Ultrasonic surgical instruments

[0001] This application is a divisional application claiming priority under 35 U.S.C. §121 to U.S. patent application Ser. No. 12/703,885, entitled OUTER SHEATH AND BLADE ARRANGEMENTS FOR ULTRASONIC SURGICAL INSTRUMENTS, filed Feb. 11, 2010, now U.S. Patent Application Publication No. 2011/0196403, the entire disclosure of which is hereby incorporated by reference herein.

[0002] The present disclosure generally relates to ultrasonic surgical systems and, more particularly, to ultrasonic systems that allow surgeons to perform cutting and coagulation of tissue.

[0003] Over the years, a variety of different types of non-ultrasonically powered cutters and shaving devices for performing surgical procedures have been developed. Some of these devices employ a rotary cutting instrument and other devices employ a reciprocating cutting member. For example, shavers are widely used in arthroscopic surgery. Arthroscopic surgery involves performing surgery in the joint space. To perform the surgery, the joints are commonly filled with pressurized saline for distention and visualization.

[0004] The aforementioned devices generally consist of a power supply, a handpiece, and a single-use end effector. The end effector commonly has an inner and outer tube. The inner tube rotates relative to the outer tube and will cut tissue with its sharpened edges. The inner tube can rotate continuously or oscillate. In addition, such device may employ a suction channel that travels through the interior of the inner tube. For example, U.S. Pat. No. 4,970,354 to McGurk-Burleson, et al., discloses a non-ultrasonically powered surgical cutting instrument that comprises a rotary cutter for cutting material with a shearing action. It employs an inner cutting member which is rotatable within an outer tube.

[0005] U.S. Pat. No. 3,776,238 to Peyman et al. discloses an ophthalmic instrument in which tissue is cut by a chopping action set-up by the sharp end of an inner tube moving against the inner surface of the end of an outer tube. U.S. Pat. No. 5,226,910 to Kajiyama et al. discloses another surgical cutting instrument that has an inner member which moves relative to an outer member to cut tissue entering through an aperture in the outer member.

[0006] U.S. Pat. No. 4,922,902 to Wuchinich et al. discloses a method and apparatus for endoscopic removal of tissue utilizing an ultrasonic aspirator. The device uses an ultrasonic probe which disintegrates compliant tissue and aspirates it through a narrow orifice. U.S. Pat. No. 4,634,420 to Spinosa et al. discloses an apparatus and method for removing tissue from an animal and includes an elongated instrument having a needle or probe, which is vibrated at an ultrasonic frequency in the lateral direction. The ultrasonic movement of the needle breaks-up the tissue into fragments. Pieces of tissue can be removed from the area of treatment by aspiration through a conduit in the needle. U.S. Pat. No. 3,805,787 to Banko discloses yet another ultrasonic instrument that has a probe that is shielded to narrow the beam of ultrasonic energy radiated from the tip of the probe. In one embodiment the shield extends past the free-end of the probe to prevent the probe from coming into contact with the tissue. U.S. Pat. No. 5,213,569 to Davis discloses a phaco-emulsification needle which focuses the ultrasonic energy. The focusing surfaces can be beveled, curved or faceted. U.S. Pat. No. 6,984,220 to Wuchinich and U.S. Patent Application Publication No. 2005/0177184 to Easley disclose ultrasonic tissue dissection systems that provide combined longitudinal and torsional motion through the use of longitudinal-torsional resonators. U.S. Patent Application Publication No. 2006/0030797 A1 to Zhou et al. discloses an orthopedic surgical device that has a driving motor for driving an ultrasound transducer and horn. An adapter is provided between the driving motor and transducer for supplying ultrasonic energy signals to the transducer.

[0007] While the use of ultrasonically powered surgical instruments provides several advantages over traditional mechanically powered saws, drills, and other instruments, temperature rise in bone and adjacent tissue due to frictional heating at the bone/tissue interface can still be a significant problem. Current arthroscopic surgical tools include punches, reciprocating shavers and radio frequency (RF) devices. Mechanical devices such as punches and shavers create minimal tissue damage, but can sometimes leave behind ragged cut lines, which are undesirable. RF devices can create smoother cut lines and also ablate large volumes of soft tissue; however, they tend to create more tissue damage than mechanical means. Thus, devices which could provide increased cutting precision while forming smooth cutting surfaces without creating excessive tissue damage would be desirable.

[0008] The foregoing discussion is intended only to illustrate the present field and should not be taken as a disavowal of claim scope.

[0009] In various embodiments, a surgical instrument is provided. The surgical instrument comprises a blade defining a longitudinal axis, wherein the blade comprises a distal end, a lumen, a first opening adjacent to the distal end and communicating with the lumen, and a first cutting edge positioned over the first opening and projecting away from the longitudinal axis, wherein the first cutting edge extends along a curved contour defined in a cutting plane, and wherein the cutting plane is transverse to the longitudinal axis. The surgical instrument further comprises, one, a suction port communicating with the lumen, wherein the blade is configured to allow suction to be applied from the suction port to the first opening and, two, at least one ultrasonic transducer operably coupled to the blade.

[0010] In various embodiments, a surgical instrument is provided comprising a blade defining a longitudinal axis, wherein the blade comprises a distal end, a lumen, a first opening communicating with the lumen, a first cutting edge positioned over the first opening and projecting away from the longitudinal axis, a second opening communicating with the lumen and a second cutting edge positioned over the second opening and projecting away from the longitudinal axis, wherein the second cutting edge is proximal to the first cutting edge, wherein the first cutting edge extends along a curved contour defined in a cutting plane, and wherein the cutting plane is transverse to the longitudinal axis. The surgical instrument further comprises, one, a suction port communicating with the lumen, wherein the blade is configured to allow suction to be applied from the suction port to the first opening and, two, at least one ultrasonic transducer operably coupled to the blade.

[0011] In various embodiments, a surgical instrument is provided comprising a blade defining a longitudinal axis, wherein the blade comprises a distal end, a lumen, a first opening communicating with the lumen, a first cutting edge positioned over the first opening and projecting away from the longitudinal axis, a second opening communicating with the lumen and a second cutting edge positioned over the second opening and proiecting away from the longitudinal axis, wherein the first cutting edge extends along a curved contour defined in a cutting plane, and wherein the cutting plane is transverse to the longitudinal axis. The surgical instrument further comprises, one, a suction port communicating with the lumen, wherein the blade is configured to allow suction to be applied from the suction port to the first opening and, two, at least one ultrasonic transducer operably coupled to the blade.

[0033] The owner of the present application also owns the following U.S. Patent Applications that were filed on Feb. 11, 2010 and which are herein incorporated by reference in their respective entireties:

[0034] U.S. patent application Ser. No. 12/703,860, entitled ULTRASONICALLY POWERED SURGICAL INSTRUMENTS WITH ROTATING CUTTING IMPLEMENT, now U.S. Patent Application Publication No. 2011/0196286;

[0035] U.S. patent application Ser. No. 12/703,864, entitled METHODS OF USING ULTRASONICALLY POWERED SURGICAL INSTRUMENTS WITH ROTATABLE CUTTING IMPLEMENTS, now U.S. Patent Application Publication No. 2011/0196287;

[0036] U.S. patent application Ser. No. 12/703,866, entitled SEAL ARRANGEMENTS FOR ULTRASONICALLY POWERED SURGICAL INSTRUMENTS, now U.S. Patent Application Publication No. 2011/0196398;

[0037] U.S. patent application Ser. No. 12/703,870, entitled ULTRASONIC SURGICAL INSTRUMENTS WITH ROTATABLE BLADE AND HOLLOW SHEATH ARRANGEMENTS, now U.S. Patent Application Publication No. 2011/0196399;

[0038] U.S. patent application Ser. No. 12/703,875, entitled ROTATABLE CUTTING IMPLEMENT ARRANGEMENTS FOR ULTRASONIC SURGICAL INSTRUMENTS, now U.S. Patent Application Publication No. 2011/0196400;

[0039] U.S. patent application Ser. No. 12/703,877, ENTITLED ULTRASONIC SURGICAL INSTRUMENTS WITH PARTIALLY ROTATING BLADE AND FIXED PAD ARRANGEMENT, now U.S. Patent Application Publication No. 2011/0196401;

[0040] U.S. patent application Ser. No. 12/703,879, entitled DUAL PURPOSE SURGICAL INSTRUMENT FOR CUTTING AND COAGULATING TISSUE, now U.S. Patent Application Publication No. 2011/0196402;

[0041] U.S. patent application Ser. No. 12/703,893, entitled ULTRASONIC SURGICAL INSTRUMENTS WITH MOVING CUTTING IMPLEMENT, now U.S. Patent Application Publication No. 2011/0196404; and

[0042] U.S. patent application Ser. No. 12/703,899, entitled ULTRASONIC SURGICAL INSTRUMENT WITH COMB-LIKE TISSUE TRIMMING DEVICE, now U.S. Patent Application Publication No. 2011/0196405.

[0043] Certain embodiments will now be described to provide an overall understanding of the principles of the structure, function, manufacture, and use of the devices and methods disclosed herein. One or more examples of these embodiments are illustrated in the accompanying drawings. Those of ordinary skill in the art will understand that the devices and methods specifically described herein and illustrated in the accompanying drawings are non-limiting embodiments and that the scope of these embodiments is defined solely by the claims. The features illustrated or described in connection with one embodiment may be combined with the features of other embodiments. Further, where an ordering of steps in a process is indicated, such ordering may be rearranged or the steps may be carried out contemporaneously as desired unless illogical or the listed order is explicitly required. Such modifications and variations are intended to be included within the scope of the appended claims.

[0044] In the following description, like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that terms such as “forward,” “rearward,” “front,” “back,” “right,” “left,” “over,” “under,” “top,” “bottom,” “upwardly,” “downwardly,” “proximally,” “distally,” and the like are words of convenience and are not to be construed as limiting terms. The description below is for the purpose of describing various embodiments and is not intended to limit the appended claims.

[0045] Various embodiments are directed to improved ultrasonic surgical systems and instruments configured for effecting tissue dissecting, cutting, and/or coagulation during surgical procedures as well as the cutting implements employed thereby. In one embodiment, an ultrasonic surgical instrument apparatus is configured for use in open surgical procedures, but has applications in other types of surgery, such as laparoscopic, endoscopic, and robotic-assisted procedures. Versatile use is facilitated by selective use of ultrasonic energy and/or suction applied near and/or through the cutting/coagulation implement.

[0046] It will be appreciated that the terms “proximal” and “distal” are used herein with reference to a clinician gripping a handpiece assembly. Thus, an end effector, including, for example, the cutting/coagulation implement, is distal with respect to the more proximal handpiece assembly. It will be further appreciated that, for convenience and clarity, spatial terms such as “top” and “bottom” also are used herein with respect to the clinician gripping the handpiece assembly. However, surgical instruments are used in many orientations and positions, and these terms are not intended to be limiting and absolute.

[0047] FIG. 1 illustrates in schematic form one embodiment of a surgical system 10 of the present invention. The surgical system 10 may include an ultrasonic generator 12 and an ultrasonic surgical instrument assembly 100 that may include ultrasonic producing components. As will be discussed in further detail below, the ultrasonic generator 12 may be connected by a cable 14 to an ultrasonic transducer assembly 114 in a housing portion 102 of the surgical instrument assembly 100. The transducer assembly 114 may include one or more ultrasonic transducers capable of producing ultrasonic vibrations. Further, attached to the ultrasonic transducer assembly 114 may be a horn 124 for amplifying and/or focusing ultrasonic motions created by the transducer assembly 114. Coupled to the horn 124 may be a blade 200 disposed at least partially within an outer, hollow sheath 230 extending from the housing portion 102. In at least one embodiment, the horn 124 and blade 200 may be unitary and integrally formed from the same piece of material. In another embodiment, the horn 124 and blade 200 may be separate components that are attached together.

[0048] In various embodiments, the ultrasonic generator 12 may include an ultrasonic generator module 13 and a signal generator module 15. See FIG. 1. The ultrasonic generator module 13 and/or the signal generator module 15 each may be integrated with the ultrasonic generator 12 or may be provided as separate circuit modules electrically coupled to the ultrasonic generator 12 (shown in phantom to illustrate this option). In one embodiment, the signal generator module 15 may be formed integrally with the ultrasonic generator module 13. The ultrasonic generator 12 may comprise an input device 17 located on a front panel of the generator 12 console. The input device 17 may comprise any suitable device that generates signals suitable for programming the operation of the generator 12 in a known manner. Still with reference to FIG. 1, the cable 14 may comprise multiple electrical conductors, such as copper wires, for the application of electrical energy to positive (+) and negative (−) electrodes of an ultrasonic transducer assembly 114 as will be discussed in further detail below.

[0049] Various forms of ultrasonic generators, ultrasonic generator modules and signal generator modules are known. For example, such devices are disclosed in commonly owned U.S. patent application Ser. No. 12/503,770, entitled ROTATING TRANSDUCER MOUNT FOR ULTRASONIC SURGICAL INSTRUMENTS, filed Jul. 15, 2007, now U.S. Pat. No. 8,461,744, which is herein incorporated by reference in its entirety. Other such devices are disclosed in one or more of the following U.S. Patents, all of which are incorporated by reference herein: U.S. Pat. No. 6,480,796 (METHOD FOR IMPROVING THE START UP OF AN ULTRASONIC SYSTEM UNDER ZERO LOAD CONDITIONS); U.S. Pat. No. 6,537,291 (METHOD FOR DETECTING A LOOSE BLADE IN A HANDLE CONNECTED TO AN ULTRASONIC SURGICAL SYSTEM); U.S. Pat. No. 6,626,926 (METHOD FOR DRIVING AN ULTRASONIC SYSTEM TO IMPROVE ACQUISITION OF BLADE RESONANCE FREQUENCY AT STARTUP); U.S. Pat. No. 6,633,234 (METHOD FOR DETECTING BLADE BREAKAGE USING RATE AND/OR IMPEDANCE INFORMATION); U.S. Pat. No. 6,662,127 (METHOD FOR DETECTING PRESENCE OF A BLADE IN AN ULTRASONIC SYSTEM); U.S. Pat. No. 6,678,621 (OUTPUT DISPLACEMENT CONTROL USING PHASE MARGIN IN AN ULTRASONIC SURGICAL HANDLE); U.S. Pat. No. 6,679,899 (METHOD FOR DETECTING TRANSVERSE VIBRATIONS IN AN ULTRASONIC HANDLE); U.S. Pat. No. 6,908,472 (APPARATUS AND METHOD FOR ALTERING GENERATOR FUNCTIONS IN AN ULTRASONIC SURGICAL SYSTEM); U.S. Pat. No. 6,977,495 (DETECTION CIRCUITRY FOR SURGICAL HANDPIECE SYSTEM); U.S. Pat. No. 7,077,853 (METHOD FOR CALCULATING TRANSDUCER CAPACITANCE TO DETERMINE TRANSDUCER TEMPERATURE); U.S. Pat. No. 7,179,271 (METHOD FOR DRIVING AN ULTRASONIC SYSTEM TO IMPROVE ACQUISITION OF BLADE RESONANCE FREQUENCY AT STARTUP); and U.S. Pat. No. 7,273,483 (APPARATUS AND METHOD FOR ALERTING GENERATOR FUNCTION IN AN ULTRASONIC SURGICAL SYSTEM).

[0050] As can be seen in FIG. 2, an ultrasonic surgical instrument 100 may comprise a housing 102 that houses the ultrasonic transducer assembly 114 and the horn 124. The transducer assembly 114 may be fixedly supported within the housing 102 by mounts 104. Extending from the horn 124 may be the blade 200, which passes through the hollow sheath 230 to a window or opening 231 defined therein. As shown in FIG. 2, a distal tip 202 of the blade 200 may be seen through the opening 231 at a distal portion 250 of the surgical instrument 100. The blade tip 202 and/or the distal portion 250 of the surgical instrument 100 may be considered the “end effector” of the instrument 100. As will be explained in more detail below, the blade 200 may cut tissue when the instrument is moved, relative to the tissue, in a proximal direction “PD” or a distal direction “DD” parallel to or coaxial with the hollow sheath's longitudinal axis A-A, in a direction transverse thereto, or in any direction therebetween. The housing 102 may be provided in two or more parts that are attached together by fasteners such as screws, snap features, etc. and/or by one or more adhesives and may be fabricated from, for example, polycarbonate, stainless steel, or other material.

[0051] Referring still to FIG. 2, the ultrasonic transducer assembly 114 may include a housing 118 that supports piezoelectric ultrasonic transducers 115 for converting electrical energy to mechanical energy that results in longitudinal vibrational motion of the ends of the transducers 115. The ultrasonic transducers 115 may comprise a stack of ceramic piezoelectric elements with a motion null point located at some point along the stack. The ultrasonic transducers 115 may be mounted between a proximal end piece 116 and a distal end piece 117. In addition, the horn 124 may be mounted to the distal end piece 117 at the null point on one side and to the blade 200 on the other side. As a result, the blade 200 will vibrate in the longitudinal direction at an ultrasonic frequency rate with the ultrasonic transducer assembly 114. The ends of the ultrasonic transducer assembly 114 achieve maximum motion with a portion of the stack constituting a motionless node, when the ultrasonic transducer assembly 114 is driven at maximum current at the transducer's resonant frequency. However, the current providing the maximum motion will vary with each instrument and is a value stored in the non-volatile memory of the instrument so the system can use it.

[0052] The parts of the surgical instrument 100 may be designed such that the combination will oscillate at the same resonant frequency. In particular, the elements may be tuned such that the resulting length of each such element is one-half wavelength or a multiple thereof. Longitudinal back and forth motion is amplified as the diameter closer to the blade 200 of the acoustical mounting horn 124 decreases. Thus, the horn 124 as well as the blade 200 may be shaped and dimensioned so as to amplify blade motion and provide ultrasonic vibration in resonance with the rest of the acoustic system, which produces the maximum back and forth motion of the end of the acoustical mounting horn 124 close to the blade 200. A motion from 20 to 25 microns at the ultrasonic transducers 115 may be amplified by the horn 124 into blade movement of about 40 to 100 microns.

[0053] Referring briefly back to FIG. 1, when power is applied to the ultrasonic instrument 110 by a switch arrangement, the ultrasonic generator 12 may, for example, cause the blade 200 to vibrate longitudinally at approximately 55.5 kHz, and the amount of longitudinal movement will vary proportionately with the amount of driving power (current) applied, as adjustably selected by the user. When relatively high cutting power is applied, the blade 200 may be designed to move longitudinally in the range of about 40 to 100 microns at the ultrasonic vibrational rate. Such ultrasonic vibration of the blade 200 will generate heat as the blade contacts tissue, i.e., the acceleration of the blade 200 through the tissue converts the mechanical energy of the moving blade 200 to thermal energy in a very narrow and localized area. This localized heat creates a narrow zone of coagulation, which will reduce or eliminate bleeding in small vessels, such as those less than one millimeter in diameter. The cutting efficiency of the blade 200, as well as the degree of hemostasis, will vary with the level of driving power applied, the cutting rate or force applied by the surgeon to the blade, the nature of the tissue type, and the vascularity of the tissue.

[0054] Referring again to FIG. 2, the surgical instrument 100, and thus, the blade 200, may be grossly moved by a user, relative to a tissue to be cut. As used herein, the term “gross motion,” and the like, is to be distinguished from “ultrasonic motion,” and the like, that may be achieved by way of the ultrasonic transducer assembly. The term “gross motion” instead encompasses translational and rotational motion that is not solely generated by operation of the ultrasonic transducer assembly 114.

[0055] To provide the ultrasonic instrument 110 with power from the ultrasonic generator 12 (see FIG. 1), a flexible wire tray or a multiple-segment jointed protector 110 may be employed. As can be seen in FIG. 2, conductors 151, 152 are coupled to the ultrasonic transducer assembly 114 and extend out of the instrument through the housing 102. Further, the protector 110 may be attached to the instrument housing 102 at one end and to the transducer assembly housing 118 at the other end. The conductors 151, 152 may pass through one or more holes in the transducer assembly housing. Accordingly, ultrasonic signals from the ultrasonic generator 12 are transferred to the ultrasonic transducers 115 through the conductors 151, 152. The protector 110 may prevent the conductors 151, 152 from being damaged or pinched within the housing 102 when the instrument 100 is manufactured, for example.

[0056] Referring still to FIG. 2, various embodiments also include a distal nosepiece 160 that may be removably attached to the distal end of the housing 102 by fasteners and/or adhesives (not shown). The nosepiece 160 may be fabricated from, for example, stainless steel, aluminum or plastic. In various embodiments, the distal end 202 of the blade 200 extends through a hollow portion 210 of the nosepiece 160. The hollow sheath 230 may likewise extend through the hollow portion 210. The hollow portion 210 may include an annular groove in which a proximal seal 212 may be held against the end of the hollow sheath 230 and against the blade 200. The seal 212 may comprise, for example, a silicone o-ring, and/or a brazing or press fit seal, and serve to establish a substantially fluid-tight and/or airtight seal between the nosepiece 160, blade 200, and hollow sheath 230.

[0057] Also in various embodiments, the hollow sheath 230 may be coaxially aligned with the blade 200 and be attached to the hollow portion 210 of the nosepiece 160 by, for example, welding, press-fitting, threading, adhering with glue or other adhesive(s), etc. As can be seen in FIG. 2, a suction port 240 may be attached to the nosepiece 160 to communicate with a proximal hole 232 in the hollow sheath 230. A flexible tube 242 may be attached to the suction port 240 and communicate with a collection receptacle 243 that is coupled to a source of vacuum, generally depicted as 244. Thus, the hollow sheath 230 forms a suction path extending around the blade 200 that begins at the distal portion 250 of the outer sheath 230, such as at the opening 231, and goes out through the hole 232 to the suction port 240. Those of ordinary skill in the art will appreciate that alternate suction paths are also possible. Further, a distal seal 213, similar to proximal seal 212, may be held in the nosepiece 160 and may help further seal the hollow sheath 230 therein such that the suction path from the opening 231, through the sheath 230, out hole 232, and through the port 240 is maintained with minimal or no ingress of air from outside the aforementioned path. Alternatively, a suction port may be omitted from the nosepiece and the surgical instrument may operate without suction being applied to the opening 231.

[0058] Various embodiments of the surgical system 10 (see FIG. 1) provide the ability to selectively apply ultrasonic axial motion to the blade 200. If desired, the clinician may activate the ultrasonic transducer assembly 114 before or while cutting tissue with the blade 200. Frequency ranges for longitudinal ultrasonic motion may be on the order of, for example, 30-80 kHz. Similarly, the clinician may desire to move the instrument 100, and thus the blade 200, without activating the ultrasonic transducer assembly 114. Thus, gross motion may be applied to the blade 200, without the application of longitudinal ultrasonic motion thereto. In other applications, the clinician may desire to use the instrument 100 by both activating the ultrasonic transducer assembly 114 and by grossly moving the blade 200 with respect to the tissue to be cut. In such embodiments, the blade 200 will experience longitudinal ultrasonic motion from the transducer assembly 114 and gross motion from the clinician's movements. Moreover, those of ordinary skill in the art will readily appreciate that various embodiments of the surgical system 10 may be affectively employed in connection with arthroscopic as well as other surgical applications.

[0059] The surgical instrument 100 may have various distal portions. FIGS. 3 and 3A illustrate an example of a distal portion 250 of a non-limiting embodiment of a surgical instrument wherein like numbers previously used to describe the various embodiments disclosed above are used to designate like components. FIG. 3 is a perspective view of the surgical instrument's distal portion 250 and FIG. 3A is a cross-sectional view of the distal portion 250, taken along line 3A-3A in FIG. 3. In these embodiments, the surgical instrument includes a thin, hollow sheath 230 including an opening 231, a blade 200 disposed at least partially within the hollow sheath 230 and extending through the opening 231, and at least one ultrasonic transducer (not shown, see transducers 115 in FIG. 2) operably coupled to the blade 200.

[0060] As can be seen in FIGS. 3 and 3A, in various embodiments, the blade 200 may comprise a distal tip 202 that projects away from the sheath's longitudinal axis A-A to facilitate the cutting of tissue. In more detail, the distal tip 202 may project a distance L₁ from the hollow sheath's longitudinal axis A-A. The distance L₁ may be of a sufficient amplitude to increase the blade's cutting effectiveness. In at least one embodiment, L₁ may be at least 0.25 inches. In another embodiment, L₁ may be less than or equal to 0.75 inches. In yet another embodiment, L₁ may be between and including 0.25 inches and 0.75 inches, in other words, ¼″≦L₁≦¾″.

[0061] Further, the hollow sheath may be configured to expose various portions of the blade 200 to further facilitate tissue cutting for varying situations. For example, referring still to FIG. 3, in at least one embodiment, the sheath's opening 231 may define a plane that intersects the longitudinal axis A-A and that is not transverse to the longitudinal axis. As used herein, the term “transverse” means at a right angle to the longitudinal axis. In other words, the opening 231 is at an angle to the longitudinal axis, thereby exposing the blade only on one side 215 of the hollow sheath 230. In such embodiments, the backside 215 of the blade, that is the side 215 opposite the direction that the blade's tip 202 is projecting, may be shielded by the sheath 230 such that tissue is not unintentionally cut on that side 215. Additionally, as noted above, the sheath 230 may be thin and configured such that it is overmolded on the blade 230. In such embodiments, the clearance between the blade 200 and the sheath 230 (see FIG. 3A) may be minimized.

[0062] Alternatively, referring now to FIG. 4, in at least one embodiment, a hollow sheath 330 of a distal portion 350 of the surgical instrument may include an opening 331 that allows the blade 200 to project therethrough while exposing the backside 215 of the blade 200 to increase the cutting surface and/or edges available to cut tissue. In such embodiments, the opening 331 may define a first plane P₁ and a second plane P₂, which intersects the first plane, and the blade may extend through the first plane P₁. The first plane P₁ may be perpendicular to the longitudinal axis A-A and, as the second plane P₂ intersects the first plane P₁, the second plane P₂ may be at an angle to the first plane.

[0063] In another alternative embodiment, a hollow sheath 450 of a distal portion 450 of the surgical instrument may include an protective lip 433 that allows the blade 200 to be further protected from unintentionally cutting tissue. In more detail, while the blade may extend through the opening 431, it may still be desirable to prevent tissue from being cut on the blade's backside 215. Accordingly, the protective lip 433 may extend towards the tip 202 and away from the longitudinal axis A-A, thereby shielding a greater portion of the blade 200 than that shown in FIG. 3, for example.

[0064] In various embodiments, referring now to FIGS. 6 and 6A, the blade 200 may include various features to enhance its cutting and/or coagulation ability. In more detail, FIG. 6 is a side view of a distal portion of the blade 200 and FIG. 6A is a cross-sectional view of the blade 200, taken along line 6A-6A. Note that cross-hatching is omitted for clarity in FIG. 6A. In at least one embodiment, as can be seen in FIG. 6, the blade 200 may be curved adjacent to the tip 202. Referring briefly back to FIG. 3, the blade 200 can be seen curving through the opening 231. The curved shape of the blade 200 may enable a smooth cut to be created along the blade 200, near the tip 202. More specifically, the blade may be curved a set amount such that the tip protrudes at a certain angle with respect to the hollow shaft's axis A-A (see FIG. 3). Focusing on FIG. 6, the blade 200 may define a first axis A′-A′. As can be seen in FIG. 3A, within the hollow shaft, the first axis A′-A′ may be collinear or parallel to the hollow shaft's axis A-A. In any event, referring back to FIG. 6, the blade 200 may also define a second axis B-B through the tip 202. The second axis A-A may be tangent to the curve of the blade at or near the tip. The first and second axes may define an angle θ that is equal to or greater than 60 degrees but equal to or less than 90 degrees. In other words, 60°≦θ≦90°. Such tip angles may provide enhanced cutting function of the blade 200.

[0065] The shape of the tip 202 and/or cross-section of the blade may further increase the cutting ability of the blade 200. For example, in various embodiments, referring now to FIG. 6A, the blade 200 may increase the number of cutting surfaces it presents by employing a cross-sectional shape adjacent to the tip 202 that is a polygon. More specifically, in at least one embodiment, the polygonal cross-sectional shape may be a quadrilateral, and, even more specifically, a rhombus or equilateral parallelogram. Colloquially, the rhombus shape may be thought of as a diamond shape. Such shapes may allow for the blade to present sharp vertices, such as vertices 207, 208, 209, and 210 defined between sides 203, 204, 205, and 206, seen in FIG. 6A, which form part of the cutting edges of the blade. The degree of sharpness of a vertex, such as vertex 207, may be defined as follows. An angle a, defined between a side of the rhombus, such as side 203, and a centerline of the rhombus, such as centerline “CL,” may be equal to or greater than 10 degrees but equal to or less than 25 degrees. In other words, 10°≦α≦25°. By employing such sharp edges, as defined by the vertices of a rhombus shape, the blade 200 may reduce the need to be buffed.

[0066] Additionally, the cross-sectional shape of the blade may allow the blade to reduce drag through an aqueous or other fluid to better operate in such an environment. For example, in at least one embodiment, the cross-sectional rhombus shape may be longer in one direction and shorter in another. In more detail, the rhombus shape may be longer generally in the proximal and distal directions, PD and DD, respectively. Specifically, two of the vertices of the rhombus, vertices 207 and 209, may also define an axis C-C, see FIG. 6A, that is coplanar with the blade's longitudinal axis, see FIG. 3A. Accordingly, as the blade is moved in the proximal and distal directions, PD and DD, respectively, the drag experienced by the blade in a fluid environment is reduced. Further, the blade may be made thin such that the blade 200 has a width L₂, from vertex 208 to vertex 210, of 0.020 inches to 0.040 inches. In other words, 0.020″≦L₂≦0.040″. In at least one embodiment, L₂ may be 0.030 inches.

[0067] In various embodiments, the tip 202 may also include a polygonal cross-section shape that tapers to a point. For example, in at least one embodiment, referring to FIG. 6, the tip may be pyramidal in shape. Accordingly, both the tip's pointed end and the edges of the tip's pyramidal shape may contribute enhanced cutting points and/or edges.

[0068] Additionally, in at least one embodiment, the blade 200 may be polygonal along its entire length, or, at least along a portion of the blade 200 that also resides within the hollow sheath 230, see FIG. 3A, for example. By using a uniform cross-section along at least a portion of the blade's length, manufacturing costs and resources may be reduced.

[0069] Other blade and/or sheath configurations may be employed by a surgical instrument to achieve enhanced cutting and/or coagulation in a fluid environment. For example, in various embodiments, a surgical instrument may utilize suction to enhance cutting and removal of severed tissue from a surgical target. In more detail, FIGS. 7-11 illustrate another example of a non-limiting embodiment of a surgical instrument 1100 wherein like numbers previously used to describe the various embodiments disclosed above are used to designate like components. FIG. 7 is a partial cross-sectional view of a handheld surgical instrument 1100 employing a blade 1200 with suction applied thereto. The housing 102, transducer assembly 114, horn 124, and related components may be similar to that described above with respect to surgical instrument 100. At least one ultrasonic transducer, such as transducers 115 in the transducer assembly 114, may be operably coupled to the blade 1200 by the horn 124. The blade 1200 may define a longitudinal axis A-A, also similar to longitudinal axis A-A described above. Further, the blade 1200 may comprise a body 1201 that defines a lumen 1220 therein and includes a distal end 1202. Adjacent to the distal end 1202 may be an opening 1204 that communicates with the lumen 1202. Moreover, a first cutting edge 1205 may be positioned over the opening 1204. The first cutting edge 1205 may also project away from the longitudinal axis A-A, to further enhance cutting of tissue, as explained in more detail below.

[0070] The surgical instrument 1100 may further include a suction port 240 attached to or formed with nosepiece 1160. The suction port 240 may communicate with the lumen 1220 via a suction hole 1221 formed in the blade 1200 , positioned within the nosepiece 1160, and aligned with the port 240. A flexible tube 242 may be attached to the suction port 240 and communicate with a collection receptacle 243 that is coupled to a source of vacuum 244. Thus, the blade 1200 may form a suction path extending through the blade 1200 that begins at a distal portion 1250 of the surgical instrument 1100, such as at the opening 1204, travels along at least a portion of lumen 1220, and goes out through the suction hole 1221 to the suction port 240. Those of ordinary skill in the art will appreciate that alternate suction paths are also possible. Further, a proximal seal 1212 and a distal seal 1213 may be held in annular grooves in the nosepiece 1160 around the port 240, and may help further seal the blade 1200 therein such that the suction path from the opening 1204, through the blade 1200, out hole 1221, and through the port 240 is maintained with minimal or no ingress of air from outside the aforementioned path. Accordingly, the blade 1200 is thereby configured to allow suction to be applied from the suction port 240 to the opening 1204.

[0071] Additionally, in at least one embodiment, an outer, hollow sheath 1230 may be employed that may function as a safety shield to cover at least the cutting edge 1205 and/or opening 1204 of the blade 1200 when introducing and/or removing the surgical instrument 1100 from a surgical site. The retractable hollow sheath 1230 may be movably mounted on the blade 1200 and may be selectively movable from a closed position substantially covering the opening 1204 and/or cutting edge 1205 to an open position exposing the opening 1204 (see FIG. 8). Such arrangement may cover the cutting edge 1205 and/or opening 1204 on the blade 1200 during insertion and removal of the blade 1200 adjacent vital nerves and other critical tissues. To facilitate movement of the hollow sheath 1230 on the blade 1200, a thumb control tab 1232 (FIG. 7) may be formed on the proximal end of the hollow sheath 1230 to enable the clinician to apply sliding actuation forces thereto.

[0072] In various embodiments, different blade configurations may be employed to enhance the cutting and evacuation of tissue from a surgical target. Focusing now on the distal portion of the surgical instrument 1250, best seen in FIG. 8, the blade may be tubular in shape. Further, the cutting edge 1205 can be seen positioned over the opening 1204 and projecting away from the blade's longitudinal axis A-A. In at least one such embodiment, focusing now on the front view of the distal portion 1250 provided by FIG. 9, the cutting edge can be seen defining an arc. Accordingly, tissue, such as vertebral disc tissue, may be cut smoothly and shaped along the arced cutting edge 1205.

[0073] Further details regarding blade 1200 may be found by focusing on FIGS. 10-11. FIG. 10 shows a side cross-sectional view of a distal portion of the blade 1200 and FIG. 11 shows a perspective view of a distal portion of the blade 1200. The cutting edge 1205 may be defined by a cutting shroud 1210 that is integrally formed with the blade's body 1201 or otherwise attached thereto. As can be seen in FIG. 10, the shroud 1210 and cutting edge 1205 may project away from the longitudinal axis A-A and from the body 1201. Further, the cross-sectional shape of the shroud, again seen in FIG. 10, may project at an angle from the body 1201 to better present the cutting edge 1205 to tissue T. Also, as can be seen in FIG. 10, the cutting edge 1205 of the blade is shown cutting tissue “T” to create tissue fragments “TF” that are subsequently pulled in through opening 1204 and evacuated by suction in a proximal direction PD, as discussed above. The tissue may be cut when the blade 1200 is advanced in the distal direction DD such that the cutting edge 1205 imbeds itself against the tissue T or otherwise scrapes the tissue's surface. Alternatively, tissue may be sucked into the cutting edge 1205 by suction applied to the opening 1204. Further, with suction present, the tissue fragments TF may be cleared out of the surgical target area, thereby eliminating or reducing the need for repeated insertion and removal of the surgical instrument from a patient. Additionally, as illustrated in FIG. 11, the blade 1200 may vibrate with ultrasonic motions created by one or more ultrasonic transducers 115 (see FIG. 7) to further enhance the cutting edge's ability to severe and/or ablate tissue.

[0074] Focusing back on FIG. 7, in use, the clinician may activate the vacuum source 244 to cut and evacuate tissue. When a bleeder is encountered, the clinician may activate the ultrasonic transducer assembly 114 to send ultrasonic motions to the blade 1200 for coagulation purposes. For example, spinal fusion surgeries require the removal of disc material due to a variety of disease states. Often times this material is toughened and requires quite a bit of force with conventional instrumentation to break up the disc and remove its fragments. Once the disc material is removed, the end plates must be scraped to reveal fresh surfaces to promote fusion of the plates to the cage. The plates must also be shaped to provide a good fit with the type of cage being used. Conventional instrumentation generally requires high forces from the surgeon very close to critical structures.

[0075] Use of the above-described surgical instrument 1100 may be particularly advantageous when performing, for example, a discectomy as shown in FIGS. 12 and 13. As can be seen in those drawings, the blade 1200 may be inserted into the disc “D”. The blade 1200 may be used to shave off small pieces of disc and suction them out. Such arrangement eliminates the need for repeated insertion/removal of surgical tools. The device may also be employed to prepare the vertebrae endplates. By incorporating suction through the blade 1200, ultrasonic motion to the blade 1200, and/or unique blade configurations, the amount of input force that a clinician must exert to prepare the endplates may be reduced. Similarly, the amount of external force required to break up and remove disc material may be lowered. Additionally, the number of instrument exchanges during a surgical procedure may be decreased.

[0076] The surgical instrument 1100 may have various blades from that provided above. For example, FIG. 14 shows a perspective view of an alternative embodiment of a distal portion of a blade 1300 for the surgical instrument 1100 (see FIG. 7) and FIG. 15 shows a front view of the distal portion of the blade 1300. In at least one embodiment, the blade 1300 may be similar to the blade 1200 described above except that it may include more than one opening and/or cutting edge, which may be advantageously positioned on the blade. In more detail, the blade may define a longitudinal axis A-A and may comprise a distal end 1302, a lumen (not shown, see lumen 1220 in FIG. 7), and a first opening 1304 adjacent to the distal end 1302 and communicating with the lumen. The blade 1300 may include a first cutting edge 1305 positioned over the first opening 1304 and projecting away from the longitudinal axis A-A, similar to cutting edge 1204, described above. Further, the blade 1300 may also include a second opening 1309 that also communicates with the lumen and a second cutting edge 1306 positioned over the second opening 1309 and projecting away from the longitudinal axis A-A. The first opening 1304 and the second opening 1309 may both be at the same relative longitudinal position along the blade 1200. In other words, both openings 1304, 1309 may be the same distance from the distal end 1302, along longitudinal axis A-A, however, both openings 1304, 1309 may be at different angular positions along the blade's body 1301.

[0077] Adding more than one opening may increase the positions at which the blade 1300 may cut tissue. Accordingly, in at least one embodiment, the blade 1300 may further comprise a third opening 1307 to further enhance the cutting positions of the blade. In more detail, the third opening may also communicate with the lumen and be positioned at the same longitudinal position as the other openings 1304, 1309. A third cutting edge 1307 may be positioned over the third opening 1314 and may also project away from the longitudinal axis A-A. Each cutting edge 1305, 1306, 1307 may be defined by a cutting shroud 1310, 1311, 1312, respectively, which may be similar to shroud 1210 described above. Additionally, each of the openings 1304, 1309, 1314, the cutting edges 1305, 1306, 1307, and/or the shrouds 1310, 1311, 1312 may be symmetric about the longitudinal axis and positioned equidistant from one another. See, for example, FIG. 15.

[0078] While some of the above embodiments have shown a distal facing cutting edge or edges, the surgical instrument 1100 may include a blade that has a proximal facing cutting edge or edges. For example, FIG. 16 shows a perspective view of another alternative embodiment of a distal portion 1400 of a blade 1400 for the surgical instrument 1100 (see FIG. 7), FIG. 17 shows a front view of the distal portion of the blade 1400, and FIG. 18 shows a side cross-sectional view of a distal portion of the blade 1400 while the blade 1400 is cutting tissue T to create tissue fragments TF that are subsequently evacuated by suction in a proximal direction, similar to that described above. In at least one embodiment, the blade 1400 may be similar to the blade 1200 described above except that it may include more than one opening and/or cutting edge, which may be juxtaposed to one another.

[0079] In more detail, the blade may define a longitudinal axis A-A and may comprise a distal end 1402, a lumen 1420, and a first opening 1404 adjacent to the distal end 1402 and communicating with the lumen 1420. The blade 1400 may include a first cutting edge 1405 positioned over the first opening 1404 and projecting away from the longitudinal axis A-A, similar to cutting edge 1204, described above. Further, the blade 1400 may also include a second opening 1409 that is proximal to the first opening and/or to the first cutting edge 1405. The second opening 1409 may also communicate with the lumen 1420. Further, a second cutting edge 1406 may be positioned over the second opening 1409 and project away from the longitudinal axis A-A. The first opening 1404 and the second opening 1409 may be at different relative longitudinal positions along the blade 1400 but may both be at the same angular position along the blade's body 1401. In other words, the openings 1404, 1409 may be on the same side of the blade 1400. In at least one embodiment, the cutting edges 1405, 1406 may be defined by the same cutting shroud 1410. In such embodiments, the shroud 1410 may be positioned over both openings 1404, 1409.

[0080] Referring to FIG. 18, the tissue may be cut when the blade 1400 is advanced in the distal direction DD such that the first, distal-facing cutting edge 1405 imbeds itself against the tissue T or otherwise scrapes the tissue's surface. Additionally, the tissue may be cut when the blade 1400 is retracted in the proximal direction such that the second, proximal-facing cutting edge 1406 imbeds itself against the tissue T or otherwise scrapes the tissue's surface. Alternatively, tissue may be sucked into one or more of the cutting edges 1405, 1406 by suction applied to the openings 1404, 1409, as described above. Further, with suction present, tissue fragments TF may be cleared out of the surgical target area, thereby eliminating or reducing the need for repeated insertion and removal of the surgical instrument from a patient. Additionally, the blade 1400 may vibrate with ultrasonic motions created by one or more ultrasonic transducers 115 (see FIG. 7) to further enhance the cutting edge's ability to severe and/or ablate tissue.

[0081] The devices disclosed herein can be designed to be disposed of after a single use, or they can be designed to be used multiple times. In either case, however, the device can be reconditioned for reuse after at least one use. Reconditioning can include any combination of the steps of disassembly of the device, followed by cleaning or replacement of particular pieces, and subsequent reassembly. In particular, the device can be disassembled, and any number of the particular pieces or parts of the device can be selectively replaced or removed in any combination. Upon cleaning and/or replacement of particular parts, the device can 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 can 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.

[0082] Preferably, the various embodiments described herein will be processed before surgery. First, a new or used instrument is obtained and if necessary cleaned. The instrument can 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 are then placed in a field of radiation that can penetrate the container, such as gamma radiation, x-rays, or high-energy electrons. The radiation kills bacteria on the instrument and in the container. The sterilized instrument can then be stored in the sterile container. The sealed container keeps the instrument sterile until it is opened in the medical facility. Sterilization can also be done by any number of ways known to those skilled in the art including beta or gamma radiation, ethylene oxide, and/or steam.

[0083] In various embodiments, an ultrasonic surgical instrument can be supplied to a surgeon with a waveguide and/or end effector already operably coupled with a transducer of the surgical instrument. In at least one such embodiment, the surgeon, or other clinician, can remove the ultrasonic surgical instrument from a sterilized package, plug the ultrasonic instrument into a generator, as outlined above, and use the ultrasonic instrument during a surgical procedure. Such a system can obviate the need for a surgeon, or other clinician, to assemble a waveguide and/or end effector to the ultrasonic surgical instrument. After the ultrasonic surgical instrument has been used, the surgeon, or other clinician, can place the ultrasonic instrument into a sealable package, wherein the package can be transported to a sterilization facility. At the sterilization facility, the ultrasonic instrument can be disinfected, wherein any expended parts can be discarded and replaced while any reusable parts can be sterilized and used once again. Thereafter, the ultrasonic instrument can be reassembled, tested, placed into a sterile package, and/or sterilized after being placed into a package. Once sterilized, the reprocessed ultrasonic surgical instrument can be used once again.

[0084] Although various embodiments have been described herein, many modifications and variations to those embodiments may be implemented. For example, different types of end effectors may be employed. Also, where materials are disclosed for certain components, other materials may be used. The foregoing description and following claims are intended to cover all such modification and variations.

[0085] 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.