Abstract: A surgical instrument, has an end effector that includes an ultrasonic blade, and a clamp arm that moves relative to the ultrasonic blade from an opened position toward an intermediate position and a closed position. The clamp arm is offset from the ultrasonic blade to define a predetermined gap in the intermediate position between the opened position and the closed position. A clamp arm actuator connects to the clamp arm and moves from an opened configuration to a closed configuration to direct the clamp arm from the opened position toward the intermediate position and the closed position. A spacer connects with the clamp arm to inhibit movement of the clamp arm from the intermediate position toward the closed position for maintaining the predetermined gap between the clamp arm and the ultrasonic blade.

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 includes a body, an ultrasonic transducer rotatably supported within the body and having a threaded distal end, a shaft extending from the body, a waveguide extending through the shaft and having a threaded proximal end configured to threadedly engage the threaded distal end to define a threaded coupling, and an end effector at a distal end of the shaft. An integrated torque wrench mechanism is arranged within the body and includes a first torque wrench member rotationally coupled with a proximal end of the transducer, and a second torque wrench member arranged proximally of the first torque wrench member. The torque wrench members are configured to selectively couple together and frictionally engage one another to facilitate application of a predetermined maximum torque to the threaded coupling. The torque wrench members are configured to automatically decouple upon application of the predetermined maximum torque to the threaded coupling.

Abstract: A surgical instrument includes an ultrasonic waveguide extending through a body assembly. An ultrasonic blade connects to the ultrasonic waveguide. A clamp arm assembly of the surgical instrument is able to move from an opened position for receiving a tissue toward a closed position for clamping the tissue. The clamp arm assembly includes a clamp body and a clamp pad facing the ultrasonic blade. A clamp arm actuator of the surgical instrument is able to move from a first position toward a second position to direct the clamp arm assembly from the opened position toward the closed position. A modular coupling of the surgical instrument connects to the clamp pad such that at least the clamp pad can be disconnected relative to the ultrasonic blade for replacement thereof.

Abstract: Various systems and methods for controlling the activation of energy surgical instruments are disclosed. An advance energy surgical instrument, such an electrosurgical instrument or an ultrasonic surgical instrument, can include one or more sensor assemblies for detecting the state or position of the end effector, arm, or other components of the surgical instrument. A control circuit can be configured to control the activation of the surgical instrument according to the state or position of the components of the surgical instrument.

Abstract: An ultrasonic instrument includes a housing, an ultrasonic transducer support by the housing, and an integrated usage indicator. The housing is configured to removably connect to a shaft assembly. The ultrasonic transducer is configured to be acoustically connected to a waveguide and operated a predetermined number of use cycles. The integrated usage indicator is operatively connected to the housing and includes a used state indicator. The used state indicator is configured to indicate to a clinician in a used state when the ultrasonic transducer has been operated at least the predetermined number of use cycles for limiting usage of the ultrasonic transducer to the predetermined number of use cycles.

Abstract: An ultrasonic instrument includes a housing, an ultrasonic transducer support by the housing, and an integrated usage indicator. The housing is configured to removably connect to a shaft assembly. The ultrasonic transducer is configured to be acoustically connected to a waveguide and operated a predetermined number of use cycles. The integrated usage indicator is operatively connected to the housing and includes a used state indicator. The used state indicator is configured to indicate to a clinician in a used state when the ultrasonic transducer has been operated at least the predetermined number of use cycles for limiting usage of the ultrasonic transducer to the predetermined number of use cycles.

Abstract: Various systems and methods for controlling the activation of energy surgical instruments are disclosed. An advance energy surgical instrument, such an electrosurgical instrument or an ultrasonic surgical instrument, can include one or more sensor assemblies for detecting the state or position of the end effector, arm, or other components of the surgical instrument. A control circuit can be configured to control the activation of the surgical instrument according to the state or position of the components of the surgical instrument.

Abstract: An apparatus includes a body, a shaft assembly, an end effector, a first acoustic sensor, and a processor. The shaft assembly extends distally from the body. The end effector is located at the distal end of the shaft assembly. The end effector is operable to apply energy to tissue and thereby change a state of the tissue. The first acoustic sensor is configured to pick up sound emitted by tissue. The processor is in communication with the first acoustic sensor. The processor is configured to provide an automated response in response to a signal from the first acoustic sensor indicating a change in the state of the tissue.

Abstract: A surgical instrument, has an end effector that includes an ultrasonic blade, and a clamp arm that moves relative to the ultrasonic blade from an opened position toward an intermediate position and a closed position. The clamp arm is offset from the ultrasonic blade to define a predetermined gap in the intermediate position between the opened position and the closed position. A clamp arm actuator connects to the clamp arm and moves from an opened configuration to a closed configuration to direct the clamp arm from the opened position toward the intermediate position and the closed position. A spacer connects with the clamp arm to inhibit movement of the clamp arm from the intermediate position toward the closed position for maintaining the predetermined gap between the clamp arm and the ultrasonic blade.

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 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, has an end effector that includes an ultrasonic blade, and a clamp arm that moves relative to the ultrasonic blade from an opened position toward an intermediate position and a closed position. The clamp arm is offset from the ultrasonic blade to define a predetermined gap in the intermediate position between the opened position and the closed position. A clamp arm actuator connects to the clamp arm and moves from an opened configuration to a closed configuration to direct the clamp arm from the opened position toward the intermediate position and the closed position. A spacer connects with the clamp arm to inhibit movement of the clamp arm from the intermediate position toward the closed position for maintaining the predetermined gap between the clamp arm and the ultrasonic blade.

Abstract: An ultrasonic surgical instrument includes a body, an ultrasonic transducer rotatably supported within the body and having a threaded distal end, a shaft extending from the body, a waveguide extending through the shaft and having a threaded proximal end configured to threadedly engage the threaded distal end to define a threaded coupling, and an end effector at a distal end of the shaft. An integrated torque wrench mechanism is arranged within the body and includes a first torque wrench member rotationally coupled with a proximal end of the transducer, and a second torque wrench member arranged proximally of the first torque wrench member. The torque wrench members are configured to selectively couple together and frictionally engage one another to facilitate application of a predetermined maximum torque to the threaded coupling. The torque wrench members are configured to automatically decouple upon application of the predetermined maximum torque to the threaded coupling.

Abstract: Various ultrasonic instruments are disclosed. The ultrasonic instruments include an ultrasonic waveguide acoustically coupled to an ultrasonic transducer. Several techniques for acoustically coupling the ultrasonic transducer to the ultrasonic waveguide are disclosed.

Abstract: An ultrasonic surgical instrument includes a body, a shaft, an ultrasonic transducer, a waveguide, and an end effector coupled to a distal end of the shaft. A rotation knob is rotatably coupled to the body and is configured to rotate the shaft, the waveguide, and the end effector together relative to the body. A torque transfer structure is positioned radially outwardly of and in direct contact with the waveguide at an acoustic node thereof. The torque transfer structure is rotationally fixed relative to the waveguide and is configured to rotationally couple the waveguide with the shaft and the rotation knob. The waveguide includes a first axial constraining feature defining a distally facing surface, and the torque transfer structure includes a second axial constraining feature defining a proximally facing surface configured to abut the distally facing surface to constrain the waveguide axially relative to the torque transfer structure and the body.

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: Disclosed is an ultrasonic surgical instrument comprising a transducer base plate, first and second piezoelectric elements positioned on opposite faces of the transducer base plate. The transducer base plate is coupled to a waveguide. The waveguide is electrically coupled to the first and second piezoelectric elements by a conductive adhesive. The first and second piezoelectric elements are electrically coupled to an ultrasonic signal generator through an electrode. A thermal conductor conducts thermal energy away from the first and second piezoelectric elements. Also disclosed is a method of fabricating such an ultrasonic surgical instrument.

Abstract: An ultrasonic surgical instrument includes a body, an ultrasonic transducer rotatably supported within the body and having a threaded distal end, a shaft extending from the body, a waveguide extending through the shaft and having a threaded proximal end configured to threadedly engage the threaded distal end to define a threaded coupling, and an end effector at a distal end of the shaft. An integrated torque wrench mechanism is arranged within the body and includes a first torque wrench member rotationally coupled with a proximal end of the transducer, and a second torque wrench member arranged proximally of the first torque wrench member. The torque wrench members are configured to selectively couple together and frictionally engage one another to facilitate application of a predetermined maximum torque to the threaded coupling. The torque wrench members are configured to automatically decouple upon application of the predetermined maximum torque to the threaded coupling.

Abstract: An ultrasonic instrument includes a housing, an ultrasonic transducer support by the housing, and an integrated usage indicator. The housing is configured to removably connect to a shaft assembly. The ultrasonic transducer is configured to be acoustically connected to a waveguide and operated a predetermined number of use cycles. The integrated usage indicator is operatively connected to the housing and includes a used state indicator. The used state indicator is configured to indicate to a clinician in a used state when the ultrasonic transducer has been operated at least the predetermined number of use cycles for limiting usage of the ultrasonic transducer to the predetermined number of use cycles.