Abstract: An improved ultrasonic surgical instrument is disclosed having a design that extends horn or tip life and minimizes instrument breakage and disintegration during use. The instrument comprises an ultrasonic tip having a distal working end and a metal sheath around the tip; the tip further having projections located in the vicinity of nodal points near the tip working end, said tip radially extending from the tip towards the sheath so as to provide the tip with radial inward support. The instrument can further comprise said tip with a substantially flat or convex end and said sheath with an inwardly projecting portion located distally of said tip projection and extending sufficiently radially inward so as to capture the tip with its projection should a tip break occur.

Abstract: A method for vibration or orbital welding of a fabric to a thermoplastic substrate includes forming an assembly which has a decorative outer face without markings or pin dents that need to be removed or brushed out. The fabric can be woven or non-woven material and usually is characterized by high and low density regions that are bonded to a thermoplastic substrate in a vibration welder having a smooth surfaced platen applying pressure to the exposed surface of the fabric. High quality bonds or vibration welds are obtained between a fabric and a thermoplastic substrate characterized by a textured surface having tiny raised regions.

Abstract: A control for an ultrasonic surgical instrument is described wherein a transducer having an elongate tip is vibrated to perform surgery. The amplitude of the vibrations by the tip are controlled and the power delivered to the tip can be set so that the operator of the instrument can in effect render the instrument sensitive to different tissues to avoid damage thereto and enhance the safety of the patient.