 1056 of the ultrasonic transducer 1026 from reaching the threaded bore 1058 at the proximal end of the acoustic waveguide 1038. When moving between the locked and unlocked configurations, the translatable jacket 1048 translates relative to the one-way door 1046, pushing the one-way door 1046 into the unlocked configuration (shown in FIGS. 30C and 31C ), allowing full coupling of the threaded stud 1056 with the threaded bore 1058, thereby completing the acoustic coupling between the ultrasonic transducer 1026 and the ultrasonic waveguide 1038.

[0104] As shown, linear translation of the outer tube 1034 of the shaft assembly 1014 relative to the translatable jacket 1048 opens the one-way door 1046. As shown, the outer tube 1034 includes a rotating component 1050 and a yoke 1052, although the rotating component 1050 and yoke 1052 may be integrally formed as a single piece or may be fixedly coupled together using various well-known attachment methods. As shown, rotation of the rotating component 1050 of the outer tube 1034 causes translation of the yoke 1052 of the outer tube 1034 and the translatable jacket 1048 toward the handle assembly 1012. Yoke (1052) may be threadably coupled to rotating component (1050), with yoke (1052) keyed to shaft assembly (1014) such that yoke (1052) translates relative to shaft assembly (1014) without rotating relative to shaft assembly (1014). Rotation of rotating component (1050) drives yoke (1052) proximally, allowing translatable jacket (1048) to translate proximally, thereby allowing one-way door (1046) to rotate open at hinge point (1054).

[0105] Figures 30C and 31C show an unlocked configuration in which the shaft assembly 1014 is fully coupled to the handle assembly 1012 and the transducer 1026 is fully coupled to the waveguide 1038, thereby enabling ultrasonic actuation of the ultrasonic blade 1028. Figures 30C and 31C also show that once the one-way door 1046 is open, the externally threaded stud 1056 of the ultrasonic transducer 1026 can be threadably coupled to the internally threaded proximal recess 1058 of the ultrasonic waveguide 1038. In other words, once the one-way door 1046 is open and the outer tube 1034 is fully translated, the ultrasonic transducer 1026 can be acoustically coupled to the ultrasonic waveguide 1038. One-way door (1046) ensures that the acoustic drive train can only be assembled when shaft assembly (1014) is fully coupled with handle assembly (1012).

[0106] For instruments (1010) that include a clamp arm (1030) that is assembled to a handle assembly (1012) by an operator, it is beneficial to precisely align the clamp arm (1030) with the ultrasonic blade (1028). A mechanical lockout assembly (1044) incorporates a means for locking out the acoustic drive train so that the ultrasonic blade (1028) cannot be activated by the energy control button (1022) until the shaft assembly (1014) is fully coupled with the handle assembly (1012). Additionally, without full rotational engagement, the translatable jacket (1048) will not reach the one-way door (1046) and the one-way door cannot be opened, resulting in the handle assembly (1012) contacting the one-way door (1046) and not threading onto the ultrasonic waveguide (1038). This prevents use of the trigger (1024) to drive the clamp arm (1030) and champion pad (1032) towards the ultrasonic blade (1028), and the locked configuration provides tactile feedback to the operator that the instrument (1010) is inoperable.

[0107] L. Twelfth Exemplary Ultrasonic Surgical Instrument Having a Twelfth Embodiment of a Mechanical Lockout Assembly 32-34D show a twelfth exemplary ultrasonic surgical instrument (1110) including a twelfth mechanical lockout assembly (1144). The instrument (1110) of this example comprises a first modular assembly shown as a handle assembly (1112), a second modular assembly shown as a shaft assembly (1114), an end effector (1116), a body (1118), a pistol grip (1120), an energy control button (1122), a trigger (1124), an ultrasonic transducer (1126), an ultrasonic blade (1128), a clamp arm (1130), a clamp pad (1132), an outer tube (1134), an inner tube (1136), a rotation knob (1142), and a shaft coupler (1143).

[0108] FIG. 33 shows that the instrument (1110) includes a mechanical lockout assembly (1144). The mechanical lockout assembly (1144) includes a coupling (1146) operably coupled to the handle assembly (1112) using a retaining member (1148) that limits distal translation of a head portion (1152) of the coupling (1146). More specifically, the coupling (1146) translates longitudinally to transfer clamp arm closing motion from the trigger (1124) to the clamp arm actuator of the shaft assembly (1114), and then the coupling (1146) subsequently translates proximally from the position shown in FIG. 33. The coupling (1146) then translates distally back to the position shown in FIG. 33. In this manner, the retaining member (1148) limits distal translation of the coupling (1146). The clamp arm actuation member translates relative to the rest of the shaft assembly 1114 to drive pivotal movement of the clamp arm 1130 toward and away from the ultrasonic blade 1128. When the shaft assembly 1114 couples with the handle assembly 1112, a protrusion 1150, shown integral with the clamp arm actuation member of the shaft assembly 1114, enters a track 1154 to optimally couple the shaft assembly 1114 and the handle assembly 1112.

[0109] 34A-34D show four exemplary linkages (1156, 1158, 1160, 1162) configured for use with the mechanical lockout assembly (1144) of the instrument (1110). The linkages (1146, 1156, 1158, 1160, 1162) translate longitudinally in response to pivotal movement of the trigger (1124). The linkages (1146, 1156, 1158, 1160, 1162) also couple the trigger (1124) to a clamp arm closure actuator of the shaft assembly (1114). The clamp arm closure actuator includes a protrusion (1150). Thus, when the protrusions 1150 of the shaft assembly 1114 are fully seated in the couplings 1146, 1156, 1158, 1160, 1162, the clamp arm closing actuator translates, thereby driving the clamp arm 1130 toward and away from the ultrasonic blade 1128 based on the translation of the couplings 1146, 1156, 1158, 1160, 1162 when actuated by the trigger 1124. When the protrusions 1150 of the shaft assembly 1114 are not fully seated in the couplings 1146, 1156, 1158, 1160, 1162, the couplings 1146, 1156, 1158, 1160, 1162 further translate in response to pivotal movement of the trigger 1124. However, the translational movement of the couplings 1146, 1156, 1158, 1160, 1162 is not transferred to the clamp arm closing actuator. Therefore, the clamp arm 1130 does not move at all in response to movement of the trigger 1124. The couplings 1146, 1156, 1158, 1160, 1162 move proximally to actuate the clamp arm 1130.

[0110] As described below, each coupling device (1156, 1158, 1160, 1162) includes a guide track (1164, 1166, 1168, 1170) configured to engage with a protrusion (1150) shown in FIG. 33 of the shaft assembly (1114). The guide tracks (1154, 1164, 1166, 1168, 1170) of each coupling device (1146, 1156, 1158, 1160, 1162) are configured to translate and rotate the shaft assembly (1114) using interaction between the protrusions (1150) and the guide tracks (1154, 1164, 1166, 1168, 1170) from a locked configuration when the shaft assembly (1114) is partially coupled to the handle assembly (1112) to an unlocked configuration when the shaft assembly (1114) is fully coupled to the handle assembly (1112).

[0111] Figure 34A shows a coupling device 1156 having a guide track 1164 disposed within a body portion 1172 and a head portion 1174 configured to be retained by a retaining member 1148, with an aperture 1175 extending therethrough. The coupling device 1156 is similar to the coupling device 1146 shown in Figure 33, except that the coupling device 1156 additionally includes a detent 1176 in the guide track 1164 to ensure that the trigger 1124 and clamp arm 1130 are unresponsive until the projection 1150 is fully seated and fully rotated. When protrusion 1150 is captured by detent 1176, translation of coupling device 1156 is transmitted to the clamp arm actuator of shaft assembly 1114, thereby closing clamp arm 1130 in response to pivoting trigger 1124. Detent 1176 provides tactile feedback to the operator, informing the operator that shaft assembly 1114 is fully coupled, and also prevents inadvertent decoupling of shaft assembly 1114 after it is fully coupled.

[0112] Figures 34B-34D show three exemplary embodiments of track patterns (1166, 1168, 1170) that provide various variations in the opening / closing of the clamp arm (1130) during operation when the shaft assembly (1114) is not fully coupled with the handle assembly (1112). Figure 34B shows a coupling device (1158) that includes a guide track (1166) disposed within a body portion (1178) and a head portion (1180) configured to be retained by the retaining member (1148) and an opening (1181) extending therethrough. Figure 34B shows a coupling device (1158) that includes an additional relief portion (1182) in front of the seated position that allows the clamp arm (1130) to open but not close, thereby alerting the operator to potential misalignment. As shown, the additional relief portion (1180) is longer than the travel length.

[0113] 34B, when shaft assembly 1114 is not fully coupled, protrusion 1150 of shaft assembly 1114 resides in relief portion 1182. When protrusion 1150 of shaft assembly 1114 resides in relief portion 1182, translation of coupling device 1158 is not transmitted to the clamp arm actuator of shaft assembly 1114, and thus clamp arm 1130 does not close in response to pivoting of trigger 1124. When shaft assembly 1114 is fully coupled, protrusion 1150 seats in seat 1183. When the projection 1150 is captured by the seat 1183, translation of the coupling device 1158 is transmitted to the clamp arm actuator of the shaft assembly 1114, thereby opening but not closing the clamp arm 1130 in response to pivoting of the trigger 1124. Proximal movement of the clamp arm actuator of the shaft assembly 1114 provides pivoting movement of the clamp arm 1130 toward the ultrasonic blade 1128.

[0114] FIG. 34C shows a coupling device (1160) including a guide track (1168) disposed within a body portion (1184), a head portion (1186) configured to be retained by a retaining member (1148), and an opening (1187) extending therethrough. FIG. 34B shows a coupling device (1158) including an additional relief portion (1188) positioned beyond the normal seating position that allows the clamp arm (1130) to close if not fully rotated, but does not allow the clamp arm (1130) to return, thereby alerting the operator to potential misalignment. As shown, the additional relief portion (1180) is longer than the travel length. Distal movement of the clamp arm actuator of the shaft assembly (1114) provides pivotal movement of the clamp arm (1130) toward the ultrasonic blade (1128).

[0115] 34C, when the shaft assembly (1114) is not fully coupled, the projection (1150) of the shaft assembly (1114) is in the relief portion (1188). When the projection (1150) of the shaft assembly (1114) is in the relief portion (1188), translation of the coupling device (1160) is not transmitted to the clamp arm actuator of the shaft assembly (1114), and therefore the clamp arm (1130) does not open in response to pivoting of the trigger (1124). When the shaft assembly (1114) is fully coupled, the projection (1150) seats in the seat (1189). When the projection 1150 is captured by the seat 1189, translation of the coupling device 1160 is transmitted to the clamp arm actuator of the shaft assembly 1114, thereby closing but not opening the clamp arm 1130 in response to pivoting of the trigger 1124. Proximal movement of the clamp arm actuator of the shaft assembly 1114 provides pivoting movement of the clamp arm 1130 toward the ultrasonic blade 1128.

[0116] Figure 34D shows a coupling device 1162 including a guide track 1170 disposed within a body portion 1190, a head portion 1192 configured to be retained by a retaining member 1148, and an opening 1196 extending therethrough. Figure 34D shows the guide track 1170 angled to rotate while advancing. To be fully seated, the projection 1150 of the shaft coupler 1143 rotates fully on the coupling device 1162. The coupling device 1162 may additionally include a stop member 1194 within the guide track 1170 to ensure that the trigger 1124 and clamp arm 1130 are unresponsive until the projection 1150 is fully seated and fully rotated, allowing the instrument 1110 to be switched from a locked to an unlocked configuration. Similar to the detent (1176) shown in FIG. 34A, the detent (1194) provides tactile feedback to the operator to prevent inadvertent uncoupling. Unlike FIG. 34A, the curved configuration of the guide track (1170) causes the connector's protrusion (1150) to release when the operator activates the trigger (1124), thereby translating the connector (1162) if the protrusion (1150) is not fully seated against the back of the detent (1194). The connector (1162) moves proximally, actuating the clamp arm (1130).

[0117] The instrument 1110 prevents the outer shaft 1134 from moving forward / backward, thereby preventing the clamp arm 1130 from closing when the shaft assembly 1114 is not fully rotated into position. The mechanical lockout assembly 1144 and its various linkages 1146, 1156, 1158, 1160, 1162 prevent the clamp arm 1130 from responding to movement of the trigger until the shaft assembly 1114 is fully seated. A mechanical lockout assembly (1144) using a shaft coupler (1143) having a protrusion (1150) couples with the guide tracks (1154, 1164, 1166, 1168, 1170) of each coupling device (1146, 1156, 1158, 1160, 1162) to provide the operator with immediate and clear feedback of any misalignment between the shaft assembly (1114) and the handle assembly (1112).

[0118] M. Thirteenth Exemplary Ultrasonic Surgical Instrument Having a Thirteenth Embodiment of a Mechanical Lockout Assembly 35-41 illustrate a thirteenth exemplary ultrasonic surgical instrument (1210) including a thirteenth mechanical lockout assembly (1244). The instrument (1210) of this example comprises a first modular assembly shown as a handle assembly (1212), a second modular assembly shown as a shaft assembly (1214), an end effector (1216), a body (1218), a pistol grip (1220), an energy control button (1222), a trigger (1224), an ultrasonic transducer (1226), an ultrasonic blade (1228), a clamp arm (1230), a clamp pad (1232), an outer tube (1234), an inner tube (1236), and a rotation knob (1242).

[0119] FIG. 36 illustrates an instrument (1210) including a mechanical lockout assembly (1244). As shown, the mechanical lockout assembly (1244) includes an outer tube collar (1246), a bayonet collar (1248), and a rotation collar (1249) (see FIG. 41). The outer tube collar (1246) is integrated into the handle assembly (1212). The outer tube collar (1246) can rotate and translate within the handle assembly (1212). The outer tube collar (1246) is part of a clamp arm drive assembly that connects the trigger (1224) of the handle assembly (1212) to the outer tube (1234) of the shaft assembly (1214). Actuation of the trigger (1224) causes the outer tube collar (1246) to translate longitudinally. As the outer tube collar 1246 translates, the translation of the outer tube collar 1246 is transmitted to the outer tube 1234 of the shaft assembly 1214. As the outer tube 1234 of the shaft assembly 1214 translates, the clamp arm 1230 pivots toward and away from the ultrasonic blade 1228. A bayonet collar 1248 may be removably coupled to the shaft assembly 1214 and is fixedly secured to the proximal end of the outer tube 1234 of the shaft assembly 1214. A rotation collar 1249 (see FIG. 41 ) is integrated into the handle assembly 1212 as part of the rotation knob 1242 that rotates the entire shaft assembly 1214 relative to the handle assembly 1212. Rotating collar (1249) rotates relative to handle assembly (1212), but does not translate relative to handle assembly (1212).

[0120] FIG. 37 shows an outer tube collar 1246 including a spring leg 1250 having a distal end 1252. The distal end 1252 of the spring leg 1250 includes a resilient interference tab 1254 having a contact surface 1255. The spring leg 1250 also includes a cam surface 1256 that acts as a ramp, as will be described in more detail below with reference to FIGS. 39A-40C. The outer tube collar 1246 also includes first and second passageways 1258, 1260 extending generally longitudinally relative to the outer tube collar 1246, and a third passageway 1262 having a width W1 extending generally perpendicular to the longitudinal direction of the outer tube collar 1246. The fourth passageway, like the third passageway 1262, is hidden in the figure. Outer tube collar (1246) also includes notch (1264), which will be described with reference to Figure 39B. Outer tube collar (1246) can be threadably coupled to a portion of the clamp arm drive train using threaded portion (1266). Thus, outer tube collar (1246) translates with the clamp arm drive train.

[0121] FIG. 38 illustrates a bayonet collar 1248 including at least one bayonet protrusion 1268, two of which are shown in FIGS. 40A-40C , configured to contact the cam surface 1256 of the spring leg 1250 when the bayonet collar 1248 rotates relative to the outer tube collar 1246 from a locked configuration to an unlocked configuration. The bayonet collar 1248 also includes a protrusion 1270 configured to be received in the notch 1264, as shown in FIG. 39C , to provide a detent interlock. The bayonet protrusion 1268 serves two purposes. First, the bayonet protrusion 1268 pulls down on the interference tab 1254, disengaging it from the side opening 1276 of the rotating collar 1249, shown in FIG. 41 , thereby allowing the clamp arm drive train to translate longitudinally. Second, the bayonet projection (1268) provides an interlock between the bayonet collar (1248) and the outer tube collar (1246) such that longitudinal movement of the outer tube collar (1246) is transferred to the bayonet collar (1248). When the interference tab (1254) disengages from the side opening (1276) of the rotation collar (1249) (see FIG. 41 ), movement of the clamp arm actuation assembly components within the handle assembly (1212) is transferred to the outer tube (1234) of the shaft assembly (1214) via engagement of the outer tube with the bayonet collars (1246, 1248), as provided by the interference tab (1254).

[0122] Figures 39A, 40A, and 41 show the instrument 1210 in a locked configuration, in which the handle assembly 1212 and the shaft assembly 1214 are not fully coupled together. The rotation collar 1249 (see Figure 41) includes a side opening 1276 that receives the interference tab 1254 to provide the locked configuration. In the locked configuration shown in Figures 39A, 40A, and 41, when the interference tab 1254 of the outer tube collar 1246 is positioned in the side opening 1276 of the rotation collar 1249, the outer tube collar 1246 cannot translate. When the outer tube collar 1246 is prevented from translating, the trigger 1224 cannot pivot, and the clamp arm 1230 cannot pivot toward the ultrasonic blade 1228. At this stage, the shaft assembly 1214 is fully inserted longitudinally into the handle assembly 1212, as indicated by the bayonet collar 1248 contacting the outer collar 1246. However, the shaft assembly 1212 has not yet rotated relative to the handle assembly 1212 to fully seat the shaft assembly 1214. More specifically, in the locked configuration, the resilient interference tabs 1254 of the outer collar 1246 do not deflect inward but instead are captured in the side openings 1276 of the rotation collar 1249 shown in FIG. 41 . As a result, the mechanical lockout assembly 1244 prevents the operator from using the clamp arm closure trigger 1224 to activate the instrument 1210. As shown in FIG. 40A, a central opening (1247) extends through both the outer tube collar (1246) and the bayonet collar (1248) to receive an ultrasonic waveguide (not shown).

[0123] 39B and 40B show the instrument 1210 transitioning between the locked and unlocked configurations, with the operator still prevented from actuating the trigger 1224. As shown, the resilient interference tabs 1254 are pulled inward and outward of the side openings 1276 in the rotating collar 1249 as the bayonet collar 1248 is rotated. The bayonet projections 1268 ride along the camming surfaces 1256 as the bayonet collar 1248 rotates, pulling the camming surfaces 1256 and the remaining resilient interference tabs 1254 inward. As shown, the camming surfaces 1256 are integrally formed as a single piece with the resilient interference tabs 1254. More specifically, the bayonet projection (1268) includes radially extending components (1258, 1262) that travel through the passageway and a proximally extending component (1254) that pulls down on the spring leg (1250) that supports the resilient interference tab.

[0124] 39C and 40C show the instrument 1210 in an unlocked configuration, with the handle assembly 1212 and shaft assembly 1214 fully coupled together so that an operator can activate the instrument 1210 using the trigger 1222. When the interference tab 1254 is withdrawn from the side opening 1276 of the rotation collar 1249, the outer collar 1246 can translate, thereby allowing pivotal movement of the trigger 1224 and thereby closing of the clamp arm 1230 toward the ultrasonic blade 1228. In the unlocked configuration, the bayonet protrusion 1268 of the bayonet collar 1248 presses the resilient interference tab 1254 inward toward the center of the outer collar 1246, allowing the shaft assembly 1214, including the clamp arm 1230, to function. The outer tube 1234 translates relative to the rest of the shaft assembly 1214, providing pivotal movement of the clamp arm 1230 toward and away from the ultrasonic blade 1228. Once the operator has rotated the shaft assembly 1214 to fully assemble the instrument 1210, the operator is required to grasp the rotation knob 1242 and hold it stationary.

[0125] IV. Exemplary Combinations The following examples illustrate various, non-exhaustive methods in which the teachings herein can be combined or applied. It should be understood that the following examples are not intended to limit the scope of any claims that may be presented at any time in this application or in a later application related to this application. No disclaimer is intended. The following examples are provided for illustrative purposes only. It is contemplated that the various teachings herein may be configured and applied in many other ways. It is also contemplated that certain features referred to in the following examples may be omitted in some variations. Accordingly, none of the aspects or features referred to below should be considered critical unless later expressly indicated to be so by the inventor or the inventor's successor in interest. If a claim including additional features other than those referred to below is presented in this application or in a later application related to this application, those additional features should not be presumed to have been added for any reasons related to patentability. [Example]

[0126] 1. An ultrasonic surgical instrument comprising: (a) a first modular assembly including at least one operator input feature; (b) an ultrasonic transducer supported by the first modular assembly; (c) a second modular assembly configured to be removably coupled to the first modular assembly, the second modular assembly further including at least a portion of an end effector extending distally from a distal end portion of the second modular assembly; and (d) a mechanical lockout assembly configured to switch between at least an unlocked configuration and a locked configuration, wherein in the locked configuration, the first modular assembly and the second modular assembly are partially coupled together to physically prevent an operator from activating the instrument using the operator input feature, and in the unlocked configuration, the first modular assembly and the second modular assembly are fully coupled together, allowing an operator to activate the instrument using the operator input feature. [Example]

[0127] 2. The ultrasonic surgical instrument of claim 1, wherein the first modular assembly further comprises a handle assembly, a proximal outer sheath, and an ultrasonic blade; the second modular assembly further comprises a clamp arm assembly and a distal outer sheath; the mechanical lockout assembly further comprises at least one lockout member having a body including a lockout feature, the lockout feature including at least one of a curve, an angle change, a slot, or a proximal protrusion from the body; and wherein, in a locked configuration, the lockout feature prevents rotation of the clamp arm assembly relative to the ultrasonic blade and, in an unlocked configuration, the proximal outer sheath couples with the distal outer sheath to allow closure of the clamp arm assembly relative to the ultrasonic blade. [Example]

[0128] 3. The ultrasonic surgical instrument of claim 1 or 2, wherein in the locked configuration, the lockout member prevents actuation of the clamp arm assembly by interfering with both the clamp arm assembly and the distal outer sheath. [Example]

[0129] The ultrasonic surgical instrument of any one or more of Examples 1-3, wherein the mechanical lockout assembly further comprises a pin pivotally connecting the distal outer sheath to both the clamp arm assembly and the lockout member. [Example]

[0130] The ultrasonic surgical instrument of any one or more of Examples 1-4, wherein the lockout member uses the same point of rotation as the clamp arm assembly. [Example]

[0131] An ultrasonic surgical instrument according to any one or more of Examples 1-5, wherein the clamp arm assembly further includes at least one cutout portion, and the lockout member is configured to move from the locked configuration to the unlocked configuration while being at least partially disposed within the cutout portion. [Example]

[0132] The ultrasonic surgical instrument of any one or more of Examples 1-6, wherein the cutout portion includes a protrusion to prevent translation of the lockout member while in the locked configuration. [Example]

[0133] The ultrasonic surgical instrument of any one or more of Examples 1-7, wherein the lockout member moves distally away from the prongs when moving from the locked configuration to the unlocked configuration. [Example]

[0134] The ultrasonic surgical instrument of any one or more of Examples 1-8, wherein the proximal outer sheath includes a protrusion that distally displaces the lockout member when the proximal outer sheath is coupled with the distal outer sheath. [Example]

[0135] The ultrasonic surgical instrument of any one or more of Examples 1-9, wherein in the unlocked configuration, the clamp arm assembly is free to rotate relative to the lockout member. [Example]

[0136] 11. The ultrasonic surgical instrument of any one or more of Examples 1-10, wherein the first modular assembly includes a handle assembly including a proximal outer sheath and an ultrasonic blade; the second modular assembly includes a clamp arm assembly and a distal outer sheath; the mechanical lockout assembly further includes at least one protrusion operably coupled to the clamp arm assembly, wherein in a locked configuration, the protrusion is not received by a corresponding recess in the distal outer sheath, the locked configuration being configured to prevent an operator from rotating the clamp arm assembly relative to the ultrasonic blade; and in an unlocked configuration, in which the proximal outer sheath is coupled to the distal outer sheath, the protrusion is received by a corresponding recess in the distal outer sheath, allowing an operator to rotate the clamp arm assembly relative to the ultrasonic blade. [Example]

[0137] The ultrasonic surgical instrument of any one or more of Examples 1-11, wherein the first modular assembly further includes a handle assembly including an operator input feature, the operator input feature including at least one energy control button separated from the switch by a passageway, and the mechanical lockout assembly further includes a barrier including a body portion and at least one opening that translates within the passageway between a locked configuration and an unlocked configuration, wherein in the locked configuration, the body portion is disposed within the passageway between the energy control button and the switch and prevents the switch from activating the instrument, and in the unlocked configuration, the opening is disposed within the passageway between the energy control button and the switch and allows the switch to activate the instrument. [Example]

[0138] An ultrasonic surgical instrument according to any one or more of Examples 1-12, wherein the barrier includes a flexible member operably coupled to the shaft assembly, the flexible member being urged into the passageway such that in the locked configuration the flexible member extends between the energy control button and the switch. [Example]

[0139] The ultrasonic surgical instrument of any one or more of Examples 1-13, wherein in the unlocked configuration, at least one of the energy control button or switch extends at least partially through an opening in the barrier and is in direct physical contact with the other of the energy control button or switch through the opening. [Example]

[0140] An ultrasonic surgical instrument described in any one or more of Examples 1 to 14, wherein the second modular assembly further includes a shaft assembly, and the mechanical lockout assembly further includes an angled slide configured to contact the protrusion of the shaft assembly, and the angled slide is configured to contact the barrier and transition the mechanical lockout assembly from a locked configuration to an unlocked configuration, and in the locked configuration, a body portion of the barrier is disposed within the passage between the energy control button and the switch to prevent the switch from activating the instrument. [Example]

[0141] 16. The ultrasonic surgical instrument of any one or more of Examples 1-15, wherein the first modular assembly includes an operator input feature, the operator input feature including at least one switch and a first portion of an energy control button; and the second modular assembly further includes a shaft assembly and a handle assembly including a second portion of the energy control button, wherein in a locked configuration when the shaft assembly is partially coupled with the handle assembly, misalignment of the first and second portions of the energy control button prevents the switch from activating the instrument, and in an unlocked configuration when the shaft assembly is fully coupled with the handle assembly, alignment of the first and second portions of the energy control button allows the switch to activate the instrument. [Example]

[0142] 17. The ultrasonic surgical instrument of any one or more of Examples 1-16, wherein the first modular assembly further includes a handle assembly including a trigger, the second modular assembly further includes a shaft assembly, and the mechanical lockout assembly further includes a closure lever link operably coupled to the trigger, wherein in a locked configuration when the shaft assembly is partially coupled to the handle assembly, the closure lever link is pulled over center in a first direction to prevent the closure lever link from rotating to closure and preventing the trigger from being actuated, and in an unlocked configuration when the shaft assembly is fully coupled to the handle assembly, insertion of the shaft assembly rotates the closure lever link in a second direction opposite the first direction, allowing the trigger to be actuated. [Example]

[0143] 18. The ultrasonic surgical instrument of any one or more of Examples 1-17, wherein the mechanical lockout assembly further includes a one-way door configured to be opened by coupling the handle assembly of the first modular assembly with the shaft assembly of the second modular assembly, wherein in a locked configuration when the shaft assembly is partially coupled with the handle assembly, the one-way door blocks access of the handle assembly from the shaft assembly, and when moving from the locked configuration to the unlocked configuration, as the outer sheath rotates, a translatable jacket threadably coupled to the outer sheath translates longitudinally relative to the one-way door, pivoting the one-way door to an open position and allowing coupling of the shaft assembly with the handle assembly, and in an unlocked configuration when the shaft assembly is fully coupled with the handle assembly, allowing actuation of the instrument using the operator input feature. [Example]

[0144] An ultrasonic surgical instrument described in any one or more of Examples 1 to 18, wherein the proximal portion of the shaft assembly of the second modular assembly includes a protrusion, and the mechanical lockout assembly includes a coupling device operably coupled to the handle assembly of the first modular assembly, the coupling device including a guide track, the guide track configured to translate and rotate the shaft assembly from a locked configuration when the shaft assembly is partially coupled to the handle assembly to an unlocked configuration when the shaft assembly is fully coupled to the handle assembly using interaction between the protrusion of the shaft assembly and the guide track of the coupling device. [Example]

[0145] 20. The ultrasonic surgical instrument of any one or more of Examples 1-19, wherein the mechanical lockout assembly includes: (i) an outer tube collar coupled to the handle assembly of the first modular assembly, the outer tube collar including a spring leg including a distal end, the distal end of the spring leg including a resilient interference tab; (ii) a bayonet collar coupled to the shaft assembly, the bayonet collar including a bayonet protrusion configured to contact a cam surface of the spring leg as the bayonet collar rotates relative to the outer tube collar from a locked configuration to an unlocked configuration; and (iii) a rotating collar including an opening, wherein in a locked configuration when the shaft assembly is partially coupled to the handle assembly, the interference tab of the outer tube collar deflects outward into the opening in the rotating collar, preventing actuation of the instrument, and in an unlocked configuration when the shaft assembly is fully coupled to the handle assembly, the bayonet protrusion contacts the cam surface of the interference tab, deflecting it inward, allowing actuation of the instrument. [Example]

[0146] 1. An ultrasonic surgical instrument comprising: (a) a handle assembly including at least one operator input feature; (b) an ultrasonic transducer supported by the handle assembly; (c) a shaft assembly configured to removably couple to the handle assembly, the shaft assembly including a distal end portion, the shaft assembly further including: (i) an end effector extending distally from the distal end portion; and (ii) a waveguide acoustically coupled to the ultrasonic transducer; and (d) a mechanical lockout assembly configured to move between at least an unlocked configuration and a locked configuration, wherein in the locked configuration, the handle assembly and the shaft assembly are partially coupled together to physically prevent an operator from using the operator input feature to activate the instrument, and in the unlocked configuration, the handle assembly and the shaft assembly are fully coupled together and the operator can use the operator input feature to activate the instrument. [Example]

[0147] 22. The ultrasonic surgical instrument of any one or more of Examples 1-21, wherein the operator input feature further includes at least one energy control button separated from a switch in the handle assembly by a passage in the handle assembly, and wherein the mechanical lockout assembly further includes a barrier including a body portion and at least one opening extending at least partially through the body portion, the barrier translating within the passage between a locked configuration and an unlocked configuration, wherein in the locked configuration, the body portion is disposed within the passage between the energy control button and the switch to prevent the switch from activating the instrument, and in the unlocked configuration, the opening is disposed within the passage between the energy control button and the switch to allow the switch to activate the instrument. [Example]

[0148] The ultrasonic surgical instrument of any one or more of Examples 1-22, wherein the mechanical lockout assembly further includes a one-way door configured to be opened by coupling the handle assembly to the shaft assembly, wherein in a locked configuration when the shaft assembly is partially coupled to the handle assembly, the one-way door blocks access of the handle assembly from the shaft assembly, and when moving from the locked configuration to the unlocked configuration, as the outer sheath rotates, a translatable jacket threadably coupled to the outer sheath translates longitudinally relative to the one-way door, pivoting the one-way door to an open position and allowing coupling of the shaft assembly to the handle assembly, and in an unlocked configuration when the shaft assembly is fully coupled to the handle assembly, allowing actuation of the instrument using an operator input feature. [Example]

[0149] 1. A method of operating an ultrasonic surgical instrument, the ultrasonic surgical instrument comprising: (a) a first modular assembly including at least one operator input feature; (b) an ultrasonic transducer supported by the first modular assembly; (c) a second modular assembly configured to be removably coupled to the first modular assembly, the second modular assembly further including at least a portion of an end effector extending distally from a distal end portion of the second modular assembly; and (d) a mechanical lockout assembly configured to switch between at least an unlocked configuration and a locked configuration, the method comprising: (a) preventing the operator input feature from activating the instrument while in a locked configuration when the first modular assembly and the second modular assembly are only partially coupled together to provide immediate feedback to an operator; (b) fully coupling the handle assembly and the shaft assembly together to release the mechanical lockout assembly; and (c) activating the instrument using the operator input feature when in the unlocked configuration. [Example]

[0150] The method of Example 24, wherein the first modular assembly further includes a handle assembly including at least an operator input feature, the operator input feature including an energy control button separated from the switch by a passageway, the mechanical lockout assembly further includes a barrier including a body portion and at least one opening extending at least partially through the body portion, wherein preventing activation further includes preventing activation of the instrument when the body portion of the barrier is disposed within the passageway between the energy control button and the switch, and wherein coupling further includes translating the body portion of the barrier such that the opening in the body portion is disposed within the passageway between the energy control button and the switch, allowing the switch to activate the instrument. [Example]

[0151] 1. An ultrasonic surgical instrument comprising: (a) a handle assembly including at least one operator input feature; (b) an ultrasonic transducer supported by the handle assembly; (c) a shaft assembly configured to removably couple to the handle assembly, the shaft assembly including a distal end portion, the shaft assembly further including: (i) an end effector extending distally from the distal end portion; and (ii) an ultrasonic waveguide configured to be acoustically coupled to the ultrasonic transducer; and (d) a mechanical lockout assembly configured to move between at least an unlocked configuration and a locked configuration, wherein in the locked configuration, the handle assembly and the shaft assembly are partially coupled together and physically prevent an operator from using the operator input feature to activate the instrument, and wherein in the unlocked configuration, the handle assembly and the shaft assembly are fully coupled together and allow an operator to use the operator input feature to activate the instrument. [Example]

[0152] 27. The ultrasonic surgical instrument of Example 26, wherein in the locked configuration, the mechanical lockout assembly prevents an operator input feature from activating a trigger of a handle assembly operatively coupled to the end effector, and preventing activation of the trigger prevents the operator from clamping tissue with the end effector. [Example]

[0153] An ultrasonic surgical instrument as described in Example 26 or 27, wherein in the locked configuration, the mechanical lockout assembly prevents the operator input feature from activating at least one energy control button disposed on the handle assembly, thereby preventing the operator from activating the ultrasonic blade. [Example]

[0154] 29. The ultrasonic surgical instrument of any one or more of Examples 26-28, wherein a spring urges the mechanical lockout assembly from the locked configuration to the unlocked configuration when the shaft assembly is removed from the handle assembly. [Example]

[0155] An ultrasonic surgical instrument described in any one or more of Examples 26 to 29, wherein the operator input feature includes at least one energy control button separated from the switch by a passage within the handle assembly, and the mechanical lockout assembly further includes a barrier including a body portion that translates between a locked configuration and an unlocked configuration within the passage and at least one opening, wherein in the locked configuration when the shaft assembly is not fully coupled to the handle assembly, the body portion is disposed within the passage between the energy control button and the switch to prevent the switch from activating the instrument, and in the unlocked configuration when the shaft assembly is fully coupled to the handle assembly, the opening is disposed within the passage between the energy control button and the switch to allow the switch to activate the instrument. [Example]

[0156] An ultrasonic surgical instrument described in any one or more of Examples 26-30, wherein the barrier includes a flexible member operably connected to the shaft assembly, the flexible element being pushed into the passage such that in the locked configuration the flexible member extends between the energy control button and the switch. [Example]

[0157] An ultrasonic surgical instrument described in any one or more of Examples 26-31, wherein in the unlocked configuration, at least one of the energy control button or switch extends at least partially through an opening in the barrier and is in direct physical contact with the other of the energy control button or switch through the opening. [Example]

[0158] An ultrasonic surgical instrument described in any one or more of Examples 26 to 32, wherein the mechanical lockout assembly further includes an angled slide configured to contact the protrusion of the shaft assembly, the angled slide configured to contact the barrier and transition the mechanical lockout assembly from a locked configuration to an unlocked configuration, and in the locked configuration, a body portion of the barrier is disposed within the passage between the energy control button and the switch to prevent the switch from activating the instrument. [Example]

[0159] An ultrasonic surgical instrument described in any one or more of Examples 26 to 33, wherein the shaft assembly includes a protrusion that contacts the angled slide and uses a cam action to cause the angled proximal end of the angled slide to push the barrier further into the passage. [Example]

[0160] 35. The ultrasonic surgical instrument of any one or more of Examples 26-34, wherein the handle assembly includes an operator input feature including at least one switch and a first portion of an energy control button, the shaft assembly includes a second portion of the energy control button, and wherein, in a locked configuration when the shaft assembly is partially coupled to the handle assembly, misalignment of the first and second portions of the energy control button prevents the switch from activating the instrument, and in an unlocked configuration when the shaft assembly is fully coupled to the handle assembly, alignment of the first and second portions of the energy control button allows the switch to activate the instrument. [Example]

[0161] 36. The ultrasonic surgical instrument of any one or more of Examples 26-35, wherein the handle assembly includes an operator input feature, the operator input feature including a trigger, and the mechanical lockout assembly further includes a closure lever link operably coupled to the trigger, wherein in a locked configuration when the shaft assembly is partially coupled to the handle assembly, the closure lever link is pulled past its center in a first direction to prevent the closure lever link from rotating to close, preventing the trigger from being actuated and preventing the end effector from closing, and wherein in an unlocked configuration when the shaft assembly is fully coupled to the handle assembly, insertion of the shaft assembly rotates the closure lever link in a second direction opposite to the first direction, allowing the trigger to be actuated and the end effector to close. [Example]

[0162] An ultrasonic surgical instrument described in any one or more of Examples 26 to 36, wherein the mechanical lockout assembly further includes a one-way door configured to be opened by coupling the shaft assembly to the handle assembly, wherein in a locked configuration when the shaft assembly is partially coupled to the handle assembly, the one-way door prevents the connection portion of the ultrasonic transducer from reaching the connection portion of the proximal end of the ultrasonic waveguide, and when moving from the locked configuration to the unlocked configuration, as the outer sheath rotates, a translatable jacket threadably coupled to the outer sheath translates longitudinally relative to the one-way door, pivoting the one-way door to an open position and allowing the connection portion of the ultrasonic transducer and the ultrasonic waveguide to acoustically couple, and wherein in an unlocked configuration when the shaft assembly is fully coupled to the handle assembly, actuation of the end effector using an operator input feature is enabled. [Example]

[0163] An ultrasonic surgical instrument described in any one or more of Examples 26 to 37, wherein the proximal portion of the shaft assembly includes a protrusion, the mechanical lockout assembly includes a coupling device operably connected to the handle assembly, the coupling device including a guide track, and the guide track is configured to translate and rotate the shaft assembly from a locked configuration when the shaft assembly is partially coupled to the handle assembly to an unlocked configuration when the shaft assembly is fully coupled to the handle assembly using interaction between the protrusion of the shaft assembly and the guide track of the coupling device. [Example]

[0164] An ultrasonic surgical instrument described in any one or more of Examples 26 to 38, wherein the coupling device translates longitudinally in response to pivotal movement of the trigger, and the coupling device operably couples the trigger to the clamp arm of the shaft assembly. [Example]

[0165] An ultrasonic surgical instrument according to any one or more of Examples 26-39, wherein the mechanical lockout assembly comprises: (i) an outer tube collar coupled to the handle assembly, the outer tube collar including a spring leg having a distal end, the distal end of the spring leg including a resilient interference tab; (ii) a bayonet collar coupled to the shaft assembly, the bayonet collar including a bayonet protrusion configured to contact a cam surface of the spring leg as the bayonet collar rotates relative to the outer tube collar from a locked configuration to an unlocked configuration; and (iii) a rotating collar including an opening, wherein in a locked configuration when the shaft assembly is partially coupled to the handle assembly, the interference tab of the outer tube collar deflects outward into the opening in the rotating collar, preventing actuation of the instrument, and in an unlocked configuration when the shaft assembly is fully coupled to the handle assembly, the bayonet protrusion contacts the cam surface of the interference tab, deflecting it inward and allowing actuation of the instrument. [Example]

[0166] An ultrasonic surgical instrument comprising: (a) a handle assembly including at least one energy control button separated from a switch within the handle assembly by a passageway; (b) an ultrasonic transducer supported by the handle assembly; (c) a shaft assembly configured to removably couple with the handle assembly, the shaft assembly including a distal end portion, the shaft assembly including: (i) an end effector extending distally from the distal end portion; and (ii) an ultrasonic waveguide configured to be acoustically coupled with the ultrasonic transducer; and (d) a body portion and an ultrasonic transducer extending at least partially through the body portion. and at least one opening extending through the barrier, the barrier translating within the passage between a locked configuration and an unlocked configuration, wherein in the locked configuration the body portion is disposed within the passage between the energy control button and the switch to prevent the switch from activating the instrument, and in the unlocked configuration the opening is disposed within the passage between the energy control button and the switch, and at least one of the energy control button or the switch extends at least partially through the opening in the barrier and is in direct physical contact with the other of the energy control button or the switch through the opening to allow the switch to activate the instrument. [Example]

[0167] 1. A method of operating an ultrasonic surgical instrument, the ultrasonic surgical instrument comprising: (a) a handle assembly including at least one operator input feature and an ultrasonic transducer supported by the handle assembly; (b) a shaft assembly configured to removably couple to the handle assembly, the shaft assembly including a distal end portion, the shaft assembly including: (i) an end effector extending distally from the distal end portion; and (ii) an ultrasonic waveguide configured to be acoustically coupled to the ultrasonic transducer; and (c) a mechanical lockout assembly configured to move between at least an unlocked configuration and a locked configuration, the method including: (a) preventing the operator input feature from activating the instrument while in the locked configuration when the handle assembly and the shaft assembly are partially coupled together, wherein preventing activation of the instrument provides immediate feedback to the operator; (b) fully coupling the handle assembly and the shaft assembly together to release the locking assembly; and (c) activating the instrument using the operator input feature when in the unlocked configuration. [Example]

[0168] The method of example 43, wherein preventing activation further includes a mechanical lockout assembly that prevents the operator input feature from locking an operator-activated trigger of a handle assembly operably coupled to the end effector, thereby preventing the operator from clamping tissue with the end effector. [Example]

[0169] The method of any one of Examples 43 and 44, wherein preventing activation further includes a mechanical lockout assembly that prevents the operator input feature from activating at least one energy control button and prevents the operator from activating the ultrasonic blade. [Example]

[0170] 1. An ultrasonic surgical instrument comprising: (a) an ultrasonic transducer; (b) a handle assembly supporting the ultrasonic transducer, the handle assembly including: (i) a housing; and (ii) an ultrasonic blade acoustically coupled to the ultrasonic transducer; (c) a clamp arm assembly including a clamp arm; and (d) a mechanical lockout assembly configured to switch between at least an unlocked configuration and a locked configuration, wherein in the locked configuration, the handle assembly and the clamp arm assembly are fully disengaged and an operator is physically prevented from activating the instrument using an operator input feature, and wherein in the unlocked configuration, the clamp arm assembly and the shaft assembly are fully engaged and an operator can activate the instrument using an operator input feature. [Example]

[0171] The ultrasonic surgical instrument of Example 45, wherein in the locked configuration, the mechanical lockout assembly prevents the operator input feature from rotating the clamp arm relative to the ultrasonic blade, thereby preventing the operator from clamping tissue by rotating the clamp arm relative to the ultrasonic blade. [Example]

[0172] An ultrasonic surgical instrument as described in Example 45 or 46, wherein a mechanical lockout assembly prevents an operator input feature from activating at least one energy control button disposed on the handle assembly, thereby preventing activation of the ultrasonic blade. [Example]

[0173] An ultrasonic surgical instrument described in any one or more of Examples 45 to 47, wherein the mechanical lockout assembly further includes at least one lockout member having a body including a lockout feature, the lockout feature including at least one of a curve, an angle change, a slot, or a proximal protrusion from the body, and wherein in the locked configuration, the lockout feature prevents rotation of the clamp arm relative to the ultrasonic blade, and in the unlocked configuration, the lockout feature allows rotation of the clamp arm relative to the ultrasonic blade. [Example]

[0174] An ultrasonic surgical instrument according to any one or more of Examples 45-48, wherein the lockout member uses the same point of rotation as the clamp arm assembly. [Example]

[0175] An ultrasonic surgical instrument described in any one or more of Examples 45 to 49, wherein the clamp arm assembly further includes at least one cutout portion, and the lockout member is configured to move from a locked configuration to an unlocked configuration while being at least partially disposed within the cutout portion. [Example]

[0176] The ultrasonic surgical instrument of any one or more of Examples 45-50, wherein the cutout portion includes a protrusion to prevent translation of the lockout member while in the locked configuration. [Example]

[0177] An ultrasonic surgical instrument according to any one or more of Examples 45-51, wherein in the unlocked configuration, the clamp arm assembly is free to rotate relative to the lockout member. [Example]

[0178] 53. An ultrasonic surgical instrument according to any one or more of Examples 45 to 52, wherein the clamp arm assembly includes an outer sheath, and the mechanical lockout assembly further includes at least one protrusion operably coupled to the clamp arm assembly, wherein in a locked configuration, the protrusion is not received by a corresponding recess in the outer sheath, and in the locked configuration, when the protrusion provides a hard stop, the operator input feature prevents the clamp arm from rotating relative to the ultrasonic blade and prevents the clamp arm from pivoting toward the ultrasonic blade, and in an unlocked configuration, the proximal outer sheath is coupled to the distal outer sheath, the protrusion is received by a corresponding recess in the distal outer sheath, and the operator input feature allows the clamp arm assembly to rotate relative to the ultrasonic blade. [Example]

[0179] An ultrasonic surgical instrument described in any one or more of Examples 45 to 53, wherein the protrusions are curved protrusions that are received by curved recesses in the outer sheath in the unlocked configuration. [Example]

[0180] An ultrasonic surgical instrument described in any one or more of Examples 45 to 54, wherein the handle assembly further includes an operator input feature, the operator input feature including at least one energy control button separated from a switch in the housing by a passage, and the mechanical lockout assembly further includes a barrier including a body portion that translates within the passage between a locked configuration and an unlocked configuration and at least one opening, wherein in the locked configuration, the body portion is disposed within the passage between the energy control button and the switch to prevent the switch from activating the instrument, and in the unlocked configuration, the opening is disposed within the passage between the energy control button and the switch to allow the switch to activate the instrument. [Example]

[0181] An ultrasonic surgical instrument described in any one or more of Examples 45 to 55, wherein the barrier includes a flexible member operably connected to the shaft assembly, the flexible element being pushed into the passage so that in the locked configuration the flexible member extends between the energy control button and the switch. [Example]

[0182] An ultrasonic surgical instrument described in any one or more of Examples 45-56, wherein in the unlocked configuration, at least one of the energy control button or switch extends at least partially through an opening in the barrier and is in direct physical contact with the other of the energy control button or switch through the opening. [Example]

[0183] An ultrasonic surgical instrument described in any one or more of Examples 45-57, wherein a linkage mechanism attaches the barrier to the clamp arm assembly. [Example]

[0184] An ultrasonic surgical instrument described in any one or more of Examples 45 to 58, wherein a spring urges the mechanical lockout assembly from a locked configuration to an unlocked configuration when the clamp arm is removed from the handle assembly. [Example]

[0185] 1. An ultrasonic surgical instrument comprising: (a) an ultrasonic transducer; (b) a handle assembly supporting the ultrasonic transducer, the handle assembly including: (i) a housing; and (ii) an ultrasonic blade acoustically coupled to the ultrasonic transducer; (c) a clamp arm assembly including a clamp arm; and (d) at least one lockout member having a body including a lockout feature, the lockout feature including at least one of a curve, an angle change, a slot, or a proximal protrusion from the body, wherein in a locked configuration, the lockout feature prevents rotation of the clamp arm relative to the ultrasonic blade, and in an unlocked configuration, the lockout feature allows rotation of the clamp arm relative to the ultrasonic blade. [Example]

[0186] An ultrasonic surgical instrument described in any one or more of Examples 45 to 58 and 60, wherein the handle assembly includes a protrusion that distally displaces the lockout member when the handle assembly is coupled to the clamp arm assembly. [Example]

[0187] 1. A method of operating an ultrasonic surgical instrument, the ultrasonic surgical instrument comprising: (a) an ultrasonic transducer; (b) a handle assembly supporting the ultrasonic transducer, the handle assembly including: (i) a housing; and (ii) an ultrasonic blade acoustically coupled to the ultrasonic transducer; (c) a clamp arm assembly including a clamp arm; and (d) a mechanical lockout assembly configured to switch between at least an unlocked configuration and a locked configuration; the method including: (a) preventing an operator input feature from actuating the instrument while in the locked configuration when the handle assembly and the clamp arm assembly are partially coupled together, wherein preventing rotation of the clamp arm provides immediate feedback to the operator; (b) fully coupling the handle assembly and the clamp arm assembly together to release the locking assembly; and (c) actuating the instrument using the operator input feature when in the unlocked configuration. [Example]

[0188] The method of example 62, wherein blocking the operator input feature further includes a mechanical lockout assembly that prevents the operator input feature from rotating the clamp arm relative to the ultrasonic blade and prevents the operator from clamping tissue. [Example]

[0189] The method of example 62 or 63, wherein blocking the operator input feature further includes a mechanical lockout assembly that prevents the operator input feature from activating at least one energy control button disposed on the handle assembly, thereby preventing the operator from activating the ultrasonic blade.

[0190] V. Other It should be understood that the various teachings herein may be readily combined with the various teachings of U.S. Patent Application Publication No. 2017 / 0105754, entitled "Surgical Instrument with Dual Mode End Effector and Side-Loaded Clamp Arm Assembly," published April 2017, the disclosure of which is incorporated herein by reference. Various suitable ways in which the teachings herein may be combined with the teachings of U.S. Patent Application Publication No. 2017 / 0105754 will be apparent to those skilled in the art.

[0191] It should be understood that the various teachings herein can be readily combined with the various teachings of U.S. Patent Application Publication No. 2017 / 0105755, entitled "Surgical Instrument with Dual Mode End Effector and Compound Lever with Detents," published April 20, 2017, the disclosure of which is incorporated herein by reference. Various suitable ways in which the teachings herein can be combined with the teachings of U.S. Patent Application Publication No. 2017 / 0105755 will be apparent to those skilled in the art.

[0192] It should be understood that the various teachings herein may be readily combined with the various teachings of U.S. Patent Application Publication No. 2017 / 0105788, entitled "Surgical Instrument with Dual Mode End Effector and Modular Clamp Arm Assembly," published April 20, 2017, the disclosure of which is incorporated herein by reference. Various suitable ways in which the teachings herein may be combined with the teachings of U.S. Patent Application Publication No. 2017 / 0105788 will be apparent to those skilled in the art.

[0193] The various instruments described above may be used in various types of surgical procedures. By way of example only, the instruments may be used to perform liver resections, colorectal surgeries, gynecological surgeries, and / or various other types of surgical procedures. Various other types of surgeries and methods in which the instruments described above may be used will be apparent to those skilled in the art in view of the teachings herein.

[0194] It should be understood that any of the versions of the devices described herein can include various other features in addition to or in place of those described above. By way of example only, any of the devices described herein can also include one or more of the various features disclosed in any of the various references incorporated by reference herein. It should also be understood that the teachings herein can be readily applied to any of the devices described in any of the other references cited herein, and thus the teachings herein can be readily combined in many ways with the teachings of any of the references cited herein. Other types of devices into which the teachings herein can be incorporated will be apparent to those skilled in the art.

[0195] Any patent, publication, or other disclosure referred to as being incorporated herein by reference, in whole or in part, should be understood to be incorporated herein only to the extent that the incorporated content does not contradict current definitions, opinions, or other disclosures set forth herein. As such, and to the extent necessary, the disclosures explicitly set forth herein shall supersede any conflicting statements incorporated herein by reference. Any content, or portions thereof, that contradicts current definitions, opinions, or other disclosures set forth herein shall be incorporated herein by reference, but only to the extent that no conflict arises between the referenced content and the current disclosure.

[0196] Variations of the above-described devices may have application not only in traditional medical procedures and surgeries performed by medical professionals, but also in robotically-assisted medical procedures and surgeries. By way of example only, the various teachings herein may be readily incorporated into robotic surgical systems, such as the DAVINCI™ system by Intuitive Surgical, Inc. (Sunnyvale, California). Similarly, those skilled in the art will understand that the various teachings herein may be readily combined with the various teachings of U.S. Patent No. 6,783,524, entitled "Robotic Surgical Tool with Ultrasound Cauterizing and Cutting Instrument," issued August 31, 2004, the disclosure of which is incorporated herein by reference.

[0197] The above-described variations may be designed to be disposed of after a single use, or they may be designed to be used multiple times. The variations, in either or both cases, may be reconditioned for reuse after at least one use. Reconditioning may include any combination of the steps of disassembly of the device, followed by cleaning or replacement of particular parts, and subsequent reassembly. In particular, some variations of the device may be disassembled, and any number of particular parts or components of the device may be selectively replaced or removed in any combination. Upon cleaning and / or replacement of particular parts, some variations of the device may be reassembled for subsequent use either at a reconditioning facility or by an operator immediately prior to surgery. Those skilled in the art will appreciate that reconditioning of a device can utilize a variety of techniques for disassembly, cleaning / replacement, and reassembly. Use of such techniques, and the resulting reconditioned device, are all within the scope of the present application.

[0198] By way of example only, the variations described herein may be sterilized before and / or after treatment. In one sterilization technique, the device is placed in a closed and 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 radiation, x-rays, or a high-energy electron beam. The radiation may kill bacteria on the device and in the container. The sterilized device may then be stored in the sterile 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 radiation, ethylene oxide, or steam.

[0199] Although various embodiments of the present invention have been shown and described above, further adaptations of the methods and systems described herein may be realized by those skilled in the art through appropriate modifications without departing from the scope of the present invention. While some of such possible modifications have been described, other modifications will be apparent to those skilled in the art. For example, the above examples, embodiments, shapes, materials, dimensions, proportions, steps, etc. are illustrative and not required. Therefore, the scope of the present invention should be considered in light of the following claims and should not be understood to be limited to the details of structure and operation shown and described in the specification and drawings.

[0200] [Embodiment] (1) An ultrasonic surgical instrument, (a) a first modular assembly including at least one operator input feature; (b) an ultrasonic transducer supported by the first modular assembly; and (c) a second modular assembly configured to be removably coupled to the first modular assembly, the second modular assembly further including at least a portion of an end effector extending distally from a distal end portion of the second modular assembly; and (d) a mechanical lockout assembly configured to switch between at least an unlocked configuration and a locked configuration, in the locked configuration, the first modular assembly and the second modular assembly are partially coupled together to physically prevent an operator from using the operator input feature to activate the instrument; and a mechanical lockout assembly, wherein in the unlocked configuration, the first modular assembly and the second modular assembly are fully coupled together and the operator can activate the instrument using the operator input feature. (2) The ultrasonic surgical instrument of embodiment 1, wherein the first modular assembly further includes a handle assembly, a proximal outer sheath, and an ultrasonic blade; the second modular assembly further includes a clamp arm assembly and a distal outer sheath; the mechanical lockout assembly further includes at least one lockout member having a body including a lockout feature, the lockout feature including at least one of a curve, an angle change, a slot, or a proximal protrusion from the body; and wherein, in the locked configuration, the lockout feature is configured to prevent rotation of the clamp arm assembly relative to the ultrasonic blade; and, in the unlocked configuration, the proximal outer sheath couples with the distal outer sheath to allow closure of the clamp arm assembly relative to the ultrasonic blade. (3) An ultrasonic surgical instrument as described in embodiment 2, wherein in the locked configuration, the lockout member prevents actuation of the clamp arm assembly by interfering with both the clamp arm assembly and the distal outer sheath. (4) The ultrasonic surgical instrument of claim 2, wherein the mechanical lockout assembly further includes a pin pivotally connecting the distal outer sheath to both the clamp arm assembly and the lockout member. (5) The ultrasonic surgical instrument of claim 2, wherein the proximal outer sheath includes a protrusion that distally displaces the lockout member when the proximal outer sheath is coupled to the distal outer sheath.

[0201] (6) The ultrasonic surgical instrument of embodiment 1, wherein the first modular assembly includes a handle assembly including a proximal outer sheath and an ultrasonic blade; the second modular assembly includes a clamp arm assembly and a distal outer sheath; the mechanical lockout assembly further includes at least one protrusion operably coupled to the clamp arm assembly, wherein in the locked configuration, the protrusion is not received by a corresponding recess in the distal outer sheath, the locked configuration being configured to prevent an operator from rotating the clamp arm assembly relative to the ultrasonic blade; and in the unlocked configuration, in which the proximal outer sheath is coupled to the distal outer sheath, the protrusion is received by the corresponding recess in the distal outer sheath, allowing the operator to rotate the clamp arm assembly relative to the ultrasonic blade. (7) The ultrasonic surgical instrument of claim 1, wherein the first modular assembly further includes a handle assembly including the operator input feature, the operator input feature including at least one energy control button separated from a switch by a passageway, and the mechanical lockout assembly further includes a barrier including a body portion and at least one opening that translates within the passageway between the locked configuration and the unlocked configuration, wherein in the locked configuration, the body portion is disposed within the passageway between the energy control button and the switch to prevent the switch from activating the instrument, and in the unlocked configuration, the opening is disposed within the passageway between the energy control button and the switch to allow the switch to activate the instrument. (8) The ultrasonic surgical instrument of claim 7, wherein the barrier includes a flexible member operably coupled to a shaft assembly, the flexible member being urged into the passage such that in the locked configuration the flexible member extends between the energy control button and the switch. (9) The ultrasonic surgical instrument of claim 7, wherein in the unlocked configuration, at least one of the energy control button or the switch extends at least partially through the opening in the barrier and is in direct physical contact with the other of the energy control button or the switch through the opening. (10) The ultrasonic surgical instrument of embodiment 7, wherein the second modular assembly further includes a shaft assembly, and the mechanical lockout assembly further includes an angled slide configured to contact a protrusion on the shaft assembly, the angled slide configured to contact the barrier and transition the mechanical lockout assembly from the locked configuration to the unlocked configuration, and in the locked configuration, the body portion of the barrier is disposed within the passage between the energy control button and the switch and prevents the switch from activating the instrument.

[0202] (11) The ultrasonic surgical instrument of claim 1, wherein the first modular assembly includes the operator input feature, the operator input feature including at least one switch and a first portion of an energy control button; and the second modular assembly further includes a shaft assembly and a handle assembly including a second portion of the energy control button, wherein in the locked configuration when the shaft assembly is partially coupled with the handle assembly, misalignment of the first and second portions of the energy control button prevents the switch from activating the instrument, and in the unlocked configuration when the shaft assembly is fully coupled with the handle assembly, alignment of the first and second portions of the energy control button allows the switch to activate the instrument. (12) The ultrasonic surgical instrument of claim 1, wherein the first modular assembly further includes a handle assembly including a trigger, the second modular assembly further includes a shaft assembly, and the mechanical lockout assembly further includes a closure lever link operably coupled to the trigger, wherein in the locked configuration when the shaft assembly is partially coupled to the handle assembly, the closure lever link is pulled over center in a first direction to prevent the closure lever link from rotating closed and preventing the trigger from being actuated, and in the unlocked configuration when the shaft assembly is fully coupled to the handle assembly, insertion of the shaft assembly rotates the closure lever link in a second direction opposite the first direction to allow the trigger to be actuated. 13. The ultrasonic surgical instrument of claim 1, wherein the mechanical lockout assembly further includes a one-way door configured to be opened by coupling a handle assembly of the first modular assembly with a shaft assembly of the second modular assembly, wherein in the locked configuration when the shaft assembly is partially coupled with the handle assembly, the one-way door blocks access of the handle assembly from the shaft assembly, and when moving from the locked configuration to the unlocked configuration, as the outer sheath rotates, a translatable jacket threadably coupled to the outer sheath translates longitudinally relative to the one-way door, pivoting the one-way door to an open position and enabling coupling of the shaft assembly with the handle assembly, and in the unlocked configuration when the shaft assembly is fully coupled with the handle assembly, enabling actuation of the instrument using the operator input feature. (14) The ultrasonic surgical instrument of embodiment 1, wherein a proximal portion of the shaft assembly of the second modular assembly includes a protrusion, and wherein the mechanical lockout assembly includes a coupling device operably coupled to the handle assembly of the first modular assembly, the coupling device including a guide track, the guide track configured to translate and rotate the shaft assembly using interaction between the protrusion of the shaft assembly and the guide track of the coupling device from the locked configuration when the shaft assembly is partially coupled to the handle assembly to the unlocked configuration when the shaft assembly is fully coupled to the handle assembly. (15) The mechanical lockout assembly (i) an outer tube collar coupled to a handle assembly of the first modular assembly, the outer tube collar including a spring leg including a distal end, the distal end of the spring leg including a resilient interference tab; (ii) a bayonet collar coupled to the shaft assembly, the bayonet collar including a bayonet protrusion configured to contact a cam surface of the spring leg as the bayonet collar rotates relative to the outer tube collar from the locked configuration to the unlocked configuration; and (iii) a rotating collar including an aperture, In the locked configuration when the shaft assembly is partially coupled with the handle assembly, the interference tabs of the outer collar flex outwardly into the openings in the rotation collar to prevent actuation of the instrument; and a rotating collar, wherein in the unlocked configuration when the shaft assembly is fully coupled with the handle assembly, the bayonet projection contacts the cam surface of the interference tab, deflecting the interference tab inward and allowing actuation of the instrument.

[0203] (16) An ultrasonic surgical instrument, (a) a handle assembly including at least one operator input feature; (b) an ultrasonic transducer supported by the handle assembly; (c) a shaft assembly configured to removably couple with the handle assembly, the shaft assembly including a distal end portion, the shaft assembly comprising: (i) an end effector extending distally from the distal end portion; (ii) a shaft assembly further including a waveguide acoustically coupled to the ultrasonic transducer; (d) a mechanical lockout assembly configured to move between at least an unlocked configuration and a locked configuration; in the locked configuration, the handle assembly and the shaft assembly are partially coupled together to physically prevent an operator from using the operator input feature to activate the instrument; and a mechanical lockout assembly, wherein in the unlocked configuration, the handle assembly and the shaft assembly are fully coupled together and the operator can activate the instrument using the operator input feature. (17) The ultrasonic surgical instrument of claim 16, wherein the operator input features further include at least one energy control button separated from a switch in the handle assembly by a passage in the handle assembly, and the mechanical lockout assembly further includes a barrier including a body portion and at least one opening extending at least partially through the body portion, the barrier translating within the passage between the locked configuration and the unlocked configuration, wherein in the locked configuration, the body portion is disposed within the passage between the energy control button and the switch to prevent the switch from activating the instrument, and in the unlocked configuration, the opening is disposed within the passage between the energy control button and the switch to allow the switch to activate the instrument. (18) The ultrasonic surgical instrument of claim 16, wherein the mechanical lockout assembly further includes a one-way door configured to be opened by coupling the handle assembly with the shaft assembly, wherein in the locked configuration when the shaft assembly is partially coupled with the handle assembly, the one-way door blocks access of the handle assembly from the shaft assembly, and when moving from the locked configuration to the unlocked configuration, as the outer sheath rotates, a translatable jacket threadably coupled to the outer sheath translates longitudinally relative to the one-way door, pivoting the one-way door to an open position and enabling coupling of the shaft assembly with the handle assembly, and in the unlocked configuration when the shaft assembly is fully coupled with the handle assembly, enabling actuation of the instrument using the operator input feature. (19) A method of operating an ultrasonic surgical instrument, the ultrasonic surgical instrument comprising: (a) a first modular assembly including at least one operator input feature; (b) an ultrasonic transducer supported by the first modular assembly; (c) a second modular assembly configured to removably couple with the first modular assembly, the second modular assembly further including at least a portion of an end effector extending distally from a distal end portion of the second modular assembly; and (d) a mechanical lockout assembly configured to switch between at least an unlocked configuration and a locked configuration, the method comprising: (a) preventing the operator input feature from activating the instrument while in the locked configuration when the first modular assembly and the second modular assembly are only partially coupled together to provide immediate feedback to an operator; (b) fully coupling the handle assembly and the shaft assembly together to release the mechanical lockout assembly; (c) activating the tool using the operator input feature when in the unlocked configuration. (20) The first modular assembly further includes a handle assembly including the at least one operator input feature, the operator input feature including the energy control button separated from the switch by a passageway, and the mechanical lockout assembly further includes a barrier including a body portion and at least one opening extending at least partially through the body portion; and preventing activation further includes preventing activation of the appliance when the body portion of the barrier is disposed within the passageway between the energy control button and the switch; The method of embodiment 19, wherein the connecting step further includes translating the body portion of the barrier so that the opening in the body portion is disposed within the passage between the energy control button and the switch, enabling the switch to activate the device.

Claims

1. 1. An ultrasonic surgical instrument comprising: (a) a first modular assembly including at least one operator input feature; (b) an ultrasonic transducer supported by the first modular assembly; and (c) a second modular assembly configured to be removably coupled to the first modular assembly, the second modular assembly further including at least a portion of an end effector extending distally from a distal end portion of the second modular assembly; and (d) a mechanical lockout assembly configured to switch between at least an unlocked configuration and a locked configuration; the mechanical lockout assembly is in the locked configuration when the second modular assembly is not coupled to the first modular assembly, and the mechanical lockout assembly is in the unlocked configuration when the second modular assembly is coupled to the first modular assembly; the locked configuration physically prevents an operator from activating the ultrasound transducer using the operator input feature; In the unlocked configuration, the operator can activate the ultrasound transducer using the operator input feature; the first modular assembly further includes a handle assembly including the operator input feature, the operator input feature including at least one energy control button separated from a switch by a passageway; the mechanical lockout assembly further includes a barrier releasably coupled to the second modular assembly, the barrier including a body portion and at least one opening, the body portion moving within the passageway from the locked configuration to the unlocked configuration upon movement of the second modular assembly toward the first modular assembly; wherein in the locked configuration, the body portion is disposed within the passageway between the energy control button and the switch and prevents the switch from activating the ultrasonic transducer; and in the unlocked configuration, the opening is disposed within the passageway between the energy control button and the switch and allows the switch to activate the ultrasonic transducer upon operation of the energy control button.

2. An ultrasonic surgical instrument as described in claim 1, wherein the main body portion of the barrier is a flexible member.

3. The ultrasonic surgical instrument of claim 1 , wherein in the unlocked configuration, the energy control button extends at least partially through the opening in the barrier and is in direct physical contact with the switch through the opening.

4. the mechanical lockout assembly further includes an angled slide configured to contact a protrusion of the second modular assembly; when the second modular assembly is not coupled to the first modular assembly, the mechanical lockout assembly is in the locked configuration and the body portion of the barrier is disposed in the passageway between the energy control button and the switch to prevent the switch from activating the ultrasonic transducer; 2. The ultrasonic surgical instrument of claim 1, wherein when the second modular assembly moves from a state where it is not coupled to the first modular assembly to a state where it is coupled to the first modular assembly, the mechanical lockout assembly is in the unlocked configuration and the protrusion of the second modular assembly contacts the angled slide, causing the angled slide to move into contact with the barrier, and the barrier moves to dispose the opening in the passageway between the energy control button and the switch, allowing the switch to activate the ultrasonic transducer.

5. 1. An ultrasonic surgical instrument comprising: (a) a handle assembly including at least one operator input feature; (b) an ultrasonic transducer supported by the handle assembly; (c) a shaft assembly configured to be removably coupled to the handle assembly, the shaft assembly further including at least a portion of an end effector extending distally from a distal end portion of the shaft assembly; and (d) a mechanical lockout assembly configured to switch between at least an unlocked configuration and a locked configuration; the mechanical lockout assembly is in the locked configuration when the shaft assembly is not coupled to the handle assembly, and the mechanical lockout assembly is in the unlocked configuration when the shaft assembly is coupled to the handle assembly; the locked configuration physically prevents an operator from activating the ultrasound transducer using the operator input feature; In the unlocked configuration, the operator can activate the ultrasound transducer using the operator input feature; 10. The ultrasonic surgical instrument of claim 9, wherein the operator input features include at least one energy control button separated from a switch by a passageway, and the mechanical lockout assembly further includes a barrier including a body portion and at least one opening releasably coupled to the shaft assembly and moving within the passageway from the locked configuration to the unlocked configuration upon movement of the shaft assembly toward the handle assembly, wherein in the locked configuration, the body portion is disposed within the passageway between the energy control button and the switch to prevent the switch from activating the ultrasonic transducer, and in the unlocked configuration, the opening is disposed within the passageway between the energy control button and the switch to allow the switch to activate the ultrasonic transducer upon operation of the energy control button.

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