Ultrasonic surgical apparatus with silicon waveguide

An ultrasonic core for an ultrasonic surgical instrument, the core comprising:

• a longitudinally elongated, generally planar waveguide constructed from a single crystal or polycrystalline material, the waveguide including, in order, a first resonator or proximal end portion, a transduction portion, and a second resonator, wherein the second resonator is configured to vary the magnitude of a mode of ultrasonic vibration created in the transduction portion, and the second resonator includes a proximal end having first transverse extent, a distal end having a second, lesser transverse extent, and a body generally narrowing between the first and second transverse extents;
• and
• a transducing structure, including at least a transducer, affixed upon at least one side of the transduction portion of the waveguide;
• wherein the transducer is constructed from a piezoelectric or electrostrictive ceramic, and the transducer is directly bonded to a side of the transduction portion, the transduction portion includes at least one aperture, the transducer includes a bridging portion bridging the transduction portion through the aperture, and the transducer is directly bonded to both sides of the transduction portion.

An ultrasonic core for an ultrasonic surgical instrument, the core comprising:

• a longitudinally elongated, generally planar waveguide constructed from a single crystal or polycrystalline material, the waveguide including, in order, a first resonator or proximal end portion, a transduction portion, and a second resonator;
• and
• a transducing structure, including at least one transducer configured to create a transverse mode of vibration, affixed upon at least one side of the transduction portion of the waveguide;
• wherein a first transducer is affixed upon an exposed side of the transduction portion, a second transducer is affixed upon an opposite exposed side of the transduction portion, and the first and second transducers are configured to operate in a transverse resonant mode perpendicular to the plane of the waveguide, with the first transducer 180 degrees out of phase with the second transducer.

An ultrasonic core for an ultrasonic surgical instrument, the core comprising:

• a longitudinally elongated, generally planar waveguide constructed from a single crystal or polycrystalline material, the waveguide including, in order, a first resonator or proximal end portion, a transduction portion, and a second resonator;
• and
• a transducing structure, including at least a transducer, affixed upon at least one side of the transduction portion of the waveguide;
• wherein the transduction portion includes at least one electrical contact disposed on an exposed side of the transduction portion;
• and wherein the transducer includes an electrode portion joined to the electrical contact by a braze.

An ultrasonic core for an ultrasonic surgical instrument, the core comprising:

• a longitudinally elongated, generally planar waveguide constructed from a single crystal or polycrystalline material, the waveguide including, in order, a first resonator or proximal end portion, a transduction portion, and a second resonator;
• and
• a transducing structure, including at least a transducer, affixed upon at least one side of the transduction portion of the waveguide;
• wherein the transduction portion includes first and second generally linear arrays of electrical contacts disposed on an exposed side of the transduction portion, with the first array electrically connected to a first remote electrical contact, and the second array electrically connected to a second remote electrical contact.

An ultrasonic core for an ultrasonic surgical instrument, the core comprising:

• a longitudinally elongated, generally planar waveguide constructed from a single crystal or polycrystalline material, the waveguide including, in order, a first resonator or proximal end portion, a transduction portion, and a second resonator;
• and
• a transducing structure, including at least a transducer, affixed upon at least one side of the transduction portion of the waveguide;
• wherein the transduction portion is configured to have a first plurality of source electrical contacts and a second plurality of ground electrical contacts, both disposed on an exposed side of the transduction portion, with the first plurality electrically connected to an electric source and the second plurality electrically connected to an electric ground;
• wherein the transducer is a multi-element transducer stack indirectly bonded to the transduction portion at least through a first plurality of source electrical contacts, electrically connected to the elements of the stack to supply power, and a second plurality of ground contacts, electrically connected to the elements of the stack to provide ground;
• and wherein the first plurality of source electrical contacts of the transducer stack are conductively bonded to the first plurality of source electrical contacts of the transduction portion, and the second plurality of ground electrical contacts of the transducer stack are conductively bonded to the second plurality of ground electrical contacts of the transduction portion.

An ultrasonic core for an ultrasonic surgical instrument, the core comprising:

• a longitudinally elongated, generally planar waveguide constructed from a single crystal or polycrystalline material, the waveguide including, in order, a first resonator or proximal end portion, a transduction portion, and a second resonator;
• and
• a transducing structure, including at least a transducer, affixed upon at least one side of the transduction portion of the waveguide;
• wherein an end mass is affixed to the first resonator or proximal end, the first resonator or proximal end is a projecting portion of the waveguide including at least one aperture, the end mass includes at least one corresponding aperture, and the projecting portion and end mass are joined by a compressive fastener received in the apertures.

An ultrasonic core for an ultrasonic surgical instrument, the core comprising:

• a longitudinally elongated, generally planar waveguide constructed from a single crystal or polycrystalline material, the waveguide including, in order, a first resonator or proximal end portion, a transduction portion, and a second resonator;
• and
• a transducing structure, including at least a transducer, affixed upon at least one side of the transduction portion of the waveguide;
• wherein an end mass is affixed to the first resonator or proximal end, the first resonator or proximal end is a projecting portion of the waveguide, and the end mass includes a channel configured to receive the projecting portion.