U.S. patent application number 10/166314 was filed with the patent office on 2002-10-24 for ultrasonic surgical blade with improved cutting and coagulation features.
Invention is credited to Cook, Sarah A., Gallagher, Laura A., Gutierrez, Jorge N., Houser, Kevin L..
Application Number | 20020156493 10/166314 |
Document ID | / |
Family ID | 24156247 |
Filed Date | 2002-10-24 |
United States Patent
Application |
20020156493 |
Kind Code |
A1 |
Houser, Kevin L. ; et
al. |
October 24, 2002 |
Ultrasonic surgical blade with improved cutting and coagulation
features
Abstract
The present invention is directed to an ultrasonic surgical
blade including a top surface, a bottom surface and a cutting-edge.
The cutting-edge is defined by a cutting-surface intermediate the
top surface and the bottom surface, and the top surface has a width
greater than the width of the bottom surface. The blade may be
straight or curved In one embodiment of the invention, at least a
portion of the cutting-surface is substantially parallel to at
least a portion of the top surface. In still another embodiment of
the invention first and second side-walls intersect the top surface
to form first and second cutting-edges that may be sharp or blunt.
Alternately, a second cutting-edge may be defined by a second
cutting surface intermediate the top and bottom surfaces. Depending
on the angle between the intermediate cutting-surface and the top
surface, the cutting-edge may be sharp or blunt. In yet another
embodiment of the present invention, a central ridge is provided on
the bottom surface of the blade to eliminate blade burrowing and
improve precision during coagulation. The cutting-edge is optimized
to increase cutting speed of the blade while providing desirable
hemostasis. The invention is of particular benefit for breast
surgery, due to its cutting and coagulation characteristics.
Inventors: |
Houser, Kevin L.;
(Springboro, OH) ; Gutierrez, Jorge N.;
(Cincinnati, OH) ; Cook, Sarah A.; (Cincinnati,
OH) ; Gallagher, Laura A.; (Cincinnati, OH) |
Correspondence
Address: |
AUDLEY A. CIAMPORCERO JR.
JOHNSON & JOHNSON
ONE JOHNSON & JOHNSON PLAZA
NEW BRUNSWICK
NJ
08933-7003
US
|
Family ID: |
24156247 |
Appl. No.: |
10/166314 |
Filed: |
June 10, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10166314 |
Jun 10, 2002 |
|
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09540620 |
Mar 31, 2000 |
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6423082 |
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Current U.S.
Class: |
606/169 |
Current CPC
Class: |
A61B 2017/320077
20170801; A61B 2017/320071 20170801; A61B 2017/320089 20170801;
A61B 17/320068 20130101; A61B 2017/320069 20170801 |
Class at
Publication: |
606/169 |
International
Class: |
A61B 017/32 |
Claims
What is claimed is:
1. An ultrasonic surgical blade comprising: a bottom surface; a top
surface, wherein said top surface has a width greater than said
bottom surface; and a cutting-edge, wherein said cutting-edge is
defined by a first cutting-surface intermediate said top surface
and said bottom surface.
2. An ultrasonic surgical blade according to claim 1 wherein said
ultrasonic surgical blade is sterile.
3. An ultrasonic surgical blade according to claim 1 wherein the
included angle at the intersection between said top surface and
said first cutting-surface is from about 25 to about 35
degrees.
4. An ultrasonic surgical blade according to claim 1, wherein said
first cutting surface is curvilinear.
5. An ultrasonic surgical blade according to claim 1 wherein said
top surface further comprises a second cutting-surface intersecting
said first cutting-surface at said cutting-edge.
6. An ultrasonic surgical blade according to claim 5, wherein the
intersection of said first cutting-surface and said second
cutting-surface has an included angle of between about 10 to about
60 degrees.
7. An ultrasonic surgical blade according to claim 6, wherein the
included angle between said first cutting-surface and said second
cutting-surface is from about 25 to about 35 degrees.
8. An ultrasonic surgical blade according to claim 7, wherein at
least a portion of said top surface is flat, and at least a portion
of said first cutting-surface is flat, wherein said flat portion of
said top surface is substantially parallel to said flat portion of
said first cutting-surface.
9. An ultrasonic surgical blade according to claim 7 wherein said
top surface has a width about 0.002 inches to about 0.060 inches
wider than the width of said bottom surface.
10. An ultrasonic surgical blade according to claim 9 wherein said
cutting-edge is sharp.
11. An ultrasonic surgical blade according to claim 9 wherein said
cutting-edge is blunt.
12. An ultrasonic surgical blade according to claim 11 wherein said
blunt cutting-edge is square.
13. A curved ultrasonic surgical blade comprising: a bottom
surface; a top surface; and a cutting-edge, wherein said
cutting-edge is defined by a first cutting-surface intermediate
said top surface and said bottom surface.
14. A curved ultrasonic surgical blade according to claim 13
wherein said top surface further comprises a second cutting-surface
intersecting said first cutting-surface at said cutting-edge.
15. A curved ultrasonic surgical blade according to claim 14,
wherein the intersection of said first cutting-surface and said
second cutting-surface has an included angle of between about 10 to
about 60 degrees.
16. A curved ultrasonic surgical blade according to claim 15,
wherein the included angle between said first cutting-surface and
said second cutting-surface is from about 25 to about 35
degrees.
17. A curved ultrasonic surgical blade according to claim 16
wherein said top surface has a width about 0.002 inches to about
0.060 inches wider than the width of said bottom surface.
18. A curved ultrasonic surgical blade according to claim 17,
wherein said first cutting-surface is curvilinear.
19. A curved ultrasonic surgical blade according to claim 17
wherein said cutting-edge is sharp.
20. A curved ultrasonic surgical blade according to claim 17
wherein said cutting-edge is blunt.
21. A curved ultrasonic surgical blade according to claim 17
wherein said curved ultrasonic blade is sterile.
22. A curved ultrasonic surgical blade according to claim 20
wherein said blunt cutting-edge is square.
23. A curved ultrasonic surgical blade according to claim 21,
wherein at least a portion of said top surface is flat, and at
least a portion of said first cutting-surface is flat, wherein said
flat portion of said top surface is substantially parallel to said
flat portion of said first cutting-surface.
Description
[0001] This application is related to the following co-pending
patent applications: application Ser. No. 09/106,415 filed Jun. 29,
1999; application Ser. No. 09/413,225, filed Oct. 5, 1999; and
Attorney Docket Number END.sub.--638, application Ser. No. ______
filed Mar. 31, 2000.
FIELD OF THE INVENTION
[0002] The present invention relates, in general, to ultrasonic
surgical blades for use in surgical instruments and, more
particularly, to an ultrasonic surgical blade with improved cutting
and coagulation features.
BACKGROUND OF THE INVENTION
[0003] Ultrasonic instruments, including both hollow core and solid
core instruments, are used for the safe and effective treatment of
many medical conditions. Ultrasonic instruments, and particularly
solid core ultrasonic instruments, are advantageous because they
may be used to cut and/or coagulate organic tissue using energy in
the form of mechanical vibrations transmitted to a surgical
end-effector at ultrasonic frequencies. Ultrasonic vibrations, when
transmitted to organic tissue at suitable energy levels and using a
suitable end-effector, may be used to cut, dissect, or cauterize
tissue. Ultrasonic instruments utilizing solid core technology are
particularly advantageous because of the amount of ultrasonic
energy that may be transmitted from the ultrasonic transducer,
through the waveguide, to the surgical end-effector. Such
instruments may be used for open procedures or minimally invasive
procedures, such as endoscopic or laparoscopic procedures, wherein
the end-effector is passed through a trocar to reach the surgical
site.
[0004] Activating the end-effector (e.g. cutting blade) of such
instruments at ultrasonic frequencies induces longitudinal
vibratory movement that generates localized heat within adjacent
tissue, facilitating both cutting and coagulation. Because of the
nature of ultrasonic instruments, a particular ultrasonically
actuated end-effector may be designed to perform numerous
functions, including, for example, cutting and coagulation. The
structural stress induced in such end-effectors by vibrating the
blade at ultrasonic frequencies may have a number of undesirable
effects. Such undesirable effects may include, for example,
transverse motion in the instrument waveguide that may lead to, for
example, excess heat generation in the waveguide or premature
stress failure.
[0005] Long thin ultrasonic waveguides, such as those used in
instruments for minimally invasive surgery, are particularly
susceptible to transverse vibrations introduced by imbalances in
the end-effector. For certain applications, it is desirable to
include one or more axially asymmetrical features, (e.g. blade
curvature) to enhance performance of the end-effector. It may also
be desirable to design such end-effectors to be relatively long, in
order to facilitate certain surgical procedures. A method of
balancing asymmetric ultrasonic surgical blades is described in
U.S. patent application Ser. No. 09/106,661 filed Jun. 29, 1999,
hereby incorporated herein by reference.
[0006] Although ultrasonic surgical instruments such as those
described in U.S. patent application Ser. No. 09/106,661 have been
eminently successful, some areas of improvement still remain. One
complaint sometimes heard from surgeons is that cutting is too
slow, or that control is not as precise as would be desired.
Ultrasonic surgical blade edges are often dulled or rounded to slow
the cutting process, thereby providing more heat delivery to the
tissue during cutting. This improves hemostasis during cutting. It
would, therefore, be desirable to design an improved ultrasonic
surgical blade. It would further be advantageous to provide an
ultrasonic surgical blade that cuts faster, while maintaining
hemostasis desired by the surgeon. It would also be advantageous to
provide an ultrasonic surgical blade that is more controllable and
precise, to providing cutting where needed with significant
control. An ultrasonic surgical instrument is described with
improved cutting and coagulation features to provide these
advantages and overcome the disadvantages of previous
instruments.
SUMMARY OF THE INVENTION
[0007] The present invention is directed to an ultrasonic surgical
blade including a top surface, a bottom surface and at least one
cutting-edge. The cutting-edge is defined by a cutting-surface
intermediate the top surface and the bottom surface, and whereby
the top surface has a width greater than the width of the bottom
surface. The cutting-edge is optimized to increase cutting speed of
the blade while providing desirable hemostasis. Further, the blade
may be straight or curved. In one embodiment, at least a portion of
the cutting-surface is substantially parallel to at least a portion
of the top surface. In still a further embodiment, the cutting edge
is defined by a second cutting surface that intersects the first
cutting surface to form the cutting edge. In yet another embodiment
of the invention, the bottom surface further includes a first
side-wall that intersects the first cutting-surface to form the
first cutting-edge. Depending on the angle between the
cutting-surfaces and the top surface, the cutting-edge may be sharp
or blunt. In yet another embodiment of the present invention, a
central ridge is provided on the bottom surface of the blade to
eliminate blade burrowing and improve precision during coagulation.
A second cutting edge may be formed by including a second
intermediate cutting surface formed between the top and bottom
surfaces. The second cutting edge may be further defined by a
second cutting surface intersecting the second intermediate cutting
surface and/or a second side wall intersecting the second
intermediate cutting surface to form the second cutting edge.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The novel features of the invention are set forth with
particularity in the appended claims. The invention itself,
however, both as to organization and methods of operation, together
with further objects and advantages thereof, may best be understood
by reference to the following description, taken in conjunction
with the accompanying drawings in which:
[0009] FIG. 1 is an exploded perspective view of an ultrasonic
surgical instrument according to the present invention;
[0010] FIG. 2 is a top view of the distal end of an ultrasonic
transmission assembly according to the present invention;
[0011] FIG. 3 is a side view of the distal end of an ultrasonic
transmission assembly according to the present invention;
[0012] FIG. 4 is a bottom view of the distal end of an ultrasonic
transmission assembly according to the present invention;
[0013] FIG. 5 is a bottom perspective view of the distal end of an
ultrasonic transmission assembly according to the present
invention;
[0014] FIG. 6 is a top perspective view of the distal end of the
ultrasonic transmission assembly shown in FIG. 5;
[0015] FIG. 7 is a side view of a straight blade in accordance with
the present invention;
[0016] FIG. 8 is a section view taken along line 8-8 of FIG. 7;
[0017] FIG. 9 is a side view of a curved blade according to the
present invention, including radii of curvatures;
[0018] FIG. 10 is a section view taken along line 10-10 of FIG.
9;
[0019] FIG. 10-A is an alternate embodiment section view taken
along line 10-10 of FIG. 9;
[0020] FIG. 11 is a magnification of the blade edge region
indicated in FIG. 10;
[0021] FIG. 12 is a magnification of an alternate embodiment of the
blade edge region indicated in FIG. 10;
[0022] FIG. 13 illustrates a blade in accordance with the present
invention connected to an ultrasonic transducer and its associated
ultrasonic generator; and
[0023] FIG. 14 illustrates a method of deburring an ultrasonic
surgical blade in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0024] The present invention relates, in general, to ultrasonic
surgical blades for use in surgical instruments and, more
particularly, to an ultrasonic surgical blade with improved cutting
and coagulation features. A blade according to the present
invention is of particular benefit for breast surgery, due to its
cutting and coagulation characteristics, however the blade is
useful for general soft tissue cutting and coagulation. The blade
may be straight or curved, and useful for both open or laparoscopic
applications.
[0025] FIG. 1 illustrates an exploded perspective view of a sterile
ultrasonic surgical instrument 10 according to the present
invention. Ultrasonic surgical instrument 10 may be sterilized by
methods known in the art such as, for example, gamma radiation
sterilization, Ethelyne Oxide processes, autoclaving, soaking in
sterilization liquid, or other known processes. In FIG. 1,
ultrasonic transmission assembly 11 includes an ultrasonic
end-effector, generally designated blade 12, and ultrasonic
transmission waveguide 14. Ultrasonic blade 12 and ultrasonic
transmission waveguide 14 are illustrated as a single unit
construction from a material suitable for transmission of
ultrasonic energy such as, for example, Ti6A14V (an alloy of
Titanium including Aluminum and Vanadium), Aluminum, Stainless
Steel, or other known materials. Alternately, blade 12 may be
separable (and of differing composition) from waveguide 14, and
coupled by, for example, a stud, welding, gluing, or other known
methods.
[0026] Ultrasonic transmission waveguide 14 is positioned in outer
sheath 16 by mounting o-ring 18 and sealing ring 20. One or more
additional dampers or support members (not shown) may also be
included along ultrasonic transmission waveguide 14. Ultrasonic
transmission waveguide 14 is affixed to outer sheath 16 by mounting
pin 21, that passes through mounting holes 23 in outer sheath 16
and mounting slot 25 in transmission waveguide 14.
[0027] FIG. 2 includes an ordinate system in which: the x-axis lies
along central axis 24 of ultrasonic transmission waveguide 14 while
the y-axis is the axis of curvature of treatment region 26. In the
embodiments of the invention described herein, blade 12 is affixed
to the distal end of transmission waveguide 14 at balance node 22.
Central axis 24 of transmission waveguide 14 extends from the
proximal end of transmission waveguide 14 to the distal end of
transmission waveguide 14. Blade 12 includes treatment region 26,
located at the distal end of blade 12. Treatment region 26 further
includes rounded tip 34.
[0028] Referring to FIG. 3, treatment region 26 includes one or
more cutting-edges 36. Cutting-edges 36 (only one shown) are
positioned on both sides of treatment region 26 and extend from the
proximal end of treatment region 26 to rounded tip 34. Treatment
region 26 includes atop surface 30 and a bottom surface 32. Top
surface 30 is substantially planar or flat along the z-axis of the
blade.
[0029] As illustrated in FIG. 4, bottom surface 32 includes
side-walls 33 and central ridge 37. Central ridge 37 runs from the
distal end of balance region 28 to rounded tip 34 along the center
of treatment region 26. Central ridge 37 adds strength, stiffness
and rigidity to treatment region 26.
[0030] In FIG. 5, central ridge 37 and side-walls 33 form the
substantial portion of bottom surface 32. Side-walls 33 originate
at central ridge 37 and terminate at cutting-surface 52.
Cutting-edge 36 is defined by the intersection of top surface 30
and cutting-surface 52 as shown in FIG. 10-A. Alternatively, top
surface 30 may include a second cutting-surface 54, whereby
cutting-edge 36 is defined by the intersection of second
cutting-surface 54 and cutting-surface 52, as illustrated in FIG.
10.
[0031] FIGS. 7 and 8 illustrate an alternate embodiment of the
present invention wherein top surface 300 does not include a second
cutting-surface. Treatment region 26 includes one or more
cutting-edges 360. Cutting-edges 360 are positioned on both sides
of treatment region 26 and extend from the proximal end of
treatment region 26 to rounded tip 340. Treatment region 26
includes a top surface 300 and a bottom surface 320. Top surface
300 is substantially planar or flat along the z-axis of the blade,
but may alternately be curvilinear. Cutting-edge 360 is defined by
the intersection of top surface 300 and cutting-surface 520.
[0032] In FIG. 9, treatment region 26 is a curved blade 31, having
a blade curvature A. In one embodiment of the present invention,
blade curvature A may be, for example, about 0.9 inches.+-.about
0.3 inches. Further, curved blade 31 may have a thickness R of
about 0.050 inches.+-.about 0.02 inches. Curved blade 31 may, in
one embodiment of the invention, include first radius of curvature
M and second radius of curvature S. In this embodiment of the
invention, first radius of curvature M and second radius of
curvature S act as first and second balance features respectively.
In one embodiment of the present invention, radius of curvature S
may be, for example, about 0.25 inches.+-.about 0.125 inches. In
the illustrated embodiment of the invention, curved blade 31 may
have a radius M of approximately about 0.750 inches.+-.about 0.749
inches. In one embodiment of the invention, curved blade 31 may
have a length G of approximately 1.0 inches.+-.about 0.5 inches
where G is measured from node point 22 to the distal end of curved
blade 31.
[0033] In the embodiment of the invention illustrated in FIG. 10,
top surface 30 has a width C of, for example, about 0.115
inches.+-.about 0.001 inches. Central ridge 37 has a width D of,
for example, about 0.030 inches.+-.about 0.003 inches. In the
embodiment of FIG. 10, the cross section of curved blade 31 is
formed by side-walls 33, central ridge 37, cutting-surface 52, and
top surface 30. Top surface 30 has a width about 0.004 inches wider
than the width of bottom surface 32, and preferably, about 0.010
inches wider than the width of bottom surface 32.
[0034] The cutting-edge 36 is seen in greater detail in FIG. 11.
Top surface 30 is beveled, or shaved, by second cutting-surface 54.
Second cutting-surface 54 intersects cutting-surface 52 with an
included angle of .alpha.. Angle a has a useful range of from about
10 to about 60 degrees, and is preferably within the range of about
25 to about 35 degrees. The width of cutting-surface 52 has a
useful range of from about 0.002 to about 0.060 inches, and is
preferably within the range of about 0.005 to about 0.020 inches.
Providing cutting-edges 36 with cutting-surface 52 has the
unexpected result of increasing the cutting speed of treatment
region 26 without compromising coagulation.
[0035] The embodiment of FIG. 12 illustrates an alternate way to
provide a cutting-surface to an ultrasonic blade in accordance with
the present invention. In this embodiment, side-wall 33 meets
second cutting-surface 54 through radial-cutting-surface 72. Radial
cutting-surface 72 may be formed by, for example, machining
side-wall 33 with a rounded cutting tool having a radius of
curvature 70. Angle .beta. is the angle between the tangent of
radial-cutting-surface 72 at edge 36 and second cutting-surface 54.
Angle .beta. has a useful range of from about 10 to about 60
degrees, and is preferably within the range of about 25 to about 35
degrees.
[0036] FIGS. 13 and 14 illustrate a method of deburring the edges,
including cutting-edges 36, of treatment region 26. Burrs are
fragments of material at the blade 31 edges due to the
manufacturing process. These burrs can cause inconsistent cutting
speed from blade to blade resulting in a lowered sense of precision
by the surgeon during use. It is desirable to remove the burrs to
provide consistent function from blade to blade. However, standard
deburring methods are less than optimal for preserving the
advantages of cutting-surface 52 on edge 36.
[0037] Normally burrs are removed by, for example, buffing,
sanding, or chemical etching. However standard deburring methods
may dull edge 36 and decrease the cutting speed of blade 31. A
novel approach to deburring ultrasonic devices such as blade 31 is
to use the tuned ultrasonic properties of the ultrasonic surgical
instrument 10 to deburr, as described below in conjunction with
FIGS. 13 and 14.
[0038] In FIG. 13, ultrasonic transmission assembly 11 is shown
acoustically coupled to hand-piece 56. Hand-piece 56 is
electrically connected to generator 60, which is activated by
foot-switch 58. Depressing foot-switch 58 activates generator 60,
and delivers electrical energy to hand-piece 56. Hand-piece 56
converts the electrical energy to ultrasonic motion of ultrasonic
transmission assembly 11 and treatment region 26. Treatment region
26 vibrates at an excursion magnitude of 20 micrometers to 150
micrometers, and at a frequency of approximately 55.5
kilohertz.
[0039] The method of deburring ultrasonically activated devices is
illustrated in FIG. 14 using, as an example, treatment region 26 of
the distal portion of ultrasonic surgical instrument 10. A jar 64,
including a lid 66, contains an abrasive material, or media 62. Lid
66 includes at least one opening 68, through which treatment region
26 is inserted into media 62. Activation of treatment region 26 in
media 62 deburrs treatment region 26 while maintaining desirable
qualities of treatment region 26.
[0040] Media 62 is an abrasive material. For example, media 62 may
include, either singly or in combinations, talc, crushed walnut
shells, crushed fired ceramics, glass beads, plastic, Aluminum
oxide, steel, sand, crushed champagne bottle glass, or other known
materials used for polishing, bead-blasting, sand-blasting, or the
like. For an ultrasonic surgical instrument such as treatment
region 26, it is preferable to use crushed champagne bottle glass
using particles of glass having a mesh size of from 10 to 40 mesh,
and most preferably 24 mesh. A mesh is a size of screen or of
particles passed by it in terms of the number of openings per
linear inch. A suitable media is Aluma Glass #24, available from N.
T. Ruddock, 26123 Broadway Ave., Cleveland, Ohio 44140.
[0041] Finer mesh media 62 produces a sand-blasted appearance
without removing large burrs from treatment region 26. Coarser mesh
media 62 removes large burrs from treatment region 26 and produces
an appealing finish without dulling the cutting-edges 36 and
compromising clinical efficacy. However, very course media does not
remove burrs and leaves the blade 31 with a scratched or damaged
surface appearance.
[0042] Short durations of blade 31 activation in media 62 knocks
off large burrs, while maintaining cutting-edge 36 sharpness due to
the motion of cutting-edges 36 preferred direction while in contact
with media 62. Two to twenty seconds of activation are sufficient
to remove all unwanted burrs without compromising sharpness,
depending on media type and mesh size. Longer durations of
activation will controllably decrease cutting-edge 36 radius, or
sharpness, to optimize desired treatment region 26 efficacy.
[0043] While preferred embodiments of the present invention have
been shown and described herein, it will be obvious to those
skilled in the art that such embodiments are provided by way of
example only. Numerous variations, changes, and substitutions will
now occur to those skilled in the art without departing from the
invention. Accordingly, it is intended that the invention be
limited only by the spirit and scope of the appended claims.
* * * * *