U.S. patent application number 13/274496 was filed with the patent office on 2012-05-10 for cam driven coupling between ultrasonic transducer and waveguide in surgical instrument.
Invention is credited to Stephen J. Balek, William D. Dannaher, Wells D. Haberstich, Kevin L. Houser, Matthew C. Miller, Scott A. Woodruff.
Application Number | 20120116262 13/274496 |
Document ID | / |
Family ID | 66810611 |
Filed Date | 2012-05-10 |
United States Patent
Application |
20120116262 |
Kind Code |
A1 |
Houser; Kevin L. ; et
al. |
May 10, 2012 |
CAM DRIVEN COUPLING BETWEEN ULTRASONIC TRANSDUCER AND WAVEGUIDE IN
SURGICAL INSTRUMENT
Abstract
A surgical instrument includes a body assembly, a waveguide, a
transducer, and a coupling assembly. In some versions the coupling
assembly translates the transducer to couple the transducer to the
waveguide. For instance, a gear having arcuate troughs may engage
pins on the transducer and/or waveguide to mate the transducer to
waveguide. A pawl may selectively engage and prevent rotation of
the gear. Alternatively, lever arms may cam the transducer into the
waveguide. The lever arms may selectively couple to a casing to
prevent decoupling of the transducer and waveguide. In another
configuration, a locking tab can be slid and locked into a slot to
couple the transducer and waveguide. Further still, levers with
self-locking pins may engage and couple the transducer to the
waveguide. In another version, a rotatable body portion may engage
a tab on the transducer to rotate and couple the transducer to the
waveguide.
Inventors: |
Houser; Kevin L.;
(Springboro, OH) ; Dannaher; William D.;
(Cincinnati, OH) ; Balek; Stephen J.; (Springboro,
OH) ; Haberstich; Wells D.; (Loveland, OH) ;
Miller; Matthew C.; (Cincinnati, OH) ; Woodruff;
Scott A.; (Boston, MA) |
Family ID: |
66810611 |
Appl. No.: |
13/274496 |
Filed: |
October 17, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61410603 |
Nov 5, 2010 |
|
|
|
61487846 |
May 19, 2011 |
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|
Current U.S.
Class: |
601/2 |
Current CPC
Class: |
A61B 2017/00119
20130101; H02J 7/0047 20130101; A61B 2017/00473 20130101; A61B
17/064 20130101; A61B 18/1206 20130101; A61B 18/1442 20130101; A61B
2017/320095 20170801; A61B 2018/00601 20130101; Y10T 29/53913
20150115; A61B 17/320092 20130101; A61B 18/1445 20130101; A61B
2017/291 20130101; Y02E 60/10 20130101; A61B 90/08 20160201; A61B
2017/320071 20170801; A61B 2050/0076 20160201; H01M 50/20 20210101;
A61B 17/2812 20130101; A61B 17/00234 20130101; A61B 2018/00178
20130101; A61B 2090/0807 20160201; H01M 2220/30 20130101; A61B
2017/00482 20130101; A61B 2018/126 20130101; A61B 2050/0067
20160201; Y10T 29/49005 20150115; A61B 46/10 20160201; A61B 50/30
20160201; A61B 2017/00734 20130101; A61B 2017/0084 20130101; A61B
2050/0065 20160201; A61B 2090/0803 20160201; A61B 2017/00398
20130101; A61B 2017/2933 20130101; A61B 2050/3008 20160201; A61B
17/285 20130101; A61B 2090/0814 20160201; Y10T 29/49895 20150115;
A61B 2017/320069 20170801; A61B 2018/1253 20130101; A61B 2018/00589
20130101; A61B 2018/00988 20130101; A61B 18/12 20130101; A61B 90/40
20160201; A61B 2034/2048 20160201; A61B 2017/2931 20130101; A61B
2018/1412 20130101; H02J 7/025 20130101; A61B 2017/0046 20130101;
A61B 2017/294 20130101; A61B 2018/00595 20130101; A61B 2018/00607
20130101; A61B 2018/1455 20130101; A61B 2050/005 20160201; A61B
18/14 20130101; A61B 18/00 20130101; H02J 7/0048 20200101; A61B
2017/00017 20130101; A61B 2017/00084 20130101; A61B 2034/254
20160201; A61B 2017/00221 20130101; A61N 7/00 20130101; H01M 10/46
20130101; A61B 2017/2929 20130101; A61B 2018/00702 20130101; H01M
10/425 20130101; H02J 7/0045 20130101; A61B 17/320068 20130101;
A61B 18/04 20130101; A61B 2017/00022 20130101; A61B 2017/00128
20130101; A61B 2050/008 20160201; A61B 2090/502 20160201; H02J
7/0044 20130101; A61B 2018/1226 20130101; G16H 40/63 20180101; A61B
2018/00791 20130101; A61B 2090/0813 20160201; A61B 2017/293
20130101; H01M 50/531 20210101; A61B 2050/3007 20160201; A61B
2090/372 20160201; A61B 34/25 20160201; A61B 2017/00477 20130101;
A61B 2017/320094 20170801; A61B 2018/0019 20130101; G16H 20/40
20180101; A61B 18/1233 20130101; H01M 10/48 20130101 |
Class at
Publication: |
601/2 |
International
Class: |
A61N 7/00 20060101
A61N007/00 |
Claims
1. A surgical instrument comprising: (a) a body assembly having a
casing, the casing at least partially defining a cavity therein;
(b) a waveguide; (c) a transducer comprising: i. a transducer body,
and ii. a distal coupling member, wherein the distal coupling
member is configured to couple the transducer to a proximal end of
the waveguide; and (d) a coupling assembly operable to couple the
distal coupling member of the transducer to the proximal end of the
waveguide; wherein the transducer is at least partially insertable
into the cavity of the casing; and wherein the coupling assembly is
operable to translate the transducer relative to the body
assembly.
2. The surgical instrument of claim 1 wherein the coupling assembly
comprises a troughed gear having a first trough formed on a side of
the troughed gear, wherein the troughed gear is rotatable relative
to the casing, wherein the transducer body comprises a first pin
extending outwardly from the transducer body, and wherein the first
pin is insertable into the first trough of the troughed gear.
3. The surgical instrument of claim 2 wherein the troughed gear
comprises a second trough formed on the side of the troughed gear,
wherein the waveguide comprises a second pin extending outwardly
from the waveguide, and wherein the second pin is insertable into
the second trough of the troughed gear.
4. The surgical instrument of claim 3 wherein the first trough is
operable to translate the transducer distally and the second trough
is operable to translate the waveguide proximally in response to
rotation of the troughed gear.
5. The surgical instrument of claim 2 wherein the troughed gear
comprises gear teeth formed on a circumferential surface of the
troughed gear, wherein the body assembly comprises a pawl, and
wherein the pawl is selectively engageable with the gear teeth.
6. The surgical instrument of claim 2 wherein the first trough
comprises an arcuate portion, and wherein the arcuate portion
comprises a channel curving inwardly toward an axial center of the
troughed gear.
7. The surgical instrument of claim 1 wherein the proximal end of
the waveguide comprises a conical recess, wherein the distal
coupling member of the transducer comprises a cone, wherein the
coupling assembly is operable to translate the transducer distally
to engage the cone with the conical recess.
8. The surgical instrument of claim 1 wherein the coupling assembly
comprises a lever arm pivotably coupled to the casing, wherein the
lever arm comprises a distally camming portion, and wherein the
distally camming portion is operable to distally translate the
transducer.
9. The surgical instrument of claim 8 wherein the lever arm further
comprises a proximally camming portion, and wherein the proximally
camming portion is operable to proximally translate the
transducer.
10. The surgical instrument of claim 8 wherein the lever arm is
selectively coupleable to the casing.
11. The surgical instrument of claim 8 comprising a second lever
arm pivotably coupled to the casing and disposed on an opposite
side of the casing.
12. The surgical instrument of claim 1 wherein the transducer body
comprises a locking tab extending radially outward from the
transducer body, wherein the body assembly comprises a ramped cam
slot formed in a side of the casing at least partially defining the
cavity, and wherein the ramped cam slot is configured to secure the
locking tab relative to the body assembly.
13. The surgical instrument of claim 12 wherein the ramped cam slot
comprises an opening portion, a transition portion, and a locking
portion, wherein the locking portion is distal of the opening
portion, and wherein the transition portion links the opening
portion with the locking portion such that the locking tab is
actuatable along the transition portion from the opening portion to
the locking portion.
14. The surgical instrument of claim 13 wherein the locking portion
comprises a detent, wherein the detent is configured to
substantially secure the locking tab within the locking portion
when the locking tab is rotated past the detent.
15. The surgical instrument of claim 13 wherein the distal coupling
member of the transducer couples to the proximal end of the
waveguide when the locking tab is actuated along the transition
portion.
16. A surgical instrument comprising: (a) a casing; (b) a waveguide
having a proximal end, wherein the proximal end comprises a
longitudinal recess and a first transaxial hole transecting the
longitudinal recess; (c) a transducer comprising a horn insertable
into the longitudinal recess and a second transaxial hole; (d) a
first pin and lever assembly comprising: i. a first lever rotatably
coupled to the casing, and ii. a first pin portion actuatable by
the first lever; and (e) a second pin and lever assembly
comprising: i. a second lever rotatably coupled to the casing, and
ii. a second pin portion actuatable by the second lever; wherein
the first pin portion and the second pin portion are operable to
selectively couple the transducer to the waveguide via insertion
into the first transaxial hole and the second transaxial hole.
17. The surgical instrument of claim 16 wherein the first pin
portion comprises a first pin end having a first ramped portion,
and wherein the second pin portion comprising a second pin end
having a second ramped portion.
18. The surgical instrument of claim 17 wherein the first ramped
portion is defined by a first angle, wherein the second ramped
portion is defined by a second angle, and wherein the first angle
and the second angle are alternate interior angles such that second
ramped portion and first ramped portion are parallel planar
portions.
19. A surgical instrument comprising: (a) a body assembly
comprising: i. a first body portion having a transducer recess, and
ii. a second body portion comprising: (1) a notch, and (2) a
rotatable hinge coupling the first body portion to the second body
portion; (b) a waveguide coupled to the first body portion; and (c)
a transducer comprising a tab configured to insert into the notch;
wherein the transducer is configured to couple to the waveguide
when the second body portion is rotated about the first body
portion via the rotatable hinge and the tab is inserted into the
notch.
20. The surgical instrument of claim 19 wherein the rotatable hinge
is operable to rotate the second body portion from 0 to 180 degrees
relative to the first body portion.
Description
PRIORITY
[0001] This application claims priority to U.S. Provisional
Application Ser. No. 61/410,603, filed Nov. 5, 2010, entitled
"Energy-Based Surgical Instruments," the disclosure of which is
incorporated by reference herein.
[0002] This application also claims priority to U.S. Provisional
Application Ser. No. 61/487,846, filed May 19, 2011, entitled
"Energy-Based Surgical Instruments," the disclosure of which is
incorporated by reference herein.
BACKGROUND
[0003] In some settings, endoscopic surgical instruments may be
preferred over traditional open surgical devices since a smaller
incision may reduce the post-operative recovery time and
complications. Consequently, some endoscopic surgical instruments
may be suitable for placement of a distal end effector at a desired
surgical site through a cannula of a trocar. These distal end
effectors may engage tissue in a number of ways to achieve a
diagnostic or therapeutic effect (e.g., endocutter, grasper,
cutter, stapler, clip applier, access device, drug/gene therapy
delivery device, and energy delivery device using ultrasound, RF,
laser, etc.). Endoscopic surgical instruments may include a shaft
between the end effector and a handle portion, which is manipulated
by the clinician. Such a shaft may enable insertion to a desired
depth and rotation about the longitudinal axis of the shaft,
thereby facilitating positioning of the end effector within the
patient.
[0004] Examples of endoscopic surgical instruments include those
disclosed in U.S. Pat. Pub. No. 2006/0079874, entitled "Tissue Pad
for Use with an Ultrasonic Surgical Instrument," published Apr. 13,
2006, the disclosure of which is incorporated by reference herein;
U.S. Pat. Pub. No. 2007/0191713, entitled "Ultrasonic Device for
Cutting and Coagulating," published Aug. 16, 2007, the disclosure
of which is incorporated by reference herein; U.S. Pat. Pub. No.
2007/0282333, entitled "Ultrasonic Waveguide and Blade," published
Dec. 6, 2007, the disclosure of which is incorporated by reference
herein; U.S. Pat. Pub. No. 2008/0200940, entitled "Ultrasonic
Device for Cutting and Coagulating," published Aug. 21, 2008, the
disclosure of which is incorporated by reference herein; U.S. Pat.
Pub. No. 2011/0015660, entitled "Rotating Transducer Mount for
Ultrasonic Surgical Instruments," published Jan. 20, 2011, the
disclosure of which is incorporated by reference herein; U.S. Pat.
No. 6,500,176, entitled "Electrosurgical Systems and Techniques for
Sealing Tissue," issued Dec. 31, 2002, the disclosure of which is
incorporated by reference herein; and U.S. Pat. Pub. No.
2011/0087218, entitled "Surgical Instrument Comprising First and
Second Drive Systems Actuatable by a Common Trigger Mechanism,"
published Apr. 14, 2011, the disclosure of which is incorporated by
reference herein. Additionally, such surgical tools may include a
cordless transducer such as that disclosed in U.S. Pat. Pub. No.
2009/0143797, entitled "Cordless Hand-held Ultrasonic Cautery
Cutting Device," published Jun. 4, 2009, the disclosure of which is
incorporated by reference herein. In addition, the surgical
instruments may be used, or adapted for use, in robotic-assisted
surgery settings such as that disclosed in U.S. Pat. No. 6,783,524,
entitled "Robotic Surgical Tool with Ultrasound Cauterizing and
Cutting Instrument," issued Aug. 31, 2004.
[0005] While several systems and methods have been made and used
for surgical instruments, it is believed that no one prior to the
inventors has made or used the invention described in the appended
claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] While the specification concludes with claims which
particularly point out and distinctly claim this technology, it is
believed this technology will be better understood from the
following description of certain examples taken in conjunction with
the accompanying drawings, in which like reference numerals
identify the same elements and in which:
[0007] FIG. 1 depicts a perspective view of an exemplary surgical
system having a surgical instrument and a generator;
[0008] FIG. 2 depicts partial side view of an exemplary
transmission assembly and an exemplary transducer having a conical
coupling;
[0009] FIG. 3 depicts a side view of an exemplary troughed gear
showing a pair of troughs, gear teeth, and a pawl;
[0010] FIG. 4A depicts a top view of an exemplary coupling
mechanism utilizing the transmission assembly and transducer of
FIG. 2 and the troughed gear of FIG. 3 shown in an unlocked
position;
[0011] FIG. 4B depicts a top view of the coupling mechanism of FIG.
4A shown in a locked position;
[0012] FIG. 5 depicts a side view of an exemplary alternative
coupling mechanism having an actuatable sled;
[0013] FIG. 6A depicts a partial top cross-sectional view of
another exemplary coupling mechanism having a self-locking pin
assembly and shown in an unlocked position;
[0014] FIG. 6B depicts a partial top cross-sectional view of the
coupling mechanism of FIG. 6A shown in a locked position;
[0015] FIG. 7 depicts an enlarged top view of a wheel of the
locking pin assembly of FIG. 6A;
[0016] FIG. 8A depicts a side view of another exemplary coupling
mechanism for coupling a transducer unit to a waveguide and a
handle assembly, showing the transducer unit unlocked;
[0017] FIG. 8B depicts a side view of the coupling mechanism of
FIG. 8A, showing the transducer unit coupled to the waveguide and
locked into the handle assembly;
[0018] FIG. 9 depicts a side cross-sectional view of yet another
coupling mechanism for an exemplary alternative transducer unit and
handle assembly, showing the transducer unit in an unlocked
position;
[0019] FIG. 10 depicts a top view of an exemplary transducer,
forked portion of a trigger, and transmission assembly of the
instrument shown in FIG. 9;
[0020] FIG. 11A depicts a top view of the instrument of FIG. 9 with
a portion of the casing removed and showing the transducer unit
inserted, but in an unlocked position;
[0021] FIG. 11B depicts a top view of the instrument of FIG. 11A
showing the transducer unit in a locked position;
[0022] FIG. 12 depicts a left side view of an exemplary rotatable
clamshell handle assembly shown in an open position;
[0023] FIG. 13 depicts a right side view of the clamshell handle
assembly of FIG. 12; and
[0024] FIG. 14 depicts a rear view of the clamshell handle assembly
of FIG. 12.
[0025] The drawings are not intended to be limiting in any way, and
it is contemplated that various embodiments of the technology may
be carried out in a variety of other ways, including those not
necessarily depicted in the drawings. The accompanying drawings
incorporated in and forming a part of the specification illustrate
several aspects of the present technology, and together with the
description serve to explain the principles of the technology; it
being understood, however, that this technology is not limited to
the precise arrangements shown.
DETAILED DESCRIPTION
[0026] The following description of certain examples of the
technology should not be used to limit its scope. Other examples,
features, aspects, embodiments, and advantages of the technology
will become apparent to those skilled in the art from the following
description, which is by way of illustration, one of the best modes
contemplated for carrying out the technology. As will be realized,
the technology described herein is capable of other different and
obvious aspects, all without departing from the technology.
Accordingly, the drawings and descriptions should be regarded as
illustrative in nature and not restrictive.
[0027] I. Overview of Exemplary Ultrasonic Surgical System
[0028] FIG. 1 shows an exemplary ultrasonic surgical system (10)
comprising an ultrasonic surgical instrument (50), a generator
(20), and a cable (30) coupling generator (20) to surgical
instrument (50). In some versions, generator (20) comprises a GEN
300 sold by Ethicon Endo-Surgery, Inc. of Cincinnati, Ohio. By way
of example only, generator (20) may be constructed in accordance
with the teachings of U.S. Pub. No. 2011/0087212, entitled
"Surgical Generator for Ultrasonic and Electrosurgical Devices,"
published Apr. 14, 2011, the disclosure of which is incorporated by
reference herein. While surgical instrument (50) is described
herein as an ultrasonic surgical instrument, it should be
understood that the teachings herein may be readily applied to a
variety of surgical instruments, including but not limited to
endocutters, graspers, cutters, staplers, clip appliers, access
devices, drug/gene therapy delivery devices, and energy delivery
devices using ultrasound, RF, laser, etc., and/or any combination
thereof as will be apparent to one of ordinary skill in the art in
view of the teachings herein. Moreover, while the present example
will be described in reference to a cable-connected surgical
instrument (50), it should be understood that surgical instrument
(50) may be adapted for cordless operation, such as that disclosed
in U.S. Pat. Pub. No. 2009/0143797, entitled "Cordless Hand-held
Ultrasonic Cautery Cutting Device," published Jun. 4, 2009, the
disclosure of which is incorporated by reference herein. For
instance, surgical device (50) may include an integral and portable
power source such as a battery, etc. Furthermore, surgical device
(50) may also be used, or adapted for use, in robotic-assisted
surgery settings such as that disclosed in U.S. Pat. No. 6,783,524,
entitled "Robotic Surgical Tool with Ultrasound Cauterizing and
Cutting Instrument," issued Aug. 31, 2004.
[0029] Surgical instrument (50) of the present example includes a
multi-piece handle assembly (60), an elongated transmission
assembly (70), and a transducer (100). Transmission assembly (70)
is coupled to multi-piece handle assembly (60) at a proximal end of
transmission assembly (70) and extends distally from multi-piece
handle assembly (60). In the present example, transmission assembly
(70) is configured as an elongated, thin tubular assembly for
endoscopic use, but it should be understood that transmission
assembly (70) may alternatively be a short assembly, such as those
disclosed in U.S. Pat. Pub. No. 2007/0282333, entitled "Ultrasonic
Waveguide and Blade," published Dec. 6, 2007, and U.S. Pat. Pub.
No. 2008/0200940, entitled "Ultrasonic Device for Cutting and
Coagulating," published Aug. 21, 2008, the disclosures of which are
incorporated by reference herein. Transmission assembly (70) of the
present example comprises an outer sheath (72), an inner tubular
actuating member (not shown), a waveguide (not shown), and an end
effector (80) located on the distal end of transmission assembly
(70). In the present example, end effector (80) comprises a blade
(82) that is mechanically and acoustically coupled to the
waveguide, a clamp arm (84) operable to pivot at the proximal end
of transmission assembly (70), and a clamp pad (86) coupled to
clamp arm (84). In some versions, transducer (100) comprises a
plurality of piezoelectric elements (not shown) that are compressed
between a first resonator (not shown) and a second resonator (not
shown) to form a stack of piezoelectric elements. The piezoelectric
elements may be fabricated from any suitable material, for example,
lead zirconate-titanate, lead meta-niobate, lead titanate, and/or
any suitable piezoelectric crystal material, for example.
[0030] Transducer (100) further comprises electrodes, including at
least one positive electrode and at least one negative electrode,
that are configured to create a voltage potential across the one or
more piezoelectric elements, such that the piezoelectric elements
convert the electrical power into ultrasonic vibrations. When
transducer (100) of the present example is activated, transducer
(100) is operable to create linear oscillations or vibrations
(e.g., torsional or transverse, etc.) at an ultrasonic frequency
(such as 55.5 kHz). When transducer (100) is coupled to
transmission assembly (70), these linear oscillations are
transmitted through the internal waveguide of transmission assembly
(70) to end effector (80). In the present example, with blade (82)
being coupled to the waveguide, blade (82) thereby oscillates at
the ultrasonic frequency. Thus, when tissue is secured between
blade (82) and clamp arm (84), the ultrasonic oscillation of blade
(82) may simultaneously sever the tissue and denature the proteins
in adjacent tissue cells, thereby providing a coagulative effect
with relatively little thermal spread. An electrical current may
also be provided through blade (82) and clamp arm (84) to cauterize
the tissue. One merely exemplary suitable ultrasonic transducer
(100) is Model No. HP054, sold by Ethicon Endo-Surgery, Inc. of
Cincinnati, Ohio, though it should be understood that any other
suitable transducer may be used. It should also be understood that
clamp arm (84) and associated features may be constructed and
operable in accordance with at least some of the teachings of U.S.
Pat. No. 5,980,510, entitled "Ultrasonic Clamp Coagulator Apparatus
Having Improved Clamp Arm Pivot Mount," issued Nov. 9, 1999, the
disclosure of which is incorporated by reference herein.
[0031] Multi-piece handle assembly (60) of the present example
comprises a mating housing portion (62) and a lower portion (64).
Mating housing portion (62) defines a cavity within multi-piece
handle assembly (60) and is configured to receive transducer (100)
at a proximal end of mating housing portion (62) and to receive the
proximal end of transmission assembly (70) at a distal end of
mating housing portion (62). A rotation knob (66) is shown in the
present example to rotate transmission assembly (70) and transducer
(100), but it should be understood that rotation knob (66) is
merely optional. Lower portion (64) of multi-piece handle assembly
(60) shown in FIG. 1 includes a trigger (68) and is configured to
be grasped by a user using a single hand. One merely exemplary
alternative version for lower portion (64) is depicted in FIG. 1 of
U.S. Pat. Pub. No. 2011/0015660, entitled "Rotating Transducer
Mount for Ultrasonic Surgical Instruments," published Jan. 20,
2011, the disclosure of which is incorporated by reference herein.
Toggle buttons (69), shown in FIG. 2 of the present disclosure, are
located on a distal surface of lower portion (64) and are operable
to selectively activate transducer (100) at different operational
levels using generator (20). For instance, a first toggle button
(69) may activate transducer (100) at a maximum energy level while
a second toggle button (69) may activate transducer (100) at a
minimum, non-zero energy level. Of course, toggle buttons (69) may
be configured for energy levels other than a maximum and/or minimum
energy level as will be apparent to one of ordinary skill in the
art in view of the teachings herein. Furthermore, any other number
of toggle buttons may be provided.
[0032] While multi-piece handle assembly (60) has been described in
reference to two distinct portions (62, 64), it should be
understood that multi-piece handle assembly (60) may be a unitary
assembly with both portions (62, 64) combined. Multi-piece handle
assembly (60) may alternatively be divided into multiple discrete
components, such as a separate trigger portion (operable either by
a user's hand or foot) and a separate mating housing portion (62).
Such a trigger portion may be operable to activate transducer (100)
and may be remote from mating housing portion (62). Multi-piece
handle assembly (60) may be constructed from a durable plastic
casing (61) (such as polycarbonate or a liquid crystal polymer),
ceramics, metals and/or any other suitable material as will be
apparent to one of ordinary skill in the art in view of the
teachings herein. Other configurations for multi-piece handle
assembly (60) will also be apparent to those of ordinary skill in
the art in view of the teachings herein. For instance, in some
versions trigger (68) may be omitted and surgical instrument (50)
may be activated by a controlled of a robotic system. In other
versions, surgical instrument (50) may be activated when coupled to
generator (20).
[0033] Further still, surgical instrument (50) may be constructed
in accordance with at least some of the teachings of U.S. Pat. No.
5,322,055 entitled "Clamp Coagulator/Cutting System for Ultrasonic
Surgical Instruments," issued Jun. 21, 1994, the disclosure of
which is incorporated by reference herein; U.S. Pat. No. 5,873,873
entitled "Ultrasonic Clamp Coagulator Apparatus Having Improved
Clamp Mechanism," issued Feb. 23, 1999, the disclosure of which is
incorporated by reference herein; U.S. Pat. No. 5,980,510, entitled
"Ultrasonic Clamp Coagulator Apparatus Having Improved Clamp Arm
Pivot Mount," filed Oct. 10, 1997, the disclosure of which is
incorporated by reference herein; U.S. Pat. No. 6,325,811 entitled
"Blades with Functional Balance Asymmetries for use with Ultrasonic
Surgical Instruments," issued Dec. 4, 2001, the disclosure of which
is incorporated by reference herein; U.S. Pub. No. 2006/0079874
entitled "Tissue Pad for Use with an Ultrasonic Surgical
Instrument," published Apr. 13, 2006, the disclosure of which is
incorporated by reference herein; U.S. Pub. No. 2007/0191713
entitled "Ultrasonic Device for Cutting and Coagulating," published
Aug. 16, 2007, the disclosure of which is incorporated by reference
herein; U.S. Pub. No. 2007/0282333 entitled "Ultrasonic Waveguide
and Blade," published Dec. 6, 2007, the disclosure of which is
incorporated by reference herein; U.S. Pub. No. 2008/0200940
entitled "Ultrasonic Device for Cutting and Coagulating," published
Aug. 21, 2008, the disclosure of which is incorporated by reference
herein; U.S. Pub. No. 2009/0143797, entitled "Cordless Hand-held
Ultrasonic Cautery Cutting Device," published Jun. 4, 2009, the
disclosure of which is incorporated by reference herein; U.S. Pub.
No. 2010/0069940 entitled "Ultrasonic Device for Fingertip
Control," published Mar. 18, 2010, the disclosure of which is
incorporated by reference herein; U.S. Pub. No. 2011/0015660,
entitled "Rotating Transducer Mount for Ultrasonic Surgical
Instruments," published Jan. 20, 2011, the disclosure of which is
incorporated by reference herein; and/or U.S. Provisional
Application Ser. No. 61/410,603, filed Nov. 5, 2010, entitled
"Energy-Based Surgical Instruments," the disclosure of which is
incorporated by reference herein.
[0034] It is further understood that any one or more of the
teachings, expressions, embodiments, examples, etc. described
herein may be combined with any one or more of the other teachings,
expressions, embodiments, examples, etc. that are described herein.
The following-described teachings, expressions, embodiments,
examples, etc. should therefore not be viewed in isolation relative
to each other. Various suitable ways in which the teachings herein
may be combined will be readily apparent to those of ordinary skill
in the art in view of the teachings herein. Such modifications and
variations are intended to be included within the scope of the
claims.
[0035] II. Exemplary Coupling Mechanisms for Ultrasonic Surgical
Instrument
[0036] In some instances it may be useful to selectively couple
transducer (100) to transmission assembly (70) without using a
torque wrench to tighten transducer (100) onto transmission
assembly (70). For instance, various mechanical couplings may be
implemented that, when cammed or actuated into a locked position,
ensure an adequate acoustic coupling of transducer (100) to
transmission assembly (70) to permit energy transmission from
transducer (100) to blade (82) of end effector (80). Such
mechanical couplings may also permit a user to quickly connect
and/or disconnect transducer (100) and/or transmission assembly
(70) from each other and/or from multi-piece handle assembly (60).
In addition, a user may only need to ensure that the coupling
mechanism is in the locked position to ensure a sufficient
connection, instead using a torque wrench to determine the proper
torque. Furthermore, such coupling mechanisms may permit
multi-piece handle assembly (60), transmission assembly (70) and/or
transducer (100) to be reusable and/or interchangeable.
Accordingly, surgical instruments (50) incorporating such coupling
mechanisms may be preferable to some users.
[0037] A. Exemplary Pin and Troughed Gear Coupling Mechanism
[0038] FIGS. 2-4B show an exemplary pin and troughed gear coupling
mechanism configured to couple a waveguide (150) to a transducer
(160). FIG. 2 depicts an exemplary waveguide (150) and an exemplary
transducer (160) configured to couple together via a cone (162) and
a conical recess (152) (shown in phantom). Waveguide (150) of the
present example comprises a conical recess (152) formed in the
proximal end and a pin hole (154) through which a first pin (194),
shown in FIGS. 4A-4B, may be inserted. Pin hole (154) is located on
waveguide (150) at a location corresponding to a node of waveguide
(150). A node is a point where the displacement due to the
ultrasonic vibrations transmitted through waveguide (150) is at
zero. In the present example, waveguide (150) comprises a titanium
rod extending though a transmission assembly, such as transmission
assembly (70), and terminating with an end effector, such as end
effector (80), at a distal end. In some versions, the end effector
includes a blade and a clamp arm to simultaneously sever the tissue
and denature the proteins in adjacent tissue cells, thereby
providing a coagulative effect with relatively little thermal
spread. In other versions, the end effector may only include a
blade. Still other configurations for the end effector will be
apparent to one of ordinary skill in the art in view of the
teachings herein.
[0039] Transducer (160) of the present example comprises a
plurality of piezoelectric elements (164) that are compressed
between a first resonator (165) and a second resonator (166) to
form a stack of piezoelectric elements. First resonator (165) of
the present example further comprises a pin hole (168) through
which a second pin (196), shown in FIGS. 4A-4B, may be inserted.
Pin hole (168) is located on first resonator (165) at a location
corresponding to a node of transducer (160). A node is a point
where the displacement due to the ultrasonic vibrations transmitted
through transducer (160) is at zero. The piezoelectric elements
(164) may be fabricated from any suitable material, for example,
lead zirconate-titanate, lead meta-niobate, lead titanate, and/or
any suitable piezoelectric crystal material. Transducer (160)
further comprises electrodes (not shown), including at least one
positive electrode and at least one negative electrode, that are
configured to create a voltage potential across the plurality of
piezoelectric elements (164), such that the plurality of
piezoelectric elements (164) convert the electrical power into
ultrasonic vibrations. A distal horn (169) terminates with a cone
(162) at the distal end. Cone (162) is sized and configured to
insert into conical recess (152) of waveguide (150) to couple
transducer (160) to waveguide (150). Other versions may include a
hemisphere and hemispherical recess for transducer (160) and
waveguide (150), respectively. Of course, cone (162) and conical
recess (152) may be omitted and transducer (160) may simply abut
against waveguide (150). In the present example, the interface
between cone (162) and conical recess (152) is located at a node,
though this is merely optional. Indeed, in some versions the
interface may be at an antinode, where the displacement due to the
ultrasonic vibrations transmitted through transducer (160) is at a
maximum, or at a point between a node and antinode. Still other
configurations for coupling waveguide (150) to transducer (160) may
include those disclosed in U.S. Pat. No. 6,051,010, entitled
"Methods and Devices for Joining Transmission Components," issued
Apr. 18, 2000. Still other configurations for transducer (160)
and/or waveguide (150) will be apparent to one of ordinary skill in
the art in view of the teachings herein. For instance, pin holes
(154, 168) may be omitted and the pins may be integrally formed on
waveguide (150) and/or first resonator (165). Alternatively, the
pins may extend out from an outer sheath covering waveguide (150)
and/or transducer (160). In such a version, the pins may be
isolated from the acoustic components of waveguide (150) and/or
transducer (160).
[0040] FIG. 3 depicts an exemplary troughed gear (170) and a pawl
(190). Troughed gear (170) comprises a first half (172) having a
pair of troughs (174) formed therein. In the present example,
troughs (174) extend only partially into troughed gear (170),
though it should be understood that in other versions troughs (174)
may extend entirely through troughed gear (170). Troughs (174) of
the present example include an entrance portion (176) and an
arcuate portion (180). Entrance portion (176) is a substantially
straight channel formed in first half (172) having an open end
(178) configured to receive a portion of pin (194, 196), shown in
FIGS. 4A-4B. Arcuate portions (180) are curved channels that curve
inwardly towards the center of troughed gear (170). Arcuate
portions (180) of the present example are designed to guide pin
(194, 196) within arcuate portion (180) inwardly along the
curvature of arcuate portion (180) as troughed gear (170) is
rotated. The movement of pins (194, 196) within arcuate portions
(180) will be described in greater detail below. Referring to FIG.
4A, troughed gear (170) further comprises a second half (182)
fixedly coupled to first half (172) via an axle (184). A gap (186)
between first half (172) and second half (182) permits troughed
gear (170) to be coupled to a casing, such as casing (61), with
second half (182) located on the outside of the casing and first
half (172) located on the inside of the casing. Second half (182)
further comprises a plurality of teeth (188) circumferentially
disposed about second half (182). Referring back to FIG. 3, pawl
(190) is also shown having teeth (192) that complement teeth (188)
such that pawl (190) engages and restricts the rotation of troughed
gear (170). In the example shown in FIGS. 4A-4B, pawl (190) is a
rotatable member coupled to the casing that includes a lever
portion (not shown) and a return spring (not shown) to selectively
disengage pawl (190) from troughed gear (170). The return spring
biases pawl (190) into engagement with teeth (188). In some
versions a slidable or translatable member having teeth may engage
teeth (188) to prevent rotation of troughed gear (170). Still other
configurations for troughed gear (170) and/or pawl (190) will be
apparent to one of ordinary skill in the art in view of the
teachings herein.
[0041] FIG. 4A depicts waveguide (150) and transducer (160) with
pins (194, 196) inserted through pin holes (154, 168), shown in
FIG. 2, and extending into troughs (174) (shown in phantom) of a
pair of opposing troughed gears (170). In the present example,
first halves (172) of troughed gears (170) are located within the
casing and second halves (182) are located on the exterior of the
casing. Axles (184) extend through openings in the casing to couple
first and second halves (172, 182) together. Pawls (190) are also
located on the exterior of the casing and are configured to
selectively engage teeth (188) of troughed gears (170). As shown,
pins (194, 196) extend through transducer (160) and waveguide (150)
and are inserted through open ends (178) of troughs (174). It
should be understood that open ends (178) of troughs (174) permit
both waveguide (150) and transducer (160) to be decoupled from
troughed gear (170). For instance, waveguide (150) may be a
disposable component and transducer (160) may be a reusable
component such that decoupling waveguide (150) permits a user to
dispose of waveguide (150) and decoupling transducer (160) permits
a user to reuse transducer (160) with other surgical instruments.
Such removable components may also allow a user to reuse the handle
assembly for other procedures as well. Of course, waveguide (150)
and/or transducer (160) may instead be non-removable and troughs
(174) may instead have closed ends to retain pins (194, 196)
therein. In the example shown in FIG. 4A, transducer (160) and
waveguide (150) are shown decoupled and in an unlocked
position.
[0042] When a user desires to couple transducer (160) to waveguide
(150), the user rotates troughed gears (170). A lever (not shown)
or finger grips may be included on troughed gear (170) to aid the
user's rotation of troughed gear (170). Alternatively, a user may
simply grasp and rotate second half (182) to rotate troughed gears
(170). As the user rotates troughed gears (170), pins (194, 196)
engage arcuate portions (180) of troughs (174) and are cammed
radially inward by arcuate portions (180). As pins (194, 196) are
cammed radially inward, transducer (160) translates distally and
waveguide (150) simultaneously translates proximally. The user
continues to rotate troughed gears (170) to engage cone (162) with
conical recess (152) (shown in phantom). In the present example,
arcuate portions (180) terminate at a predetermined point
calculated to provide a sufficient compression between transducer
(160) and waveguide (150) to ensure that cone (162) adequately
couples with conical recess (152) to transmit the ultrasonic
vibrations produced by the stacks of piezoelectric elements (164)
to waveguide (150). In other versions, arcuate portions (180) may
continue to spiral inwardly on troughed gears (170) to permit a
user to tighten transducer (160) to waveguide (150) as desired.
[0043] FIG. 4B shows a locked position for the present coupling
mechanism showing transducer (160) engaged and coupled to waveguide
(150). In the present example, pawls (190) are selectively engaged
with teeth (188) of troughed gears (170) to prevent troughed gears
(170) from rotating. Accordingly, troughed gears (170), pawls
(190), and pins (194, 196) of the present example provide a
coupling mechanism for coupling transducer (160) to waveguide
(150).
[0044] When a user desires to detach transducer (160) and/or
waveguide (150), the user disengages pawls (190) from teeth (188)
of troughed gears (170). The user may then pull out transducer
(160) and/or waveguide (150) (effectively rotating troughed gears
(170) via pins (194, 196) and arcuate portions (180)) or rotate
troughed gears (170) until pins (194, 196) can be removed through
open ends (178) of troughs (174). In some versions, troughed gears
(170) may include a torsion spring (not shown) that is biased to
rotate troughed gears (170) toward the unlocked position once pawl
(190) is disengaged. Thus, a user may quickly connect transducer
(160) to waveguide (150) and also ensure an adequate connection
between transducer (160) and waveguide (150) by using the pin and
troughed gear coupling mechanism described herein.
[0045] Of course other configurations for a pin and troughed gear
coupling mechanism will be apparent to one of ordinary skill in the
art in view of the teachings herein. For instance, a single
troughed gear (170) may be used instead of a pair of troughed gears
(170). Alternatively, troughed gears (170) may be mechanically
coupled together, either directly through an axle or indirectly
through additional gears, to concurrently rotate both troughed
gears (170). Further still, troughed gears (170) may be located
entirely within casing (61) and a key hole (not shown) may be
provided to permit a user to insert a geared key to rotate one or
both troughed gears (170). Such a key hole and gearing may be
configured in similar fashion to the keys used for winding clocks.
Further still, troughed gears (170), transducer (160), and
waveguide (150) may be contained within a separate casing that is
rotatable relative to a main handle assembly. Such a casing may be
mounted to the main handle assembly via bearings to permit the
rotation of waveguide (150), transducer (160), troughed gears
(170), and/or any other components relative to the main handle
assembly. Still further configurations will be apparent to one of
ordinary skill in the art in view of the teachings herein.
[0046] B. Exemplary Sled Coupling Mechanism
[0047] FIG. 5 shows an exemplary sled coupling mechanism for a
handle assembly having a casing (210) and configured to couple
waveguide (150) to transducer (160) shown and described previously
in reference to FIG. 2. In the present example, a sled member (200)
includes a pair of U-shaped members (202) configured to receive the
ends of pin (196) that extend outwardly from transducer (160). It
should be understood that, while a single U-shaped member (202) is
shown, a second U-shaped member (202) is located on the opposite
side of transducer (160) and is identical to U-shaped member (202)
shown. In some versions, U-shaped members (202) may include a
resilient snap fastener (not shown) configured to receive and snap
the ends of pin (196) into U-shaped members (202), thereby further
securing transducer (160) to sled member (200). In addition or in
the alternative, U-shaped members (202) may include and/or be
coupled to sled member (200) by a resiliently biased member (such
as a spring) and/or a force limiting member (not shown).
Accordingly, when sled member (200) slidably engages transducer
(160) with waveguide (150), the resiliently biased member and/or
force limiting member may ensure that the engagement forces between
transducer (160) and waveguide (150) are not too high. Of course
such resiliently biased member and/or force limiting member may be
located anywhere else, including, but not limited to, on waveguide
(150) on transducer (160), on pillar (230) (described below),
and/or elsewhere.
[0048] An actuation arm (220) is coupled to a distal end of sled
member (200) by a first axle (222). A second axle (224) couples
actuation arm (220) to casing (210) to provide a pivot point about
which actuation arm (220) rotates. Actuation arm (220) further
includes a handle portion (226) that a user uses to rotate
actuation arm (220), as will be described in more detail below.
Handle portion (226) includes a recess (228) into which a latch
(240) is selectively insertable. Latch (240) includes a
spring-loaded camming member and a slidable release to selectively
decouple the spring-loaded camming member from handle portion
(226). A pair of pillars (230) are located distally of sled member
(200) and include a notch (232). It should also be understood that
while a single pillar (230) is shown, a pillar (230) is located on
the opposite side of waveguide (150) and is identical to pillar
(230) shown. Pillars (230) are fixedly attached to casing (210) and
notches (232) are configured to receive the ends of pin (194).
Notches (232) may also include a resilient snap fastener configured
to receive and snap the ends of pin (194) into notch (232). It
should be understood that in some versions, waveguide (150) and pin
(194) may be affixed to pillar (230) such that waveguide (150) is
not removable. Still other configurations for sled member (200) and
pillar (230) will be apparent to one of ordinary skill in the art
in view of the teachings herein.
[0049] Initially, a user couples waveguide (150) to pillars (230)
by inserting the ends of pin (194) into notches (232). Pin (196) of
transducer (160) is then inserted into U-shaped members (202) of
sled member (200). With waveguide (150) prevented from translating
distally by notches (232) and transducer (160) longitudinally
secured by U-shaped members (202), the user actuates actuation arm
(220) by rotating handle portion (226) downwardly toward casing
(210). Actuation arm (220) rotates about second axle (224) and
translates sled member (200) distally toward waveguide (150) and
pillar (230). The user continues to rotate handle portion (226) to
engage cone (162) of transducer (160) with conical recess (152)
(shown in phantom) of waveguide (150). In present example, sled
member (200) and pillar (230) are spaced at a predetermined
distance calculated to induce a sufficient compressive force
between transducer (160) and waveguide (150) to ensure proper
coupling of cone (162) with conical recess (152) when actuation arm
(220) is rotated and latch (240) engages recess (228) of handle
portion (226). Such a compressive force may be calculated such that
the ultrasonic vibrations produced by the stacks of piezoelectric
elements (164) are adequately transmitted to waveguide (150). When
a user desires to decouple transducer (160) from waveguide (150),
latch (240) is released and actuation arm (220) is actuated to
translate sled member (200) proximally. The user may then remove
transducer (160) and/or waveguide (150) for reuse, disposal, and/or
reclamation. Thus, a user may quickly connect transducer (160) to
waveguide (150) and also ensure an adequate connection between
transducer (160) and waveguide (150) by using the sled coupling
mechanism described herein.
[0050] Of course other configurations for a sled coupling mechanism
will be apparent to one of ordinary skill in the art in view of the
teachings herein. For instance, a pair of actuation arms (220) may
be located on either side of sled member (200). Alternatively, in
versions in which transducer (160) is a cordless transducer,
transducer (160) may be affixed to U-shaped members (202) or
directly to sled member (200). Further still, a separate casing
containing the sled coupling mechanism may be rotatably coupled via
bearings to a handle assembly to permit rotation of the entire
coupling mechanism relative to the handle assembly. In yet a
further configuration, a spring may be provided to resiliently bias
sled member (200) proximally such that the user merely needs to
release latch (240). Still further configurations will be apparent
to one of ordinary skill in the art in view of the teachings
herein.
[0051] C. Exemplary Self-Locking Pin and Lever Coupling
Mechanism
[0052] FIGS. 6A-7 show yet another coupling mechanism that includes
a self-locking pin and lever coupling mechanism. As shown in FIGS.
6A-6B, an exemplary waveguide (250) and an exemplary transducer
(260) are configured to couple together via a horn (262) and a
recess (252). Horn (262) includes a transaxial pin hole (264)
configured to receive first and second pin ends (320, 330),
described in more detail below. Transaxial pin hole (264) of the
present example is located at a node of transducer (260), though
this is merely optional. Waveguide (250) also includes a transaxial
pin hole (254) that transects recess (252) and, as shown in FIG.
6B, at least partially aligns with transaxial pin hole (264) of
horn (262) when first and second pin ends (320, 330) are inserted
therein. Transaxial pin hole (254) of the present example is
likewise located at a node of waveguide (250), though this is also
merely optional. In the present example, waveguide (250) comprises
a titanium rod that terminates at a distal end with an end
effector, such as end effector (80). Waveguide (250) may also be
included in a transmission assembly, such as transmission assembly
(70) described above. In some versions, the end effector includes a
blade and a clamp arm to simultaneously sever the tissue and
denature the proteins in adjacent tissue cells, thereby providing a
coagulative effect with relatively little thermal spread. In other
versions, the end effector may only include a blade. Still other
configurations for the end effector will be apparent to one of
ordinary skill in the art in view of the teachings herein.
[0053] An outer casing (270) of a handle assembly, such as
multi-piece handle assembly (60), includes a pair of pin apertures
(272) and a pair of pin and lever assemblies (280). In the present
example, pin and lever assemblies (280) are located on opposing
sides of casing (270), though in some versions a pin and lever
assembly (280) may be located on the top of casing (270) and a
second pin and lever assembly (280) may be located on the bottom of
casing (270). Further still, pin and lever assemblies (280) do not
need to be directly opposed. Indeed, in some versions pin and lever
assemblies (280) may be disposed in a V shaped arrangement or at
any other suitable arrangement as will be apparent to one of
ordinary skill in the art in view of the teachings herein. Pin and
lever assemblies (280) of the present example are each coupled to
casing (270) by a respective axle (not shown) such that pin and
lever assemblies (280) are pivotable relative to casing (270).
Torsion springs (282) are coupled to pin and lever assemblies (280)
and to casing (270) to bias pin and lever assemblies (280) toward a
locked position, as shown in FIG. 6B. Pin and lever assemblies
(280) each comprise a lever (284) and a pin portion (300). Lever
(284) includes a handle (286) extending proximally away from the
axle and torsion spring (282) and a lever portion (290) extending
distally from the axle torsion spring (282). Handle (286) includes
thumb treads (288) to provide a ridged surface for a user to press
upon, though this is merely optional.
[0054] Referring now to FIG. 7, lever portion (290) further
comprises an L-shaped member (292) defining a ledge (294). Pin
portion (300) includes a wheel (302) that is rotatably coupled to a
pin body (310) and insertable onto ledge (294). Wheel (302) of the
present example comprises a rotatable Teflon.RTM. (of E. I. du Pont
de Nemours and Company of Wilmington, Del.) wheel coupled to an
axle (304) and rotatable relative to pin body (310). When wheel
(302) is placed upon ledge (294), ledge (294) permits wheel (302)
to slide and/or roll on ledge (294) while substantially restricting
the vertical movement of wheel (302). Thus, if ultrasonic
vibrations are transmitted to pin portions (300), then wheels (302)
slide and/or roll on ledges (294) to reduce the transmission of the
ultrasonic vibrations to levers (284). In one alternative, a
Teflon.RTM. cap may be used instead of wheel (302) such that
Teflon.RTM. cap only slides on ledge (294). Of course other
materials may be used, including rubber, plastic, and/or any other
acoustically isolating material as will be apparent to one of
ordinary skill in the art in view of the teachings herein.
[0055] Referring back to FIGS. 6A-6B, the ends of pin bodies (310)
opposite of wheels (302) terminate at a first pin end (320) or
second pin end (330). First pin end (320) comprises a ramped
portion (322) having a wedge angle .alpha.. By way of example only,
wedge angle .alpha. may be between about 10 degrees, inclusive, and
about 20 degrees, inclusive. It should be understood that wedge
angle .alpha. may be as small as 0.01 degree or as large as 45
degrees. Second pin end (330) also includes a ramped portion (332)
with a wedge angle .alpha.; however, ramped portion (332) of second
pin end (330) is oriented in the opposite direction relative to
ramped portion (322) of first pin end (320) such that ramped
portions (322, 332) are parallel planar portions and the wedge
angles are alternate interior angles. As will be appreciated by one
of ordinary skill in the art, when ramped portions (322, 332) are
not engaged, first pin end (320) and second pin end (330) do not
overlap. As shown in FIG. 6B, when ramped portions (322, 332)
engage, ramped portions (322, 332) slide against each other and cam
first and second pin ends (320, 330) outwardly in the longitudinal
direction, thereby effectively expanding the longitudinal width
that first and second pin ends (320, 330) occupy. Accordingly, as
shown in FIG. 6B, when first and second pin ends (320, 330) engage
within transaxial pin hole (264), the camming of ramped portions
(322, 332) against each other urges horn (262) of transducer (260)
into recess (252) of waveguide (250).
[0056] When a user desires to couple transducer (260) to waveguide
(250), initially the user rotates handles (286) of both pin and
lever assemblies (280) to rotate lever portions (290) about torsion
springs (282). The rotation of lever portions (290) engages wheels
(302) via L-shaped members (292) to actuate pin portions (300)
outwardly relative to pin apertures (272). Tab stops (not shown)
may be included on pin bodies (310) to prevent a user from pulling
pin portions (300) completely out of pin apertures (272), though
this is merely optional. FIG. 6A depicts pin portions (300)
outwardly actuated and in an unlocked position. With pin portions
in an unlocked position, transducer (260) and/or waveguide (250)
are inserted into the handle assembly. Horn (262) is inserted into
recess (252) and transaxial pin holes (254, 264) are substantially
axially aligned with each other and with first and second pin ends
(320, 330), as shown in FIG. 6A. Such alignment may be accomplished
using a visual indicator (not shown) on waveguide (250) and/or
transducer (260). Alternatively, a key (not shown) and keyway (not
shown) may be included on horn (262) and in recess (252),
respectively, to physically align transducer (260) with waveguide
(250). It should be noted that pin holes (254, 264) need not be
completely axially aligned as ramped portions (322, 332) may cam
pin holes (254, 256) into complete alignment as ramped portions
(322, 332) and first and second pin ends (320, 330) are inserted
therethrough.
[0057] With transaxial pin holes (254, 264) and first and second
pin ends (320, 330) substantially aligned, the user releases
handles (286) and torsion springs (282) rotate lever portions (290)
inwardly. Lever portions (290) engage wheels (302) to actuate pin
portions (300) inwardly relative to pin apertures (272). As pin
portions (300) move inwardly, first and second pin ends (320, 330)
enter transaxial pin hole (254) of waveguide (250). In the example
shown, first pin end (320) and ramped portion (322) may engage
transaxial pin hole (264) to cam horn (262) distally as first pin
end (320) enters transaxial pin hole (264). If second pin end (330)
is misaligned relative to transaxial pin hole (264), the camming of
horn (262) distally may align transaxial pin hole (264) to permit
second pin end (330) to enter transaxial pin hole (264). First and
second pin ends (320, 330) engage each other within transaxial pin
hole (264) and ramped portions (322, 332) cam against one another
as pin portions (300) continue to actuate inwardly. The engagement
of ramped portions (322, 332) within transaxial pin hole (264)
urges horn (262) of transducer (260) further into recess (252) of
waveguide (250) to couple transducer (260) to waveguide (250).
Torsion springs (282) may be designed such that a certain
compressive force between horn (262) and a distal wall of recess
(252) is achieved when pin and lever assemblies (280) are in the
locked position, shown in FIG. 6B. Such a compressive force may be
calculated such that the ultrasonic vibrations produced by
transducer (260) are adequately transmitted to waveguide (250). In
addition or in the alternative, levers (284) may disengage from pin
portions (300) once the engagement of transducer (260) with
waveguide (250) is made. In such instances, pin portions (300) may
be spring biased inwardly. Of course in other versions, waveguide
(250) may be translatable proximally in addition to, or in lieu of,
horn (262) and transducer (260) translating distally.
[0058] When a user desires to decouple transducer (260) from
waveguide (250), the user actuates handles (286) to lift pin
portions (300) outwardly relative to pin apertures (272). Ramped
portions (322, 332) disengage and first and second pin ends (320,
330) are actuated out of transaxial pin holes (254, 264). With
first and second pin ends (320, 330) removed, the user may remove
waveguide (250) and/or transducer (260) from within casing (270) of
the handle assembly. Thus, a user may quickly connect transducer
(260) to waveguide (250) and also ensure an adequate connection
between transducer (260) and waveguide (250) by using the
self-locking pin and lever coupling mechanism described herein.
[0059] Of course other configurations for a self-locking pin and
lever coupling mechanism will be apparent to one of ordinary skill
in the art in view of the teachings herein. For instance, a single
pin and lever assembly (280) may be used in which pin body (310)
comprises a substantially conical member insertable through conical
transaxial pin holes (254, 264) to couple waveguide (250) and
transducer (260). In another version, lever (284) may be omitted
and pin portions (300) may be spring-biased members each having a
handle for a user to outwardly actuate pin portions (300). Still
further configurations will be apparent to one of ordinary skill in
the art in view of the teachings herein.
[0060] D. Exemplary Bolt-Action Coupling Mechanism
[0061] FIGS. 8A-8B depict another coupling mechanism that includes
a bolt-action coupling mechanism for coupling a transducer unit
(360) to a waveguide (350). Referring initially to FIG. 8A,
transducer unit (360) of the present example includes a transducer
body (362), a locking member (364), and a distal coupling member
(366). Locking member (364) extends radially outward from
transducer body (362) at approximately the midpoint along the
longitudinal length of transducer body (362). In other versions,
locking member (364) may be located near the distal end of
transducer body (362) or near the proximal end of transducer body
(362). Locking member (364) of the present example further
comprises a handle portion (365) with which a user may grasp
locking member (364) when locking member (364) is inserted into a
ramped cam slot (380), as will be described in greater detail
below.
[0062] Waveguide (350) of the present example is coupled to a
handle assembly (370) with a proximal end (352) (shown in phantom)
extending proximally into handle assembly (370) and a distal
portion (354) extending distally from handle assembly (370). In the
present example, waveguide (350) comprises a titanium rod that
terminates at a distal end with an end effector, such as end
effector (80). Waveguide (350) may also be included in a
transmission assembly, such as transmission assembly (70) described
above. In some versions, the end effector includes a blade and a
clamp arm to simultaneously sever the tissue and denature the
proteins in adjacent tissue cells, thereby providing a coagulative
effect with relatively little thermal spread. In other versions,
the end effector may only include a blade. Still other
configurations for the end effector will be apparent to one of
ordinary skill in the art in view of the teachings herein. Proximal
end (352) of waveguide (350) is configured to be insertable into a
recess (368) (shown in phantom) of distal coupling member (366). In
the present example, proximal end (352) is a cylindrical member
that is insertable into recess (368) of distal coupling member
(366). In other versions, proximal end (352) and distal coupling
member (366) may include threading, slots and locking tabs, snap
fasteners, and/or any other coupling member as will be apparent to
one of ordinary skill in the art in view of the teachings
herein.
[0063] Handle assembly (370) of the present example includes a
casing (372), a portion of which defines a transducer recess (374),
and a ramped cam slot (380) formed in casing (372) on a side of
transducer recess (374). Handle assembly (370) may further be
configured in accordance with at least some of the teachings of
multi-piece handle assembly (60) described above; U.S. Pat. Pub.
No. 2006/0079874; U.S. Pat. Pub. No. 2007/0191713; U.S. Pat. Pub.
No. 2007/0282333; U.S. Pat. Pub. No. 2008/0200940; U.S. Pat. Pub.
No. 2011/0015660; U.S. Pat. No. 6,500,176; U.S. Pat. Pub. No.
2011/0087218; and/or U.S. Pat. Pub. No. 2009/0143797. Transducer
recess (374) of the present example is sized and configured to
receive at least a portion of transducer body (362) when inserted
therein. Ramped cam slot (380) comprises dogleg shaped slot having
an opening portion (382), a transition portion (384), a locking
portion (386), and a detent (388). In the present example, opening
portion (382) is configured to receive locking member (364) when
transducer unit (360) is initially inserted into transducer recess
(374). Transition portion (384) extends distally from opening
portion (382) toward proximal end (352) of waveguide (350). Locking
portion (386) extends downwardly from transition portion (384) and
includes a lower surface (390) and a detent (388) located above
lower surface (390). Detent (388) is configured to resist vertical
movement of locking member (364) past detent (388) in locking
portion (386). As will be apparent to one of ordinary skill in the
art, when locking member (386) is urged past detent (388) and
toward lower surface (390) of locking portion (386), locking member
(364) is secured within locking portion (386) both longitudinally
by the sides of locking portion (386) and vertically by detent
(388) and lower surface (390). Thus, with locking member (364)
secured therein, transducer unit (360) is secured to handle
assembly (370). A spring may resiliently bias transducer unit (360)
proximally to further ensure locking member (364) is urged past
detent (388). The spring may also prevent an inadvertent release of
locking member (364) past detent (388).
[0064] When a user desires to couple transducer unit (360) to
waveguide (350), initially the user inserts transducer unit (360)
into transducer recess (374). If locking member (364) is not
initially within opening portion (382) of ramped cam slot (380),
the user rotates transducer unit (360) until locking member (364)
enters opening portion (382). It should be understood at this point
that distal coupling member (366) of transducer unit (360) and
proximal end (352) of waveguide (350) are substantially axially
aligned, but are not coupled together. The user grasps handle
portion (365) and actuates locking member (364) distally along
transition portion (384). As locking member (364) is actuated
distally along transition portion (384), distal coupling member
(366) engages and couples to proximal end (352) of waveguide (350).
As noted above, proximal end (352) and distal coupling member (366)
may alternatively include threading, slots and locking tabs,
snap-on fittings, and/or any other coupling member as will be
apparent to one of ordinary skill in the art in view of the
teachings herein.
[0065] Once locking member (364) is at a distal end of transition
portion (384), the user rotates locking member (364) into locking
portion (386) and past detent (388). The rotation of transducer
unit (360) from opening portion (382) until transducer unit (360)
is locked in by detent (388) may be between 10 and 350 degrees of
rotation. The rotation of transducer unit (360) in the present
example is approximately 90 degrees. When locking member (364) is
rotated into locking portion (386) of ramped cam slot (380), distal
coupling member (366) of transducer unit (360) and proximal end
(352) of waveguide (350) are already substantially engaged and
distal coupling member (366) of the present example merely rotates
about proximal end (352). In other versions, such as in a version
including a threaded distal coupling member (366), the threads of
distal coupling member (366) may engage and thread into threads of
proximal end (352) when locking member (364) is rotated into
locking portion (386). By way of example only, a luer lock-type
fitting or quarter turn fasteners may be used. In an alternative
version having a slot and tab configuration, the rotation of
transducer unit (360) may rotate the tab to lock distal coupling
member (366) to proximal end (352). Still other configurations for
distal coupling member (366) and proximal end (352) will be
apparent to one of ordinary skill in the art in view of the
teachings herein.
[0066] FIG. 8B shows transducer unit (360) coupled to waveguide
(350) when locking member (364) is within locking portion (386). A
user may then use the assembled surgical instrument for a
procedure. To decouple transducer unit (360) from waveguide (350),
the user grasps handle portion (365) and urges locking member (364)
past detent (388) and out of locking portion (386). The user then
actuates locking member (364) proximally along transition portion
(384), thereby decoupling transducer unit (360) from waveguide
(350). Once locking member (364) is within opening portion (382),
the user may lift transducer unit (360) out of transducer recess
(374). Handle assembly (370) may then be disposed of, cleaned,
and/or reclaimed as desired. Thus, a user may quickly connect
transducer unit (360) to waveguide (350) and also ensure an
adequate connection between transducer unit (360) and waveguide
(350) by using the bolt-action coupling mechanism described
herein.
[0067] Of course other configurations for a bolt-action coupling
mechanism will be apparent to one of ordinary skill in the art in
view of the teachings herein. For instance, transducer unit (360)
may include bearings to permit rotation of a transducer contained
within transducer unit (360) relative to transducer unit (360)
and/or handle assembly (370). In another version, transducer recess
(374) may be substantially enclosed with an opening at a proximal
end of handle assembly (370). In such a version, transition portion
(384) or opening portion (382) of ramped cam slot (380) extends
proximally such that locking member (364) and transducer unit (360)
are longitudinally insertable handle assembly (370). In addition,
more than one locking member (364) and more than one ramped cam
slot (380) may be used. In yet another alternative, transducer unit
(360) may be coupled to handle assembly (370) and locking member
(364) may instead be coupled to waveguide (350). In such a version,
locking member (364) couples waveguide (350) to transducer unit
(360) and handle assembly (370) by rotation and insertion into
ramped cam slot (380). Still further configurations will be
apparent to one of ordinary skill in the art in view of the
teachings herein.
[0068] E. Exemplary Camming Lever Arms Coupling Mechanism
[0069] FIGS. 9-11B show still another coupling mechanism for an
exemplary handle assembly (400) to couple a transducer (470) to a
waveguide (450). Referring to FIG. 9, handle assembly (400) of the
present example comprises a lower handle portion (410) and a
transducer unit (460). Lower handle portion (410) includes a casing
(412), a pair of toggle buttons (414), a rotation knob (416), and a
trigger (420) pivotably mounted to lower handle portion (410).
Casing (412), toggle buttons (414), and/or rotation knob (416) may
be configured in accordance with at least some of the teachings of
casing (61), toggle buttons (69), and rotation knob (66) described
above or in accordance with U.S. Pat. Pub. No. 2006/0079874; U.S.
Pat. Pub. No. 2007/0191713; U.S. Pat. Pub. No. 2007/0282333; U.S.
Pat. Pub. No. 2008/0200940; U.S. Pat. Pub. No. 2011/0015660; U.S.
Pat. No. 6,500,176; U.S. Pat. Pub. No. 2011/0087218; and/or U.S.
Pat. Pub. No. 2009/0143797. A transmission assembly (430) is
coupled to rotation knob (416) and a portion of transmission
assembly (430) extends distally from lower handle portion (410). In
the present example, transmission assembly (430) comprises a
waveguide (450) and an outer shaft (440) coaxially disposed about
waveguide (450). A proximal end of both waveguide (450) and outer
shaft (440) extends proximally of rotation knob (416) and
terminates distally of a forked portion (424) of trigger (420), as
will be described in more detail below. In the example shown, the
proximal end of waveguide (450) comprises a tapered shaft (452)
that is configured to couple to a tapered recess (478) of a horn
(476) of transducer (470) in transducer unit (460). The proximal
end of outer shaft (440) includes a flared snap-on connector (442)
configured to snap onto a flared portion (486) of an outer tube
(484) of transducer (470). An end effector (not shown) is coupled
to the distal end of outer shaft (440) and waveguide (450). The end
effector may be configured in accordance with at least some of the
teachings of end effector (80) described above. For instance, in
one version end effector includes a blade and a clamp arm to
simultaneously sever the tissue and denature the proteins in
adjacent tissue cells, thereby providing a coagulative effect with
relatively little thermal spread. In other versions, end effector
may only include a blade. Still other configurations for the end
effector will be apparent to one of ordinary skill in the art in
view of the teachings herein.
[0070] Trigger (420) is pivotably mounted to lower handle portion
(410) with a trigger portion (422) extending out of lower handle
portion (410) and a forked portion (424) within lower handle
portion (410). Forked portion (424) comprises a pair of vertically
oriented C-shaped members (426) (a side view of which is shown in
FIG. 9 and a top view is shown in FIG. 10) configured to receive a
disc (482) of transducer (470) in a disc recess (428) between the
C-shaped members (426). C-shaped members (426) also permit outer
tube (484) and/or horn (476) of transducer (470) to extend
longitudinally through the gaps formed by the C-shape of C-shaped
members (426).
[0071] Transducer unit (460) comprises a cover portion (462), a
pair of bearing members (464), a pair of lever arms (490), shown in
FIGS. 11A-11B, coupled to cover portion (462), and a transducer
(470) rotatably mounted to cover portion (462) by bearing members
(464). Cover portion (462) is configured to couple to lower handle
portion (410), thereby forming a completed handle assembly (400).
In some versions cover portion (462) couples to lower handle
portion (410), such by snap fasteners, clips, clamps, screws,
bolts, adhesives, or any other suitable coupling mechanism. In
other versions, cover portion (462) may simply rest atop lower
handle portion (410). Transducer (470) of the present example
comprises a transducer body (472), a horn (476), a disc (482)
coaxially disposed about horn (476), and an outer tube (484)
coupled to the disc (482). As shown in FIG. 8, transducer (470)
further comprises a cable (480) extending proximally from
transducer body (472) and out of transducer unit (460) via an
aperture in cover portion (462).
[0072] Transducer body (472) of the present example comprises an
outer shell having a distal circumferential flange (474), as will
be discussed in more detail later. Transducer body (472) encases a
plurality of piezoelectric elements (not shown) compressed between
a first resonator (not shown) and a second resonator (not shown) to
form a stack of piezoelectric elements. The piezoelectric elements
may be fabricated from any suitable material, for example, lead
zirconate-titanate, lead meta-niobate, lead titanate, and/or any
suitable piezoelectric crystal material, for example. Transducer
body (472) further includes electrodes, including at least one
positive electrode and at least one negative electrode, that are
configured to create a voltage potential across the one or more
piezoelectric elements, such that the piezoelectric elements
convert the electrical power into ultrasonic vibrations.
[0073] Cable (480) is configured to electrically couple the
electrodes to a power source, such as generator (20) discussed
above. In some versions, cable (480) may be coupled to a power
source contained within transducer unit (460) or to a power source
within lower handle portion (410). In yet another version, a power
source may be integrated into transducer (470). Horn (476) extends
distally from transducer body (472) and includes a tapered recess
(478) at a distal end. Tapered recess (478) is configured to couple
to tapered shaft (452) of waveguide (450). When horn (476) is
coupled to waveguide (450) via tapered recess (478) and tapered
shaft (452), the ultrasonic vibrations produced by the stacks of
piezoelectric elements are transmitted to waveguide (450). A blade
(not shown) at the distal end of waveguide (450) oscillates
according to the ultrasonic vibrations to simultaneously sever the
tissue and denature the proteins in adjacent tissue cells, thereby
providing a coagulative effect with relatively little thermal
spread.
[0074] A disc (482) is coaxially disposed about horn (476) and is
longitudinally actuatable relative to horn (476) and transducer
body (472). In the present example, disc (482) is longitudinally
retained on horn (476) by a raised portion (not shown) on horn
(476) distal of disc (482). Accordingly, disc (482) is slidable on
horn (476), but is still retained thereon. As another merely
illustrative variation, disc (482) may include an internal annular
recess configured to loosely receive a flange of horn (476), such
that the recess permits disc (482) to slide relative to horn (476)
while the flange restricts the longitudinal sliding range of disc
(482) relative to horn (476). Disc (482) of the present example
further includes an outer tube (484) fixedly coupled to disc (482)
and extending distally from disc (482). Outer tube (484) includes a
distal end having a flared portion (486). Flared portion (486) is
configured to snap into flared snap-on connector (442) of outer
shaft (440) when transducer (470) is coupled to waveguide (450). As
noted above and shown best in FIG. 10, disc (482) is insertable
into disc recess (428) of forked portion (424) of trigger (420).
Disc (482), outer tube (484), and outer shaft (440) are actuated
when trigger (420) is actuated by a user and when outer shaft (440)
is coupled to outer tube (484). Accordingly, if the end effector
includes a mechanically actuatable element, such as clamp arm (84)
discussed above, then trigger (420) is operable to actuate that
element via disc (482), outer tube (484), and outer shaft (440).
Forked portion (424) of trigger (420) permits rotation of disc
(482) and outer tube (484) while maintaining a longitudinally
actuatable mechanical coupling. In some versions, disc (482) may
include a force limiting mechanism, such as that disclosed in U.S.
Pat. Pub. No. 2011/0015660. Of course other configurations and
couplings for disc (482), trigger (420), and/or transducer (470)
will be apparent to one of ordinary skill in the art in view of the
teachings herein. For instance, in some versions disc (482), outer
tube (484), and flared portion (486) may be a separate assembly
from transducer (470). Alternatively, versions disc (482), outer
tube (484), and flared portion (486) may be an assembly contained
within casing (412).
[0075] FIGS. 11A-11B show the coupling sequence of transducer (470)
to waveguide (450) and outer shaft (440) with a segment of cover
portion (462) omitted for a better view. Lever arms (490) each
comprise an elongated handle portion (494) and a camming member
(496). Each camming member (496) includes a distally camming
portion (497) and a proximally camming portion (498). Each camming
member (496) is pivotably attached to casing portion (462) via pins
(492) such that lever arms (490) may be rotated from an open
position, in which handle portions (494) are angled outwardly from
cover portion (462), shown in FIG. 11A, to a closed position, in
which handle portions (494) are substantially parallel or flush
against casing portion (462), shown in FIG. 11B. Recesses (not
shown) in casing portion (462) may optionally be included for
handle portions (494) to enter when in the closed position.
Referring to FIG. 11A, when lever arms (490) are in the open
position, distal camming portions (497) of camming members (496)
are disengaged from flange (474). In this position, horn (476) and
outer tube (484) are decoupled from waveguide (450) and outer shaft
(440), respectively. When lever arms (490) are actuated to the
closed position, distal camming portions (497) of camming members
(496) engage flange (474) and actuate transducer (470) distally. As
camming members (496) actuate flange (474) and transducer (470)
distally, tapered shaft (452) engages tapered recess (478) and
flared snap-on connector (442) snaps onto flared portion (486). In
some instances, disc (482) is urged forward with horn (476) by a
proximal raised portion (not shown). Alternatively, trigger (420)
may be used actuate disc (482) to snap flared portion (486) into
flared snap-on connector (442). Distal camming portions (497) may
be sized such that a predetermined coupling force is applied to
couple tapered recess (478) to tapered shaft (452) and flared
portion (486) to snap-on connector (442) when lever arms (490) are
in the closed position, as shown in FIG. 11B. For instance, distal
camming portions (497) may be configured such that a coupling force
of 5 to 10 pounds is provided, though this is merely exemplary. In
some instances, the coupling force may be reduced to substantially
zero (e.g., where tapered shaft (452) and tapered recess (478)
engage at an antinode).
[0076] Handle portions (494) of the present example further include
resilient insertable latches (495) to retain lever arms (490)
against casing portion (462) when handle portions (494) are in the
closed position. Latches (495) of the present example are
selectively coupleable to recesses in casing portion (462). In some
versions, other retention mechanisms may be used, such as snap
fasteners, spring-loaded stops, screws, bolts, etc., to retain
lever arms (490) in the closed position. When lever arms (490) are
actuated back to the open position, proximal camming portions (498)
engage transducer body (472) and/or flange (474) to urge transducer
(470) proximally. This proximal urging of transducer (470)
decouples tapered shaft (452) from tapered recess (478) and flared
snap-on connector (442) unsnaps from flared portion (486).
[0077] When a user desires to couple transducer (470) to waveguide
(450) and outer shaft (440), initially the user places transducer
unit (460) atop lower handle portion (410) when lever arms (490)
are in the open position, shown in FIG. 11A. Disc (482) of
transducer (470) is also inserted into disc recess (428) of forked
portion (424) of trigger (420), shown in FIGS. 9-10, thereby
providing an initial mechanical coupling of disc (482) to trigger
(420). As noted above, casing portion (462) of transducer unit
(460) may also be coupled to lower handle portion (410). The user
then actuates handle portions (494) of lever arms (490) to the
closed position, thereby coupling tapered recess (478) to tapered
shaft (452) and snapping flared portion (486) into flared snap-on
connector (442). Handle portions (494) are locked in the closed
position by latches (495). The mechanical coupling of outer shaft
(440) to trigger (420) via disc (482) and forked portion (424)
permits the user to actuate an actuatable portion of the end
effector, if provided. In addition, the coupling of tapered recess
(478) to tapered shaft (452) allows ultrasonic vibrations to be
transmitted from transducer (470) to a blade of end effector when
transducer (470) is activated. A user may use the assembled
surgical instrument for a procedure.
[0078] To decouple handle assembly (400), the user actuates lever
arms (490) back to the open position, thereby decoupling tapered
recess (478) from tapered shaft (452) and unsnapping flared portion
(486) from flared snap-on connector (442). The user may then remove
transducer unit (460) for use with another lower handle portion
(410). The used lower handle portion (410) may be disposed of,
cleaned, and/or reclaimed. In some instances, transmission assembly
(430) may be decoupled from lower handle portion (410). Such
decoupling may allow a user to reuse lower handle portion (410) and
only dispose of the dirty transmission assembly (430). Merely
exemplary coupling and decoupling mechanisms for transmission
assembly (430) are disclosed in U.S. patent application Ser. No.
13/269,870, entitled "Surgical Instrument with Modular Shaft and
End Effector," filed Oct. 10, 2011, the disclosure of which is
incorporated by reference herein. Thus, a user may quickly connect
transducer (470) to waveguide (450) and also ensure an adequate
connection between transducer (470) and waveguide (450) by using
the camming lever arm coupling mechanism described herein.
[0079] Of course other configurations for a camming lever arm
coupling mechanism will be apparent to one of ordinary skill in the
art in view of the teachings herein. For instance, lever arms (490)
may be replaced with longitudinal sliders that actuate transducer
(470) distally and proximally via flange (474). In other versions,
outer shaft (440), outer tube (484), disc (482), and trigger (420)
may be omitted and only waveguide (450) and transducer (470) are
used. In yet another version, transducer unit (460) may be
permanently coupled to lower handle portion (410) and transducer
(470) may be insertable through the top of casing portion (462).
Still further configurations will be apparent to one of ordinary
skill in the art in view of the teachings herein.
[0080] F. Exemplary Rotatable Clamshell Coupling Mechanism
[0081] FIGS. 12-14 show another coupling mechanism for an exemplary
handle assembly (500) to couple a transducer (520) to a
transmission assembly (530). Transmission assembly (530) of the
present example includes a waveguide (532) and an end effector (not
shown) located on the distal end of transmission assembly (530).
Transmission assembly (530) may be further configured in accordance
with at least some of the teachings for transmission assembly (70)
described above. The proximal end of waveguide (532) includes
threading (534) configured to threadably couple to a horn (526) of
transducer (520). Threading (534) of the present example is
configured to torque horn (526) of transducer (520) onto waveguide
(532) within 180 degrees of rotation, or a half turn. By way of
example only, a quarter turn connector, a leur lock-type connector,
and/or any other rotatable connection may be used to couple
transducer (520) to waveguide (532). In the present example,
transmission assembly (530) is fixed relative to handle assembly
(500), though it should be understood that this is merely optional.
For instance, transmission assembly (530) may be insertable into
handle assembly (500) and selectively fixed to handle assembly
(500) via a pin or latching mechanism (not shown). Merely exemplary
detachable transmission assemblies are described in U.S. patent
application Ser. No. 13/269,870, entitled "Surgical Instrument with
Modular Shaft and End Effector," filed Oct. 10, 2011, the
disclosure of which is incorporated by reference herein; and merely
exemplary selective fixation mechanisms are described in U.S.
patent application Ser. No. 13/269,899, entitled "Ultrasonic
Surgical Instrument with Modular End Effector," filed Oct. 10,
2011, the disclosure of which is incorporated by reference herein.
Transducer (520) comprises a transducer body (522) having a tab
(524) and a horn (526) having a recess with threading that
complements threading (534) of waveguide (532). Still other
configurations for transmission assembly (530) and transducer (520)
will be apparent to one of skill in the art in view of the
teachings herein.
[0082] Handle assembly (500) of the present example comprises a
first handle portion (502) and a second handle portion (504).
Portions of handle assembly (500) have been omitted from FIG. 12 to
provide a better view of transducer (520) and transmission assembly
(530) within handle assembly (500). First handle portion (502)
includes a first casing (506), a transducer recess (508) formed in
first casing (506), and a trigger (510) operable to actuate a
portion of transmission assembly (530), such as inner tubular
actuator described above in reference to FIG. 1. First handle
portion (502) may be further configured in accordance with at least
some of the teachings of multi-piece handle assembly (60) described
herein; U.S. Pat. Pub. No. 2006/0079874; U.S. Pat. Pub. No.
2007/0191713; U.S. Pat. Pub. No. 2007/0282333; U.S. Pat. Pub. No.
2008/0200940; U.S. Pat. Pub. No. 2011/0015660; U.S. Pat. No.
6,500,176; U.S. Pat. Pub. No. 2011/0087218; and/or U.S. Pat. Pub.
No. 2009/0143797. In some versions trigger (510) may be omitted. As
shown best in FIG. 14, transducer recess (508) is a
semi-cylindrical recess defined by a semi-cylindrical portion of
first casing (506) that is configured to receive a portion of
transducer (520) therein. An opening in transducer recess (508)
permits tab (524) of transducer (520) to enter a notch (516) formed
in second casing (512), as will be described in greater detail
below.
[0083] Second handle portion (504) of the present example includes
a second casing (512) having a rotatable hinge member (514), shown
in FIGS. 13-14. In the present example, rotatable hinge member
(514) is integrally formed with second casing (512). Rotatable
hinge member (514) wraps around the semi-cylindrical portion of
first casing (506) defining transducer recess (508), thereby
forming a slightly larger semi-cylindrical portion, as shown in
FIG. 14. Second casing (512) further comprises a notch (516)
configured to receive tab (524) of transducer (520), as shown in
FIG. 12 and FIG. 14 (shown in phantom). Second casing (512) and
first casing (506) further include interference fittings (not
shown) to couple first casing (506) to second casing (512) when
second casing (512) is rotated into a locked position, as will be
described below. Of course other attachment mechanisms, such as
snap fasteners, pins, clips, clamps, screws, bolts, adhesives,
etc., may be used to couple second casing (512) to first casing
(506).
[0084] When a user desires to coupled transducer (520) to
transmission assembly (530), initially the user places transducer
(520) within transducer recess (508) and aligns tab (524) with
notch (516). The user also initially engages threading (534) of
waveguide (532) with the threads of horn (526) of transducer (520).
Such an initial, unlocked position is shown in FIGS. 12-14. The
user then rotates second casing (512) about the semi-cylindrical
portion of first casing (506) defining transducer recess (508) via
rotatable hinge member (514). As second casing (512) is rotated,
notch (516) engages tab (524) and rotates transducer (520).
Accordingly, horn (526) rotates and torques down onto threading
(534) of waveguide (532), thereby coupling transducer (520) to
waveguide (532). Second casing (512) is then coupled to first
casing (506) via the interference fittings, resulting in the locked
position for handle assembly (500). The user may then use the
assembled surgical instrument. In some versions, a torque limiting
device may be included on first casing (506) and/or second casing
(512) to ensure transducer (520) is not overtightened to waveguide
(532).
[0085] To decouple transducer (520) from transmission assembly
(530), initially second casing (512) is decoupled from first casing
(506). The user rotates second casing (512) about the
semi-cylindrical portion of first casing (506) defining transducer
recess (508) via rotatable hinge member (514) back to the unlocked
position shown in FIGS. 12-14. When first casing (506) and second
casing (512) are back in the unlocked position, the user may then
remove transducer (520) from within handle assembly (500) for
reuse, cleaning, and/or reclamation. Handle assembly (500) and
transmission assembly (530) may be disposed of, cleaned, and/or
reclaimed. As noted above, in some versions transmission assembly
(530) is detachable from handle assembly (500). In such instances,
handle assembly (500) may also be reusable while transmission
assembly (530) is disposed of. Thus, a user may quickly connect
transducer (520) to transmission assembly (530) and also ensure an
adequate connection between transducer (520) and waveguide (532) by
using the rotatable clamshell coupling mechanism described
herein.
[0086] Of course, as with the other coupling mechanisms described
herein, other configurations for the rotatable clamshell coupling
mechanism will be apparent to one of ordinary skill in the art in
view of the teachings herein. For instance, in some versions,
nested frustoconical features may be used to couple transducer
(520) to waveguide (532) instead of threading (534) described
above. Merely exemplary frustoconical features include cone (162)
and conical recess (152) shown and described in reference to FIG. 2
above. For a rotatable clamshell incorporating the frustoconical
coupling features, second casing (512) may include a cam feature
associated with tab (524) that drives transducer (520) distally
relative to first casing (506) when second casing (512) is rotated
towards first casing (506). Accordingly, when second casing (512)
is fully rotated toward first casing (506), the cam feature urges
and secures transducer (520) to waveguide (532).
[0087] It should be appreciated that any patent, publication, or
other disclosure material, in whole or in part, that is said to be
incorporated by reference herein is incorporated herein only to the
extent that the incorporated material does not conflict with
existing definitions, statements, or other disclosure material set
forth in this disclosure. As such, and to the extent necessary, the
disclosure as explicitly set forth herein supersedes any
conflicting material incorporated herein by reference. Any
material, or portion thereof, that is said to be incorporated by
reference herein, but which conflicts with existing definitions,
statements, or other disclosure material set forth herein will only
be incorporated to the extent that no conflict arises between that
incorporated material and the existing disclosure material.
[0088] Embodiments of the present invention have application in
conventional endoscopic and open surgical instrumentation as well
as application in robotic-assisted surgery.
[0089] Embodiments of the devices disclosed herein can 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 pieces, and
subsequent reassembly. In particular, embodiments of the devices
disclosed herein may be disassembled, and any number of the
particular pieces or parts of the devices may be selectively
replaced or removed in any combination. Upon cleaning and/or
replacement of particular parts, embodiments of the devices may be
reassembled for subsequent use either at a reconditioning facility,
or by a surgical team immediately prior to a surgical procedure.
Those skilled in the art will appreciate that reconditioning of a
device may 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.
[0090] By way of example only, embodiments described herein may be
processed before surgery. First, a new or used instrument may be
obtained and if necessary cleaned. The instrument may then be
sterilized. In one sterilization technique, the instrument is
placed in a closed and sealed container, such as a plastic or TYVEK
bag. The container and instrument may then be placed in a field of
radiation that can penetrate the container, such as gamma
radiation, x-rays, or high-energy electrons. The radiation may kill
bacteria on the instrument and in the container. The sterilized
instrument may then be stored in the sterile container. The sealed
container may keep the instrument sterile until it is opened in a
medical facility. A 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.
[0091] Having shown and described various embodiments of the
present invention, further adaptations of the methods and systems
described herein may be accomplished by appropriate modifications
by one of ordinary skill in the art without departing from the
scope of the present invention. Several of such potential
modifications have been mentioned, and others will be apparent to
those skilled in the art. For instance, the examples, embodiments,
geometrics, materials, dimensions, ratios, steps, and the like
discussed above are illustrative and are not required. Accordingly,
the scope of the present invention should be considered in terms of
the following claims and is understood not to be limited to the
details of structure and operation shown and described in the
specification and drawings.
* * * * *