ELECTRICAL LOCKOUT FOR ULTRASONIC SURGICAL INSTRUMENT

• US 20190314054A1
• Filed: 04/12/2018
• Published: 10/17/2019
• Est. Priority Date: 04/12/2018
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon, LLC (Johnson & Johnson)
• Inventors: Asher, Ryan M., Black, Brian D., Brady, John E., Cuti, Alexander R., Harris, Demetrius N., Draginoff, JR., Carl J., Burkart, Ellen, Giannotti, Geni M., Kolpitcke, Andrew, Krumm, Amy M., Kuhn, Matthew T., Leuck, Stephen M., McLain, Cameron D., Nicolaescu, Ion V., Otrembiak, Candice, Sawhney, Amrita S., Voegele, Aaron C., Waters, Grace E., Zhang, Fajian
• Granted Patent: US 11,076,881 B2
• Time in Patent Office: Days
• CPC Class Codes: A61B 17/2804 with two or more pivotal connections A61B17/29 takes precedence
• 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 18/1445 at the distal end of a shaft, e.g. forceps or scissors at the end of a rigid rod
• CPC Class Codes: A61B 2017/00039 Electric or electromagnetic phenomena other than conductivity, e.g. capacity, inductivity, Hall effect
• CPC Class Codes: A61B 2017/00061 spectrum
• CPC Class Codes: A61B 2017/00137 Details of operation mode
• CPC Class Codes: A61B 2017/00199 with a console, e.g. a control panel with a display
• CPC Class Codes: A61B 2017/00402 Piezo electric actuators
• CPC Class Codes: A61B 2017/00424 ergonomic, e.g. fitting in fist
• CPC Class Codes: A61B 2017/0046 with a releasable handle; with handle and operating part separable for prosthetic joint-implanting tools A61F2/4603
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2017/320074 blade
• 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: A61B 2018/0063 Sealing
• CPC Class Codes: A61B 2018/00994 combining two or more different kinds of non-mechanical energy or combining one or more non-mechanical energies with ultrasound
• CPC Class Codes: A61B 2090/0808 for indicating correct assembly of components, e.g. of the surgical apparatus

Abstract

An ultrasonic surgical instrument and method of assembly with a predetermined alignment includes first and second modular assemblies and an electrical lockout. The first modular assembly includes at least a portion of an end effector configured to manipulate a tissue. The second modular assembly includes a transducer power circuit and an activation switch electrically connected to the transducer power circuit. The electrical lockout is electrically connected to the transducer power circuit and configured to inhibit the activation switch from powering the ultrasonic transducer with the first and second modular assemblies misaligned from the predetermined alignment such that the first and second modular assemblies are in a locked-out state. The electrical lockout is further configured to allow the activation switch to power the ultrasonic transducer with the first and second modular assemblies in the predetermined alignment such that the first and second modular assemblies are in an operational state.

Claims

1. An ultrasonic surgical instrument, comprising:

(a) a first modular assembly, including;

(i) at least a portion of an end effector configured to manipulate a tissue;

(b) a second modular assembly configured to mechanically couple with the first modular assembly in a predetermined alignment relative to each other, wherein the second modular assembly includes;

(i) a body assembly configured to support an ultrasonic transducer;

(ii) a transducer power circuit configured to electrically connect to the ultrasonic transducer and a generator, and

(iii) an activation switch electrically connected to the transducer power circuit, wherein the activation switch is configured to selectively power the ultrasonic transducer by directing electrical power from the generator to the ultrasonic transducer with the first and second modular assemblies in the predetermined alignment, and

(c) an electrical lockout electrically connected to the transducer power circuit,

wherein the electrical lockout is configured to inhibit the activation switch from powering the ultrasonic transducer with the first and second modular assemblies misaligned from the predetermined alignment such that the first and second modular assemblies are in a locked-out state, and

wherein the electrical lockout is further configured to allow the activation switch to power the ultrasonic transducer with the first and second modular assemblies in the predetermined alignment such that the first and second modular assemblies are in an operational state.

2. The ultrasonic surgical instrument of claim 1, wherein the first modular assembly further includes a shaft assembly, wherein the shaft assembly includes an acoustic waveguide extending therealong and the at least the portion of the end effector projecting distally therefrom, and wherein the at least the portion of the end effector further includes an ultrasonic blade extending from the acoustic waveguide.

3. The ultrasonic surgical instrument of claim 2, wherein the at least the portion of the end effector further includes a clamp arm assembly movably connected relative to the ultrasonic blade and configured to compress the tissue against the ultrasonic blade.

4. The ultrasonic surgical instrument of claim 1, wherein the second modular assembly further includes an acoustic waveguide extending to an ultrasonic blade, wherein the at least the portion of the end effector of the first modular assembly further includes a clamp arm assembly, wherein the clamp arm assembly is configured to be movably connected relative to the ultrasonic blade to compress the tissue against the ultrasonic blade.

5. The ultrasonic surgical instrument of claim 1, wherein the body assembly of the second modular assembly further includes an ultrasonic transducer supported therein.

6. The ultrasonic surgical instrument of claim 1, wherein the electrical lockout further includes a first lockout portion positioned on the first modular assembly and a second lockout portion electrically connected to the transducer power circuit and positioned on the body, wherein the second lockout portion is configured to inhibit the transducer power circuit from powering the ultrasonic transducer in the locked-out state, and wherein the first and second lockout portion in the predetermined alignment are collectively configured to allow the activation switch to power the ultrasonic transducer in the operational state.

7. The ultrasonic surgical instrument of claim 6, wherein the first lockout portion includes a first electrical shut, wherein the second lockout portion includes a first pair of electrical contacts, wherein the first pair of electrical contacts define a first electrical gap in the locked-out state to inhibit electrical flow between the first pair of electrical contacts, wherein the first electrical shunt in the predetermined alignment electrically connects the first pair of electrical contacts for the operational state.

8. The ultrasonic surgical instrument of claim 7, wherein the first lockout portion includes a second electrical shut, wherein the second lockout portion includes a second pair of electrical contacts, wherein the second pair of electrical contacts defines a second electrical gap in the locked-out state to inhibit electrical flow between the second pair of electrical contacts, wherein the second electrical shunt in the predetermined alignment electrically connects the second pair of electrical contacts for the operational state.

9. The surgical instrument of claim 6, wherein the first lockout portion includes a first metallic member, wherein the second lockout portion includes a second metallic member, wherein the first metallic member and the second metallic member in the predetermined alignment collectively define an electrical capacitor, and wherein the electrical capacitor is configured to generate a capacitance in the predetermined alignment for the operational state.

10. The surgical instrument of claim 6 wherein the first lockout portion includes a first metallic member, wherein the second lockout portion includes an electrical coil, wherein the electrical coil receives the metallic member in the predetermined alignment to collectively define an electrical inductor, wherein the electrical inductor is configured to generator an inductance in the predetermined alignment for the operational state.

11. The surgical instrument of claim 6, wherein the first lockout portion includes a reflective surface, wherein the second lockout portion includes an infrared light source and an infrared receiver, wherein the infrared light source is configured to direct infrared light to reflect from the reflective surface and into the infrared receiver in the predetermined alignment for the operational state.

12. The surgical instrument of claim 6, wherein the first lockout portion includes a ramp surface, wherein the second lockout portion includes a movable member connected to a potentiometer, wherein the movable member is configured to be moved by the ramp surface from a disconnected position, through an intermediate position, and to a connected position as the first modular assembly is being mechanically connected to the second modular assembly with the predetermined alignment, wherein the movable member in the disconnected position directs the potentiometer to generate a disconnected voltage for indicating that the first modular assembly is completely disconnected from the second modular assembly and in the locked-out state, wherein the movable member in the intermediate position directs the potentiometer to generate an intermediate voltage for indicating that the first modular assembly is partially connected to the second modular assembly and in the locked-out state, and wherein the movable member in the connected position directs the potentiometer to generate a connected voltage for indicating that the first modular assembly is connected to the second modular assembly with the predetermined alignment in the operational state.

13. The ultrasonic surgical instrument of claim 6, wherein the first lockout portion includes an abutment surface on the first modular assembly, wherein the second lockout portion includes a pair of electrical contacts and a movable member having an electrical shunt positioned thereon configured to move from a first position to a second position, wherein the pair of electrical contacts define an electrical gap in the locked-out state to inhibit electrical flow between the pair of electrical contacts with the movable member in the first position, wherein the abutment surface is configured to urge the movable member from the first position to the second position as the first modular assembly is mechanically connected to the second modular assembly with the predetermined alignment, and wherein the electrical shunt in the second position with the predetermined alignment electrically connects the pair of electrical contacts for the operational state.

14. The ultrasonic surgical instrument of claim 6, wherein the first lockout portion includes a magnet on the first modular assembly, wherein the second lockout portion includes a pair of electrical contacts and a movable member having an electrical shunt positioned thereon configured to move from a first position to a second position, wherein the pair of electrical contacts define an electrical gap in the locked-out state to inhibit electrical flow between the pair of electrical contacts with the movable member in the first position, wherein the magnet is configured to urge the movable member from the first position to the second position as the first modular assembly is mechanically connected to the second modular assembly with the predetermined alignment, and wherein the electrical shunt in the second position with the predetermined alignment electrically connects the pair of electrical contacts for the operational state.

15. The ultrasonic surgical instrument of claim 6, wherein the first lockout portion includes an abutment surface on the first modular assembly, wherein the second lockout portion includes a resiliently mounted movable member operatively connected to a force sensor and configured to move from a first position to a second position, wherein the force sensor in a first position is configured to measure an inoperable force in the locked-out state, wherein the abutment surface is configured to urge the movable member from the first position to the second position as the first modular assembly is mechanically connected to the second modular assembly with the predetermined alignment, and wherein the force sensor in the second position with the predetermined alignment is configured to measure an operable force for the operational state.

16. An ultrasonic surgical instrument, comprising:

(a) a first modular assembly, including;

(i) a shaft assembly having an acoustic waveguide extending therealong,

(ii) an end effector projecting distally from the shaft assembly, wherein the end effector further includes configured to manipulate a tissue, wherein the end effector includes an ultrasonic blade extending from the acoustic waveguide and a clamp arm assembly movably connected relative to the ultrasonic blade and configured to compress the tissue against the ultrasonic blade;

(b) a second modular assembly configured to mechanically couple with the first modular assembly in a predetermined alignment relative to each other, wherein the second modular assembly includes;

(i) a body assembly configured to support an ultrasonic transducer;

(ii) a transducer power circuit configured to electrically connect to the ultrasonic transducer and a generator, and

(iii) an activation switch electrically connected to the transducer power circuit, wherein the activation switch is configured to selectively power the ultrasonic transducer by directing electrical power from the generator to the ultrasonic transducer with the first and second modular assemblies in the predetermined alignment, and

(c) an electrical lockout configured to inhibit the activation switch from powering the ultrasonic transducer with the first and second modular assemblies misaligned from the predetermined alignment such that the first and second modular assemblies are in a locked-out state, wherein the electrical lockout is further configured to allow the activation switch to power the ultrasonic transducer with the first and second modular assemblies in the predetermined alignment such that the first and second modular assemblies are in an operational state, wherein the electrical lockout includes;

(i) a first lockout portion positioned on the first modular assembly, and

(ii) a second lockout portion electrically connected to the transducer power circuit and positioned on the body,

wherein the second lockout portion is configured to inhibit the transducer power circuit from powering the ultrasonic transducer in the locked-out state, and wherein the first and second lockout portion in the predetermined alignment are collectively configured to allow the activation switch to power the ultrasonic transducer in the operational state.

17. The ultrasonic surgical instrument of claim 16, wherein the second modular assembly further includes an ultrasonic transducer supported therein.

18. The ultrasonic surgical instrument of claim 16, wherein the first lockout portion includes a first electrical shut, wherein the second lockout portion includes a first pair of electrical contacts, wherein the first pair of electrical contacts define a first electrical gap in the locked-out state to inhibit electrical flow between the first pair of electrical contacts, wherein the first electrical shunt in the predetermined alignment electrically connects the first pair of electrical contacts for the operational state.

19. A method of aligning an ultrasonic surgical instrument during assembly with a predetermined alignment, wherein the ultrasonic surgical instrument includes (a) a first modular assembly, including:

(i) at least a portion of an end effector configured to manipulate a tissue;

(b) a second modular assembly configured to mechanically couple with the first modular assembly in the predetermined alignment relative to each other, wherein the second modular assembly includes;

(i) a body assembly configured to support an ultrasonic transducer;

(ii) a transducer power circuit configured to electrically connect to the ultrasonic transducer and a generator, and (iii) an activation switch electrically connected to the transducer power circuit, wherein the activation switch is configured to selectively power the ultrasonic transducer by directing electrical power from the generator to the ultrasonic transducer with the first and second modular assemblies in the predetermined alignment, and (c) an electrical lockout electrically connected to the transducer power circuit, the method comprising;

(a) inhibiting the activation switch from powering the ultrasonic transducer via the electrical lockout with the first and second modular assemblies misaligned from the predetermined alignment such that the first and second modular assemblies are in a locked-out state.

20. The method of claim 19, further comprising:

mechanically coupling the first modular assembly to the second modular assembly with the predetermined alignment such that the electrical lockout allows the activation switch to power the ultrasonic transducer in an operational state.