Offset Ultrasonic Surgical Blades for Better Site Access
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Solution Overview
Problem
Ultrasonic surgical instruments face challenges in providing increased surgical site access, visibility, and manipulability, while also being cost-effective in manufacturing.
Innovation Solution
The design incorporates ultrasonic surgical instruments with offset blade configurations and the use of sheet metal stock to fabricate blades, featuring angularly and transversely offset blades, which enhance surgical access and visibility and reduce manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional co-axial blade configuration is used, then manufacturing is simpler and costs are lower, but surgical site access and visibility are limited
Solution Approach 1:
The patent applies asymmetry by offsetting the blade from the central axis of the ultrasonic transducer and waveguide. The blade is positioned at an angular offset (e.g., 45 degrees) relative to the central axis, creating an asymmetric configuration that allows the blade to extend laterally away from the axis. This asymmetric positioning improves surgical site access and visibility by moving the blade away from the line of sight of the transducer housing, enabling better exposure of the surgical field without increasing overall device complexity significantly.
Solution Approach 2:
The patent transitions from a traditional one-dimensional co-axial arrangement to a two-dimensional offset configuration. By introducing angular offset in the rotational dimension and lateral displacement in the radial dimension, the blade is repositioned in multiple spatial dimensions relative to the transducer axis. This multi-dimensional arrangement allows the blade to reach surgical sites that are difficult to access with conventional co-axial designs while maintaining manufacturability through standardized fabrication processes.
2Ease of operation
If offset blade configuration is implemented, then surgical access and visibility improve, but manufacturing cost increases
Solution Approach 1:
The patent segments the ultrasonic assembly into distinct functional components: the ultrasonic transducer housing, the waveguide, and the offset blade. This segmentation allows each component to be manufactured separately using optimized processes and then assembled together. The blade can be fabricated as a separate element with the desired offset geometry, enabling use of cost-effective manufacturing techniques such as laser cutting, bending, or molding from sheet metal, rather than requiring complex machining of a monolithic structure.
Solution Approach 2:
The patent utilizes parameter changes in the material form and geometry to reduce manufacturing cost. By designing the blade with specific offset parameters (angular offset of 45 degrees, lateral displacement distance) that are compatible with standard manufacturing tolerances and processes, the design achieves surgical accessibility without requiring precision manufacturing beyond conventional capabilities. The use of sheet metal stock with standard gauges and the application of conventional forming operations enable cost-effective production while maintaining the functional benefits of the offset configuration.
3Ease of operation
If angular offset is applied to the blade, then manipulability and surgical visibility enhance, but structural alignment complexity increases
Solution Approach 1:
The patent incorporates preliminary action by pre-configuring the blade at the desired angular offset during the manufacturing process. The blade is fabricated and positioned at the correct angle (e.g., 45 degrees) relative to the waveguide axis before assembly, with alignment features such as alignment pins, keyed interfaces, or precision-machined mounting surfaces ensuring accurate positioning. This preliminary positioning eliminates the need for complex post-assembly alignment procedures and ensures consistent, reliable angular offset without requiring high-precision adjustment mechanisms.
Solution Approach 2:
The patent introduces intermediary alignment features between the blade and waveguide components. These intermediaries include alignment pins, reference surfaces, or modular mounting interfaces that facilitate precise angular positioning during assembly. The intermediary elements absorb minor variations in manufacturing tolerances and provide a simple, reliable method for achieving the required angular offset, reducing the overall alignment precision requirements of the final assembly while ensuring consistent surgical performance.
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 offset blade configurations improve surgical site access and visibility, while the use of sheet metal stock decreases manufacturing costs, offering a cost-effective solution with enhanced surgical performance.
Implementation Method 1
Activating an end-effector at ultrasonic frequencies induces rapid longitudinal vibratory movement that generates localized heat within contacting tissue
Implementation Method 2
an acoustic horn acoustically coupled to the ultrasonic transducer, and an ultrasonic transmission waveguide acoustically coupled to the acoustic horn
Data Source
AI summary
Ultrasonic surgical instruments having angularly and/or linearly off-set blades are described. The angularly and/or linearly off-set blades may facilitate increased surgical site access, visibility, and manipulability.