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.

Abstract: An ultrasonic surgical instrument that includes a handle assembly including at least one user input feature; an ultrasonic transducer supported by the handle assembly, a shaft assembly configured to removably couple with the handle assembly, and a mechanical lockout assembly. The shaft assembly includes a distal end portion. The shaft assembly further includes an end effector extending distally from the distal end portion, and an ultrasonic waveguide configured to be acoustically coupled with the ultrasonic transducer. The mechanical lockout assembly is configured to move between at least an unlocked configuration and a locked configuration. In the locked configuration, the handle assembly and the shaft assembly are only partially coupled together physically preventing the user from activating the instrument using the user input feature.

Abstract: An ultrasonic surgical instrument includes a first modular assembly including at least one operator input feature an ultrasonic transducer supported by the first modular assembly, and a second modular assembly configured to be removably coupled with the first modular assembly. The second modular assembly includes at least a portion of an end effector extending distally from a distal end portion of the second modular assembly. The instrument includes a mechanical lockout assembly configured to switch between at least an unlocked configuration and a locked configuration. In the locked configuration, the first modular assembly and the second modular assembly are partially coupled together such that the operator is physically prevented from activating the instrument using the operator input feature. In the unlocked configuration, the first modular assembly and the second modular assembly are completely coupled together and the operator is able to activate the instrument using the operator input feature.

Abstract: Aspects of the present disclosure include various ultrasonic surgical instruments. At least one disclosed surgical instrument includes a waveguide including a blade and a transducer base plate. The transducer base plate may be coupled to the waveguide to define a tapered joint at an interface between the waveguide and the transducer base plate. The transducer base plate may include first and second sides defining corresponding first and second flat faces configured to receive first and second piezoelectric elements. The first and second piezoelectric elements are configured to operate in a D31 mode.

Abstract: A surgical instrument includes a body, a shaft assembly, an end effector, and an electrical contact assembly. The includes a power source, while the shaft assembly extends distally from the body. The end effector includes a channel assembly and a cartridge assembly configured to selectively couple with the channel assembly. The cartridge assembly includes an electrically activated component. The electrical contact assembly is capable of electrically coupling the power source with the electrically activated component of the cartridge assembly. The electrical contact assembly includes a first electrical contact, a second electrical contact, and an insulating membrane. The first electrical contact is associated with the channel assembly while the second electrical contact is associated with the cartridge assembly. The insulating membrane is associated with either the first electrical contact or the second electrical contact.

Abstract: An ultrasonic surgical instrument includes a first modular assembly including at least one operator input feature an ultrasonic transducer supported by the first modular assembly, and a second modular assembly configured to be removably coupled with the first modular assembly. The second modular assembly includes at least a portion of an end effector extending distally from a distal end portion of the second modular assembly. The instrument includes a mechanical lockout assembly configured to switch between at least an unlocked configuration and a locked configuration. In the locked configuration, the first modular assembly and the second modular assembly are partially coupled together such that the operator is physically prevented from activating the instrument using the operator input feature. In the unlocked configuration, the first modular assembly and the second modular assembly are completely coupled together and the operator is able to activate the instrument using the operator input feature.

Abstract: An ultrasonic surgical instrument that includes a handle assembly including at least one user input feature; an ultrasonic transducer supported by the handle assembly, a shaft assembly configured to removably couple with the handle assembly, and a mechanical lockout assembly. The shaft assembly includes a distal end portion. The shaft assembly further includes an end effector extending distally from the distal end portion, and an ultrasonic waveguide configured to be acoustically coupled with the ultrasonic transducer. The mechanical lockout assembly is configured to move between at least an unlocked configuration and a locked configuration. In the locked configuration, the handle assembly and the shaft assembly are only partially coupled together physically preventing the user from activating the instrument using the user input feature.

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.

Abstract: A surgical instrument includes a body, a shaft assembly, an end effector, and an electrical contact assembly. The includes a power source, while the shaft assembly extends distally from the body. The end effector includes a channel assembly and a cartridge assembly configured to selectively couple with the channel assembly. The cartridge assembly includes an electrically activated component. The electrical contact assembly is capable of electrically coupling the power source with the electrically activated component of the cartridge assembly. The electrical contact assembly includes a first electrical contact, a second electrical contact, and an insulating membrane. The first electrical contact is associated with the channel assembly while the second electrical contact is associated with the cartridge assembly. The insulating membrane is associated with either the first electrical contact or the second electrical contact.

Abstract: Various ultrasonic surgical instruments are disclosed. At least one disclosed surgical instrument includes a waveguide including a blade and a transducer base plate. The transducer base plate coupled to the waveguide to define a joint at an interface between the waveguide and the transducer base plate. The transducer base plate including first and second sides defining corresponding first and second flat faces configured to receive first and second piezoelectric elements. The first and second piezoelectric elements are configured to operate in a D31 mode.