Ultrasonic transmission components of ultrasonic surgical instruments and methods of manufacturing the same

• US 10,624,666 B2
• Filed: 08/02/2017
• Issued: 04/21/2020
• Est. Priority Date: 08/02/2017
• Status: Active Grant

• Current Assignee: Covidien LP (Medtronic Plc)
• Original Assignee: Covidien LP (Medtronic Plc)
• Inventors: Brown, Michael J.
• Primary Examiner(s): Zhu, Weiping
• Application Number:
  US15/666,656
• Publication Number:
  US 20190038307A1
• Time in Patent Office: 993 Days
• Field of Search: 419 5
• CPC Class Codes: A61B 17/22012 in direct contact with, or very close to, the obstruction or concrement for removing obstructions in blood vessels by laser A61B18/245
• CPC Class Codes: A61B 17/2202 the ultrasound transducer being inside patient's body at the distal end of the catheter
• 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 2017/00349 Needle-like instruments having hook or barb-like gripping means, e.g. for grasping suture or tissue A61B17/06066 takes precedence
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: A61B 2017/00734 battery operated
• CPC Class Codes: A61B 2017/22014 the ultrasound transducer being outside patient's body; with an ultrasound transmission member; with a wave guide; with a vibrated guide wire not applied in A61B17/22012
• CPC Class Codes: A61B 2017/2945 Curved jaws
• CPC Class Codes: A61B 2017/320069 for ablating tissue
• CPC Class Codes: A61B 2017/320073 probe
• CPC Class Codes: A61B 2017/320074 blade
• CPC Class Codes: A61B 2017/320094 additional movable means performing clamping operation
• CPC Class Codes: A61B 2018/00023 closed, i.e. without wound contact by the fluid
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing

Abstract

A method of manufacturing an ultrasonic transmission component of an ultrasonic surgical instrument includes forming, via additive manufacturing, a waveguide, including a body portion, a curved blade extending distally from the body portion, and a lumen extending through a portion of the body portion and a portion of the curved blade. Another method of manufacturing an ultrasonic transmission component of an ultrasonic surgical instrument includes forming, via additive manufacturing, a waveguide, including a body portion and a blade extending distally from the body portion. At least one of the body portion or the blade defines a varied density.

Claims

1. A method of manufacturing an ultrasonic transmission component of an ultrasonic surgical instrument, comprising:

forming, via additive manufacturing, a waveguide, including;

a body portion;

a curved blade extending distally from the body portion,

wherein the waveguide is formed to define a lumen extending continuously through a portion of the body portion and a portion of the curved blade; and

inserting an inner tube into the lumen of the waveguide, the inner tube extending continuously inside the lumen between the body portion and the curved blade.

2. The method according to claim 1, wherein forming the waveguide via additive manufacturing includes forming the waveguide via Direct Metal Laser Sintering.

3. The method according to claim 1, wherein forming the waveguide via additive manufacturing includes forming the waveguide via Selective Laser Sintering.

4. The method according to claim 1, further comprising:

modeling the waveguide using a computer-aided design program,

wherein the modeled waveguide is utilized to form the waveguide via additive manufacturing.

5. The method according to claim 1, wherein the lumen extends a majority of a length of the body portion and a majority of a length of the curved blade.

6. The method according to claim 5, wherein the lumen defines a closed distal end portion.

7. The method according to claim 1, wherein the waveguide is formed from titanium.

8. The method according to claim 1, wherein at least one of the body portion or the curved blade of the waveguide is formed to include a varied density.

9. The method according to claim 1, wherein at least a portion of at least one of the body portion or the curved blade of the waveguide is formed to include a lattice structure.

10. A method of manufacturing an ultrasonic transmission component of an ultrasonic surgical instrument, comprising:

forming, via additive manufacturing, a waveguide, including;

a body portion;

a blade extending distally from the body portion,

wherein at least one of the body portion or the blade defines a varied density,

wherein the waveguide is formed to define a lumen extending continuously through a portion of the body portion and a portion of the curved blade; and

inserting an inner tube into the lumen of the waveguide, the inner tube extending continuously inside the lumen between the body portion and the blade.

11. The method according to claim 10, wherein forming the waveguide via additive manufacturing includes forming the waveguide via Direct Metal Laser Sintering.

12. The method according to claim 10, wherein forming the waveguide via additive manufacturing includes forming the waveguide via Selective Laser Sintering.

13. The method according to claim 10, further comprising:

modeling the waveguide using a computer-aided design program,

wherein the modeled waveguide is utilized to form the waveguide via additive manufacturing.

14. The method according to claim 10, wherein the lumen extends a majority of a length of the body portion and a majority of a length of the blade.

15. The method according to claim 10, wherein the waveguide is formed from titanium.

16. The method according to claim 10, wherein at least a portion of at least one of the body portion or the blade of the waveguide is formed to include a lattice structure.

17. The method according to claim 10, wherein the blade is curved.