Ultrasonic surgical blades

• US 10,433,866 B2
• Filed: 02/03/2017
• Issued: 10/08/2019
• Est. Priority Date: 11/30/2007
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon, LLC (Johnson & Johnson)
• Inventors: Witt, David A., Messerly, Jeffrey D., Houser, Kevin L.
• Primary Examiner(s): Stransky, Katrina M
• Application Number:
  US15/424,174
• Publication Number:
  US 20170143877A1
• Time in Patent Office: 977 Days
• CPC Class Codes: A61B 17/320068 using mechanical vibrations, e.g. ultrasonic A61B17/22012 takes precedence; dental tooth drilling devices operated by vibration A61C3/03; removing intra-ocular material using mechanical vibrations A61F9/00745
• CPC Class Codes: A61B 17/320092 with additional movable means for clamping or cutting tissue, e.g. with a pivoting jaw
• CPC Class Codes: A61B 2017/00849 with respect to tissue, e.g. hollow organs
• CPC Class Codes: A61B 2017/00853 low friction, hydrophobic and corrosion-resistant fluorocarbon resin coating (ptf, ptfe, polytetrafluoroethylene)
• CPC Class Codes: A61B 2017/0088 ceramic
• CPC Class Codes: A61B 2017/320078 Tissue manipulating surface
• CPC Class Codes: A61B 2017/320093 additional movable means performing cutting operation
• CPC Class Codes: A61B 2017/320094 additional movable means performing clamping operation
• CPC Class Codes: A61B 2017/320095 with sealing or cauterizing means
• CPC Class Codes: A61L 2400/10 Materials for lubricating medical devices
• CPC Class Codes: A61L 2420/08 Coatings comprising two or more layers
• CPC Class Codes: A61L 31/08 Materials for coatings
• CPC Class Codes: A61L 31/088 Other specific inorganic materials not covered by A61L31/084 or A61L31/086
• CPC Class Codes: A61L 31/10 Macromolecular materials
• CPC Class Codes: A61L 31/14 Materials characterised by their function or physical properties , e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
• CPC Class Codes: A61N 7/00 Ultrasound therapy lithotripsy A61B17/22, A61B17/225; massage using supersonic vibration A61H23/00 ; using ultrasound for introducing media into the body A61M37/0092
• CPC Class Codes: A61N 7/02 Localised ultrasound hyperthermia hyperthermia in general A61F7/00

Abstract

An ultrasonic surgical instrument including a waveguide extending along a longitudinal axis and an ultrasonic blade is disclosed. The ultrasonic blade includes a proximal end coupled to the waveguide, a distal end movable relative to the longitudinal axis in accordance with ultrasonic vibrations applied to the waveguide, an outer surface, a first layer adhered to at least a portion of the outer surface, and a second layer overlapping at least a portion of the first layer. At least a portion of the second layer contacts the outer surface.

Claims

1. An ultrasonic surgical instrument, comprising:

a waveguide extending along a longitudinal axis; and

an ultrasonic blade, comprising;

a proximal end coupled to the waveguide;

a distal end movable relative to the longitudinal axis in accordance with ultrasonic vibrations applied to the waveguide;

an outer surface;

a first layer adhered to at least a portion of the outer surface; and

a second layer overlapping at least a portion of the first layer, wherein at least a portion of the second layer contacts the outer surface.

2. The ultrasonic surgical instrument of claim 1, wherein the second layer comprises:

a first portion comprising a first thickness; and

a second portion laterally offset from the first portion, wherein the second portion comprises a second thickness, and wherein the second thickness is less than the first thickness.

3. The ultrasonic surgical instrument of claim 2, wherein the first layer comprises a variable thickness.

4. The ultrasonic surgical instrument of claim 1, wherein the second layer comprises a variable thickness.

5. The ultrasonic surgical instrument of claim 1, wherein at least a portion of the second layer is adhered to the outer surface.

6. The ultrasonic surgical instrument of claim 1, wherein the first layer comprises a first material, and wherein the second layer comprises a second material.

7. The ultrasonic surgical instrument of claim 1, wherein the first layer is configured to enhance adhesion of the second layer to the ultrasonic blade.

8. The ultrasonic surgical instrument of claim 1, wherein the ultrasonic blade is operably coupled to a generator that is susceptible to a lockout condition at power levels above a threshold power, and wherein the second layer is configured to reduce friction at an interface between a tissue and the ultrasonic blade to avoid exceeding the threshold power draw by the generator to prevent the lockout condition.

9. The ultrasonic surgical instrument of claim 1, further comprising a clamp arm movable between an unclamped position and a clamped position, wherein the clamp arm is positioned opposite at least a portion of the second layer when the clamp arm is in the clamped position, and wherein the clamp arm is configured to clamp a tissue against the second layer when the clamp arm is in the clamped position.

10. An ultrasonic surgical instrument, comprising:

a waveguide extending along a longitudinal axis; and

an ultrasonic blade, comprising;

a proximal end coupled to the waveguide;

a distal end movable relative to the longitudinal axis in accordance with ultrasonic vibrations applied to the waveguide;

an outer surface comprising a treatment region; and

a plurality of layered coatings, comprising;

a first coating, wherein at least a portion of the first coating contacts the outer surface; and

a second coating overlapping at least a portion of the first coating, wherein at least a portion of the second coating contacts the outer surface.

11. The ultrasonic surgical instrument of claim 10, wherein the first coating comprising a first material, wherein the second coating comprising a second material, and wherein the second material is different than the first material.

12. An ultrasonic surgical blade, comprising:

a solid metal body comprising a proximal end configured to receive ultrasonic vibrations;

an outer surface comprising a treatment region; and

a plurality of coatings, comprising;

a first coating; and

a second coating at least partially overlapping the first coating, wherein at least a portion of the second coating contacts the treatment region of the outer surface.

13. The ultrasonic surgical blade of claim 12, wherein the first coating comprises:

a first portion comprising a first thickness; and

a second portion laterally offset from the first portion, wherein the second portion comprises a second thickness, and wherein the second thickness is different than the first thickness.

14. The ultrasonic surgical blade of claim 12, wherein the first coating comprises a first material, and wherein the second coating comprises a second material.

15. The ultrasonic surgical blade of claim 12, wherein the first coating comprises a variable thickness.

16. The ultrasonic surgical blade of claim 12, wherein the second coating comprises a variable thickness.

17. The ultrasonic surgical blade of claim 12, wherein the first coating is configured to enhance adhesion of the second coating to the treatment region.

18. The ultrasonic surgical blade of claim 12, wherein the treatment region further comprises a surface treatment to enhance adhesion of the plurality of coatings.

19. The ultrasonic surgical blade of claim 12, wherein the solid metal body is configured to operably couple to a generator that is susceptible to a lockout condition at power levels above a threshold power, and wherein the plurality of coatings are configured to reduce friction at an interface between a tissue and the solid metal body to avoid exceeding the threshold power draw by the generator to prevent the lockout condition.