Hermetically Sealed Ultrasonic Transducer Assembly for Sterilization

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Solution Overview

Problem

Ultrasonic surgical instruments face challenges in maintaining a hermetic seal around the transducer assembly, which is crucial for withstanding multiple sterilization cycles and ensuring reliable operation.

Innovation Solution

A hermetically sealed ultrasonic transducer assembly is designed with a casing that encloses the piezoelectric stack and ultrasonic horn, featuring weld joints and flanges to secure the components, along with a contact assembly that allows for signal communication through slip rings, ensuring a hermetic seal and electrical isolation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a hermetic seal is implemented around the transducer assembly, then reliability is improved by withstanding sterilization cycles, but device complexity increases due to additional sealing components and weld joints

Engineering Contradiction:

Improvesterilization resistanceVSAvoidsealing structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The casing is integrated to simultaneously provide structural support and hermetic sealing for the transducer assembly. The weld joints merge the casing with the ultrasonic horn, creating a unified sealed structure that protects internal components during sterilization while maintaining structural integrity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

A hermetic seal acts as an intermediary barrier between the sterile internal environment and the external sterilization process. The seal includes features like gaskets or welded joints that mediate between the need for component access and the requirement for sterilization resistance.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a hermetic seal is created around the distal opening, then reliability is improved by preventing contamination, but manufacturing precision requirements increase due to welding and flange alignment

Engineering Contradiction:

Improvecontamination preventionVSAvoidweld joint precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The flange is pre-formed on the ultrasonic horn at the distal opening area before final assembly. This preliminary structuring allows for precise alignment and welding operations, ensuring that the hermetic seal achieves the required precision for contamination prevention during manufacturing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The hermetic seal implementation is localized to specific critical areas such as the distal opening and weld joints. The flange structure provides localized reinforcement and sealing surfaces where precision is most critical, while other areas of the casing may have different structural characteristics.

Inventive Principle:

Principle #3Local quality

3Strength

If the casing is welded to the ultrasonic horn, then strength is improved by creating a robust sealed structure, but ease of manufacture decreases due to complex welding procedures

Engineering Contradiction:

Improvesealed structure strengthVSAvoidwelding complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The hermetic seal structure is segmented into distinct components: the casing, the ultrasonic horn, and the flange. This segmentation allows each component to be manufactured separately using optimized processes, then joined through welding. The flange acts as an intermediate segment that facilitates the connection between the horn and casing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sealed structure employs composite construction combining different materials or material properties in the casing, flange, and welding joint. This may include materials selected for their weldability, thermal properties, or mechanical strength, creating a composite structure that balances manufacturing ease with structural integrity.

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The hermetically sealed design enhances the durability of the transducer assembly to withstand multiple sterilization cycles while maintaining signal integrity and operational reliability.

Implementation Method 1

The transducer may be driven by an ultrasonic generator that is on-board, e.g., on or within the handle of the ultrasonic surgical instrument

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Implementation Method 2

ultrasonic surgical instruments utilize mechanical vibration energy transmitted at ultrasonic frequencies to coagulate, cauterize, fuse, seal, cut, desiccate, and/or fulgurate tissue

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Data Source

PatentUS12426909B2Ultrasonic transducer assembly and ultrasonic surgical instrument incorporating the same

Publication Date: 2025.09.30 COVIDIEN LP

AI summary

An ultrasonic transducer assembly of an ultrasonic surgical instrument includes a piezoelectric stack, an ultrasonic horn secured to and extending distally from the piezoelectric stack, and a casing. The ultrasonic horn includes a body and a nose extending distally from the body. The casing is disposed about the piezoelectric stack and the body of the ultrasonic horn. The casing defines a distal opening through which the nose of the ultrasonic horn extends. The casing is hermetically sealed to the ultrasonic horn about the distal opening to define a hermetically sealed interior enclosing the piezoelectric stack and the body of the ultrasonic horn therein.