CN109862837A - 用于超声换能器的电连接和热连接 - Google Patents
用于超声换能器的电连接和热连接 Download PDFInfo
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- CN109862837A CN109862837A CN201780066050.1A CN201780066050A CN109862837A CN 109862837 A CN109862837 A CN 109862837A CN 201780066050 A CN201780066050 A CN 201780066050A CN 109862837 A CN109862837 A CN 109862837A
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- piezoelectric element
- waveguide
- energy converter
- surgical instrument
- electrode
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- Surgical Instruments (AREA)
- Transducers For Ultrasonic Waves (AREA)
- Apparatuses For Generation Of Mechanical Vibrations (AREA)
Abstract
本发明公开了一种超声外科器械，所述超声外科器械包括换能器基板、位于所述换能器基板的相对面上的第一电压元件和第二压电元件。所述换能器基板联接到波导。所述波导通过导电粘合剂电联接到所述第一电压元件和所述第二压电元件。所述第一电压元件和所述第二压电元件通过电极电耦合到超声信号发生器。热导体传导热能远离所述第一电压元件和所述第二压电元件。本发明还公开了一种制造这种超声外科器械的方法。
Description
优先权
本申请要求2016年8月25日提交的美国临时专利申请序列号62/379,550的权益，该临时专利申请全文以引用方式并入本文。
背景技术
本公开大体涉及超声外科器械，并且更具体地涉及用于驱动超声波导的超声换能器。包括空芯器械和实芯器械两者在内的超声器械用于安全有效地治疗许多医学病症。超声器械，尤其是实芯超声器械是有利的，因为它们可以向外科手术末端执行器传输超声频率的机械振动，以这种形式的能量切割和/或凝结有机组织。当以合适的能量级传输至有机组织并且使用合适的末端执行器时，超声振动可用于切割、解剖、拉升或烧灼组织或用于使肌肉组织与骨骼分离。由于通过波导从超声转换器可传输至外科手术末端执行器的超声能量的量，使用实芯技术的超声器械尤其有利。此类器械可用于其中端部执行器穿过套管针到达手术部位的开放式手术或微创手术，例如内窥镜式手术或腹腔镜式手术。
以超声频率激活此类器械的末端执行器(例如，切割超声刀)可引发纵向振动，该纵向振动在相邻组织内产生局部热量。由于超声器械的性质，因此特定的超声致动端部执行器可被设计用来执行多个功能，包括(例如)切割和凝结。例如，通过电激活换能器在外科手术末端执行器中引发超声振动。换能器可由器械手柄中的一个或多个压电元件或磁致伸缩元件构成。换能器产生的振动经由从换能器延伸至外科手术末端执行器的超声波导传输至外科手术末端执行器。波导和末端执行器被设计为与换能器以相同的频率共振。因此，当端部执行器附接到换能器时，整个系统的频率与换能器自身的频率相同。
末端执行器在顶端处的纵向超声振动的振幅d表现为共振频率的简单正弦曲线，用以下公式表示：
d＝A sin(ωt)
其中：
ω＝2π乘以循环频率f的角频率；和
A＝零至峰的幅值。
将末端执行器顶端的纵向偏移定义为峰到峰(p-t-p)振幅，其恰好为正弦波振幅的两倍或2A。通常，末端执行器可包括刀片，由于所述纵向偏移，该刀片可切割和/或凝结组织。在2001年9月4日发布并且题目为“METHOD OF BALANCING ASYMMETRIC ULTRASONICSURGICAL BLADES”的美国专利6,283,981；在2001年10月30日发布并且题目为“CURVEDULTRASONIC WAVEGUIDE HAVING A TRAPEZOIDAL CROSS SECTION”的美国专利6,309,400；以及在2002年8月20日发布并且题目为“BALANCED ULTRASONIC WAVEGUIDE INCLUDING APLURALITY OF BALANCE ASYMMETRIES”的美国专利6,436,115公开了各种超声外科器械，其全部公开内容通过引用并入本文。
发明内容
在一总体方面，各种方面涉及一种包括换能器的超声外科器械，所述换能器被配置成能够沿着外科工具的纵向轴线生成预定频率的振动。在各个方面中，外科工具可以包括沿纵向轴线延伸并且联接到换能器的超声波导。在各个方面中，外科工具包括具有近端和远端的主体，其中远端可通过换能器所产生的振动相对于纵向轴线移动，并且近端机械地联接到换能器。
在一个方面中，提供了一种超声外科器械。所述超声外科器械包括换能器基板(例如，换能器安装部分)，所述换能器基板包括第一面和第二面；第一压电元件，所述第一压电元件位于所述第一面上；第二压电元件，所述第二压电元件位于所述第二面上，其中所述第一电压元件和所述第二压电元件各自被配置成能够相对于联接到所述换能器基板的波导的纵向轴线以D31模式操作，其中所述波导通过导电粘合剂来电联接到所述第一压电元件和所述第二压电元件；电极，所述电极被配置成能够将所述第一电压元件和所述第二压电元件电联接到超声信号发生器；和热导体，所述热导体被配置成能够传导热能远离所述第一电压元件和所述第二压电元件。
在另一个方面中，提供了一种制造超声外科器械的方法。该方法包括从扁平金属原料的一部分加工换能器基板，其中所述换能器基板包括第一面和第二面；将第一压电元件定位在所述第一面上；将第二压电元件定位在所述第二面上，其中所述第一电压元件和所述第二压电元件各自被配置成能够相对于联接到所述换能器基板的波导的纵向轴线以D31模式操作；通过第一导电粘合剂将所述波导联接到所述第一压电元件和所述第二压电元件；通过电极来抵靠所述第一电压元件和所述第二压电元件进行压缩，以将所述第一电压元件和所述第二压电元件电联接到超声信号发生器；以及通过热导体传导热量远离所述第一电压元件和所述第二压电元件。
在另一方面中，提供了一种换能器基板。所述换能器基板包括：第一面和第二面，其中第一压电元件位于所述第一面上并且第二压电元件位于所述第二面上，并且其中所述第一电压元件和所述第二压电元件各自被配置成能够相对于联接到所述换能器基板的波导的纵向轴线以D31模式操作；导电粘合剂，所述导电粘合剂用于将所述第一电压元件和所述第二压电元件电联接到所述波导；电极，所述电极被配置成能够将所述第一电压元件和所述第二压电元件电联接到超声信号发生器；和热导体，所述热导体被配置成能够传导热量远离所述第一电压元件和所述第二压电元件。
在另一个方面，提供了一种超声换能器组件。所述超声换能器组件包括多个压电元件的堆叠，其中所述堆叠被配置成能够相对于联接到所述换能器基板的波导的纵向轴线以D33模式；压缩板，所述压缩板用于压缩所述多个压电元件的堆叠以将所述压电元件的堆叠联接到波导；和压缩元件，所述压缩元件用于抵靠所述压缩板施加压缩力。
附图说明
各种方面的特征在所附权利要求书中进行了特别描述。然而，通过参考以下结合如下附图所作的说明可最好地理解所述多个方面(有关手术组织和方法)及其进一步的目的和优点。
图1示出了根据本公开的一个方面的超声外科器械系统。
图2A-2C示出了根据本公开的一个方面的压电换能器。
图3示出了根据本公开的一个方面的D31超声换能器架构，其包括超声波导和固定到超声波导的一个或多个压电元件。
图4是根据本公开的一个方面换能器组件的透视图，该换能器组件采用楔形配置并被配置成能够以D33操作模式操作。
图5A是根据本公开的一个方面的沿图4所示的剖面线5A-5A截取的图4所示的超声换能器组件的剖视图。
图5B是根据本公开的一个方面的沿图4所示的剖面线5B-5B截取的图4所示的超声换能器组件的剖视图。
图5C-5D示出了根据本公开的一个方面的如图5A和图5B所示的沿类似剖面线截取的采用另一种楔形配置的超声换能器组件6805的截面视图。
图6是根据本发明的一个方面的超声换能器组件的透视图，该超声换能器组件采用螺钉来压靠压缩板以将压电元件压缩和声学联接到超声波导。
图7是沿图6所示的截面7-7截取的图6所示的超声换能器组件的剖视图。
图8是根据本公开的一个方面的螺钉的透视图。
图9示出了根据本公开的一个方面的被配置成能够以D31操作模式操作的超声外科器械。
图10是根据本发明的一个方面的换能器组件的剖视图，该换能器组件包括位于波导的第一侧上的第一压电元件和位于波导的第二相对侧上的第二压电元件。
图11是根据本公开的一个方面的被配置成能够以D31操作模式操作的超声外科器械的剖视图。
图12是根据本公开的一个方面的被配置成能够以D31操作模式操作的超声外科器械的分解图。
图13A是根据本公开的一个方面的被配置成能够以D31操作模式操作的超声外科器械的侧视图。
图13B是根据本公开的一个方面的图13A所示的超声波外科器械的侧面的剖视图。
图14是根据本公开的一个方面的图13A所示的超声波外科器械的顶视图。
图15是根据本公开的一个方面的图13A所示的超声波外科器械的后剖视图。
图16A是根据本公开的一个方面的以平坦配置的电极垫片的平面图。
图16B是根据本公开的一个方面的以折叠配置的图16A所示的电极垫片的透视图。
图17A-17B是根据本发明的一个方面的图13A所示的超声外科器械的一部分的视图，其中聚酰亚胺膜材料涂层作为绝缘体位于电极垫片上。
图18是根据本公开的一个方面的被配置成能够以D31操作模式操作的超声外科器械的透视图。
图19是根据本公开的一个方面的图18所示的超声波外科器械的电极的透视图。
图20是根据本公开的一个方面的图18所示的超声外科器械的换能器组件的平面图，该超声外科器械包括被配置成能够接收电极的凹陷接收部分。
图21A是根据本公开的一个方面的图20所示的换能器组件的纵向剖视图，具有电极的一部分、模制的互连焊盘、接收区域和凹陷接收部分的一部分。
图21B是根据本公开的一个方面的图20所示的换能器组件的横向剖视图，具有电极的一部分、模制的互连焊盘、接收区域和凹陷接收部分。
图22A-22C示出了根据本公开的一个方面的将图18所示的超声外科器械的电极的组装到凹陷接收部分中的过程。
图23A-23B示出了根据本公开的一个方面的图20所示的换能器组件的组装过程，其中将电极从初始未压缩状态组装到最终压缩状态。
图24示出了根据本公开的一个方面的被配置成能够以D31操作模式操作的超声外科器械的方面。
图25是根据本公开的一个方面的沿图24所示的剖面线25-25截取的图24所示的超声外科器械的剖视图。
图26是根据本公开的一个方面的图24所示的超声波外科器械的上散热器半部的透视图。
图27是根据本公开的一个方面的被配置成能够以D31操作模式操作的超声外科器械的透视图。
图28示出了根据本公开的一个方面的D31超声外科器械，其包括通过导电粘合剂在一侧附接到超声波导并且通过导电粘合剂在另一侧附接到导电板的压电元件。
图29是根据本公开的一个方面的被配置成能够以D31操作模式操作的超声外科器械的透视图。
图30是根据本发明的一个方面的图29所示的超声外科器械的剖视图，其中导电电极被配置成能够压缩压电元件和超声波导。
图31A示出了根据本公开的一个方面的在组装和极化之前的超声外科器械。
图31B示出了根据本公开的一个方面的在极化之前的图31A的超声外科器械以及以D31配置固定到超声波导的第一未极化压电元件和第二未极化压电元件。
图31C示出了根据本公开的一个方面的在极化之前的图31B的超声器械以及以D31配置固定到超声波导的第一未极化压电元件和第二未极化压电元件。
具体实施方式
本申请的申请人拥有于与其同时提交且各自全文以引用方式并入本文的以下专利申请：
发明人Jeffrey Messerly等人在2017年8月17日提交的题目为“UltrasonicTransducer Techniques for Ultrasonic Surgical Instrument”的代理人案号END7919USNP/160045M，
发明人Jeffrey Messerly等人在2017年8月17日提交的题目为“UltrasonicTransducer For Surgical Instrument”的代理人案号END7919USNP1/160045-1，
发明人Jeffrey Messerly等人在2017年8月17日提交的题目为“UltrasonicTransducer To Waveguide Acoustic Coupling,Connections,and Configurations”的代理人案号END7919USNP3/160045-3，
发明人Jeffrey Messerly等人在2017年8月17日提交的题目为“UltrasonicTransducer to Waveguide Joining”的代理人案号END7919USNP4/160045-4，
发明人Jeffrey Messerly等人在2017年8月17日提交的题目为“Tissue Loadingof a Surgical Instrument”的代理人案号END7919USNP5/160045-5。
在详细说明各种方面之前，应该指出的是，这些方面的应用或使用并不局限于附图和具体实施方式中详细示出的部件的构造和布置。示例性方面可以单独实施，也可以与其他方面、变更形式和修改形式结合在一起实施，并可以通过多种方式实践或执行。例如，以下公开的外科器械为示例性的，而并非旨在限制它们的范围或应用。此外，除非另外指明，否则本申请所用的术语和表达是为了方便读者而针对示例性方面进行描述的目而选，并非限制其范围。
现在将描述某些方面，以提供对本发明所公开的结构、功能、制造的原理、设备的用途和方法的全面理解。这些方面的一个或多个示例在附图中示出。本领域的普通技术人员将会理解，本申请特别描述和在附图中示出的器械和方法为非限制性的示例性方面，并且多个方面的范围仅由权利要求书限定。结合一个方面示出或描述的特征部可与其它方面的特征部进行组合。此类修改和变型旨在包括在权利要求书的范围内。
本申请所述的各种方面总体涉及超声外科器械以及与其一起使用的刀片。在美国专利5,322,055；5,954,736；6,309,400；6,278,218；6,283,981；6,325,811；和8,319,400中公开了超声外科器械和刀片的示例，其中所述专利的全部公开内容通过引用并入本文。
根据本公开的各个方面，公开了电联接外科工具的部件的各种方法。外科工具可以是超声外科器械的部件。
图1示出了超声系统10的一个方面。超声系统10的一个方面包括联接到超声换能器14的超声信号发生器12、包括手柄壳体16的手柄组件60以及末端执行器50。超声换能器14(称为“Langevin stack”)通常包括换能部分18、第一共振器或端罩20、第二共振器或前罩22以及辅助部件。在多个方面中，超声换能器14的长度优选地为二分之一系统波长的整数倍(nλ/2)，如下面所详细描述。声学组件24可包括超声换能器14、安装座26、速度变换器28和表面30。
应当理解，本文使用的术语“近”和“远”是相对于握住手柄组件60的外科医生而言的。因此，端部执行器50相对于较近侧的手柄组件60而言处于远侧。还应该理解，为方便和清晰起见，本文根据临床医生握住手柄组件60来使用诸如“顶部”和“底部”的空间术语。然而，外科器械能够在许多取向和位置中使用，并且这些术语并非旨在为限制性的和绝对的。
端罩20的远侧端部连接至换能部分18的近侧端部，前罩22的近侧端部连接至换能部分18的远侧端部。前罩22和端罩20的长度由多个变量来确定，这多个变量包括换能部分18的厚度、用于制造端罩20和前罩22的材料的密度和弹性模量以及超声换能器14的共振频率。可使前罩22从其近端到其远端向内成锥形，用于随着速度变换器28放大超声振动振幅，或者前罩22可不进行放大。
再参照图1，端罩20可包括从其延伸的螺纹构件，该螺纹构件可被构造成能够与前罩22中的螺纹孔通过螺纹配合。在多个方面中，当端罩20和前罩22组装在一起时，压电元件(例如，压电元件32)可被压缩于端罩20和前罩22之间。压电元件32可由任何合适的材料制成，例如锆钛酸铅、偏铌酸铅、钛酸铅和/或任何合适的压电晶体材料。
在多个方面中，如下面更详细讨论，换能器14还可包括电极，例如正电极34和负电极36，所述电极可被配置成能够在一个或多个压电元件32两端形成电势。正电极34、负电极36和压电元件32中的每一个可具有中心穿孔，所述穿孔可被构造成接纳端罩20的螺纹构件。在多个方面中，正电极34和负电极36分别电联接到导线38和40，其中导线38和40可包裹在线缆42内，并可电连接至超声系统10的超声信号发生器12。
在多个方面中，声学组件24的超声换能器14将来自超声信号发生器12的电信号转化为机械能，该机械能使超声换能器24和末端执行器50以超声频率主要在纵向振动运动。合适的发生器为得自Ethicon Endo-Surgery,Inc.(Cincinnati,Ohio)的型号GEN11。当声学组件24通电时，振动驻波通过声学组件24产生。合适的振动频率范围可为约20Hz至120kHz，较为适当的振动频率范围可为约30kHz-70kHz，一个示例性的操作振动频率可为大约55.5kHz。
沿声学组件24的任何点处的振动振幅可取决于沿声学组件24测量振动的位置。振动驻波的最小或零交点通常称为波节(即，运动通常最小的位置)，而驻波的最大绝对值或峰值通常称为波腹(即，运动通常最大的位置)。波腹与距其最近的节点之间的距离为四分之一波长(λ/4)。
如上所述，导线38和40将电信号从超声信号发生器12发送到正电极34和负电极36。响应于(例如)脚踏开关44，通过超声信号发生器12提供的电信号给压电元件32供电，从而在声学组件24中生成声驻波。电信号在压电元件32中引起反复小位移形式的扰动，使材料中出现较大的压缩力。重复的小位移会使压电元件32以连续方式沿着电压梯度的轴线膨胀和缩回，从而产生超声能量的纵向波。
在多个方面中，换能器14所生成的超声能量可经由超声传输波导46通过声学组件24传输至末端执行器50。为了使声学组件24将能量传递到末端执行器50，声学组件24的部件与末端执行器50声学联接。例如，超声换能器14的远端可在表面30处通过螺纹连接(例如，螺柱48)与超声传输波导46的近端声学连接。
可对声学组件24的部件进行声学调谐，使得任何组件的长度均为二分之一波长的整数倍(nλ/2)，其中波长λ是声学组件24的预选或工作纵向振动驱动频率fd的波长，并且其中n为任意正整数。还可考虑声学组件24结合任何合适的声学元件布置。
超声端部执行器50的长度可基本上等于系统半波长(λ/2)的整数倍。超声末端执行器50的远端52可设置在波腹处(或至少其附近)，以便提供远端的最大(或至少接近最大)纵向偏移。在多个方面中，当换能器组件通电时，超声末端执行器50的远端52可被配置成能够以预定振动频率在例如大约10至500微米峰到峰的范围内运动，并且优选地在大约30至150微米的范围内运动。
如上所述，超声末端执行器50可联接到超声传输波导46。在多个方面中，如图所示的超声末端执行器50和超声传输波导46由适合超声能量传输的材料以一体形式制成。所述材料为例如Ti6Al4V(含铝和钒的钛合金)、铝、不锈钢和/或任何其他合适的材料。另一种情况，超声末端执行器50可与超声传输波导46分离，并可通过例如螺柱、焊接、粘合剂、快速连接或其他合适的已知方法连接在一起。超声传输波导46的长度可(例如)基本上等于二分之一系统波长(λ/2)的整数倍。超声传输波导46可优选地由使用例如钛合金(即，Ti6Al4V)或铝合金等适合高效传输超声能量的材料制造的实芯轴加工而成。
在图1所示的方面中，超声传输波导46包括位于多个波节处(或至少其附近)的多个起稳定作用的硅树脂环或适形支撑件56。硅树脂环56可抑制不期望的振动并将超声能量与至少部分地围绕波导46的护套58隔离，从而确保超声能量以最大效率沿纵向流至末端执行器50的远端52。
如图1所示，护套58可联接到手柄组件60的远端。护套58通常包括适配器或鼻锥62和细长管状构件64。管状构件64附接到适配器62和/或从其延伸，并具有纵向贯穿其中的开口。在多个方面中，护套58可通过螺纹连接或按扣到壳体16的远端上。在至少一个方面中，超声传输波导46穿过管状构件64的所述开口延伸，硅树脂环56可接触所述开口的侧壁并隔离其中的超声传输波导46。在多个方面中，护套58的适配器62优选由例如构造而成，管状构件64由例如不锈钢加工而成。在至少一个方面中，超声传输波导46可带有围绕其的(例如)聚合材料，以便将其与外部接触隔离。
如上所述，电压或功率源可与换能器的一个或多个压电元件可操作地联接，其中施加于每一压电元件的电势可使压电元件沿纵向伸展和收缩(或振动)。也如上所述，电势可为循环的，并且在多个方面中，电势可以与具有包括例如换能器14、波导46和末端执行器50在内的部件的系统的谐振频率相同(或几乎相同)的频率循环。然而，在多个方面中，换能器内的某些压电元件可比换能器内的其他压电元件对纵向振动驻波贡献更多。更具体地讲，换能器内可产生纵向应变分布，其中应变分布可控制或限制纵向位移，使得一些压电元件对振动驻波做出贡献，尤其是当系统以其谐振频率或接近谐振频率振动时。
参考图1的超声外科器械系统10可以认识到，可能需要多个部件以将来自压电元件32的机械振动通过波导46联接到末端执行器50。包括声学组件24的附加元件可能向系统添加附加的制造成本、制造步骤和复杂性。以下公开了超声医疗装置的方面，该超声医疗装置可能需要比图1所示和以上公开的等效装置更少的部件、制造步骤和成本。
再次参考图1，压电元件32被配置成“Langevin”堆叠，其中压电元件32和其激活电极34和36(与换能器14仪器)是交错的。激活的压电元件32的机械振动沿换能器14的纵向轴线传播，并且经由声学组件24联接到波导46的端部。压电元件的这种操作模式经常被描述为元件的D33模式，特别是对于包括例如锆钛酸铅、偏铌酸铅或钛酸铅的陶瓷压电元件。在图2A-2C中示出了陶瓷压电元件的D33模式。
图2A描绘了由陶瓷压电材料制成的压电元件200。压电陶瓷材料是包括多个单独微晶域的多晶材料。每个微晶域具有偏振轴线，域可以响应于施加的电场而沿着该偏振轴线膨胀或收缩。然而，在天然陶瓷中，微晶域的极化轴线是随机排列的，因此在块状陶瓷中没有净压电效应。可以通过使陶瓷经受高于材料的居里温度的温度并将材料置于强电场中来引发产生偏振轴线的净重定向。一旦样品的温度下降至居里温度以下，大部分的单独偏振轴线将被重定向并固定在块极化方向上。图2A示出了在沿着感应电场轴线P极化之后的这种压电元件200。虽然未极化的压电元件200没有任何净压电轴线，但极化的元件200可以被描述为具有与感应场轴线P方向平行的偏振轴线d3。为了完整起见，与d3轴线正交的轴线可以被称为d1轴线。压电元件200的尺寸被标记为长度(L)、宽度(W)和厚度(T)。
图2B和图2C示出了压电元件200的机械变形，其可以通过使压电元件200经受沿着d3(或P)轴线定向的致动电场E而引发。图2B示出了在压电元件205上具有与沿d3轴线的极化场P相同的方向的电场E的影响。如图2B所示，压电元件205可以通过沿d3轴线膨胀并同时沿d1轴线压缩而变形。图2C示出了在压电元件210上具有与沿d3轴线的极化场P相反的方向的电场E的影响。如图2C所示，压电元件210可以通过沿d3轴线压缩并同时沿着d1轴线膨胀而变形。在沿d3轴线施加电场期间的沿d3轴线的振动联接可以被称为使用压电元件的D33模式的D33联接或激活。图1所示的换能器14使用压电元件32的D33模式以用于沿波导46将机械振动传输到末端执行器50。因为压电元件也沿着d1轴线变形，所以在沿d3轴线施加电场期间的沿d1轴线的振动联接也可以是机械振动的有效来源。这种联接可以被称为使用压电元件的D31模式的D31联接或激活。
如图2A-2C所示，在以D31模式的操作期间，压电元件200、205、210的横向膨胀可以通过以下等式在数学上建模：
在该等式中，L、W和T分别是指压电元件的长度、宽度和厚度尺寸。Vd31表示施加到以D31模式操作的压电元件的电压。由上述D31联接产生的横向膨胀量由ΔL(即压电元件沿长度方向的膨胀)和ΔW(即压电元件沿宽度方向的膨胀)表示。附加地，横向膨胀等式对ΔL和ΔW与施加电压Vd31之间的关系进行建模。以下公开了基于压电元件的D31激活的超声医疗装置的方面。
在各个方面中，如下所述，超声医疗装置可以包括：换能器，该换能器被配置成能够产生纵向振动；以及外科工具，该外科工具具有可操作地联接到换能器的换能器基板、末端执行器和其间的波导。在一些方面中，也以下所述，换能器可生成能够传输至末端执行器的振动，其中所述振动可以谐振频率(或接近谐振频率)驱动换能器基板、波导、末端执行器和/或超声医疗装置的其他各种部件。在谐振中，可在例如换能器、波导和/或末端执行器中产生纵向应变图或纵向应力图。换能器基板包括用于接收压电元件的在相对侧上的平面。在多个方面中，此类纵向应变图或纵向应力图可导致纵向应变或纵向应力沿着换能器基板、波导和/或末端执行器的长度以正弦(或大致正弦)方式变化。在至少一个方面中，例如，纵向应变图可具有最大峰和零点，其中在这样的峰和零点之间应变值可以非线性方式变化。
图3示出了根据本公开的一个方面的超声外科器械250，其包括通过粘结材料附接到超声换能器264的超声波导252，其中超声外科器械250被配置成能够以D31模式操作。超声换能器264包括通过粘结材料附接到超声波导252的第一压电元件254a和第二压电元件254b。压电元件254a、254b包括导电板256a、256b以电联接适合于驱动压电元件254a、254b的电压源(例如，通常是高电压)的一个极。电压源的相反极通过导电接头258a、258b电联接到超声波导252。在一个方面中，导电板256a、256b联接到电压源的正极，并且导电接头258a、258b通过金属超声波导252电联接到地电位。在一个方面中，超声波导252由钛或钛合金(即Ti6Al4V)制成，并且压电元件254a、254b由锆钛酸铅金属间无机化合物制成，化学式为Pb[ZrxTi1-x]O3(0≤x≤1)。也称为PZT，它是一种陶瓷钙钛矿材料，其表现出显著的压电效应，这意味着当施加电场时，化合物会改变形状。它用于许多实际应用，诸如超声换能器和压电谐振器PZT。压电元件254a、254b的极化轴线(P)由方向箭头260指示。响应于压电元件254a、245b的激励的超声波导252的运动轴线由超声波导252的远端处的运动箭头262示出，该远端通常称为超声波导252的超声刀片部分。运动轴线262与极化轴线(P)260正交。
在如图1所示的常规D33超声换能器架构中，螺栓连接的压电元件32利用电极34、36来产生与每个压电元件34的两侧的电接触。然而，根据本公开的一个方面的D31架构250采用不同的技术来产生与每个压电元件254a、254b的两侧的电接触。用于提供与压电元件254a、254b的电接触的各种技术包括将导电元件(例如，导线)粘结到每个压电元件254a、254b的自由表面以用于高电位连接，以及使用焊料、导电环氧树脂或本文所述的其他技术将每个压电元件254a、254b粘结到超声波导252以用于接地连接。压缩可以用于保持与声学系的电接触而无需进行永久连接。这可以导致装置厚度的增加，并且应当被控制以避免损坏压电元件254a、254b。低压缩可以通过火花隙来损坏压电元件254a、254b，并且高压缩可以通过局部机械磨损来损坏压电元件254a、254b。在其他技术中，可以采用金属弹簧触点来形成与压电元件254a、254b的电接触。其他技术可以包括箔上泡沫垫圈、导电泡沫、焊料。与压电元件254a、254b的两侧的电连接的是D31声学系配置。如果压电元件254a、254b与超声波导252之间存在电接触，则可以对导电的金属超声波导252进行电接地连接。
在各个方面中，如下所述，超声医疗装置可以包括：换能器，该换能器被配置成能够产生纵向振动；以及外科器械，该外科器械具有可操作地联接到换能器的换能器基板、末端执行器和其间的波导。在一些方面中，也以下所述，换能器可生成能够传输至末端执行器的振动，其中所述振动可以谐振频率(或接近谐振频率)驱动换能器基板、波导、末端执行器和/或超声医疗装置的其他各种部件。在谐振中，可在例如换能器、波导和/或末端执行器中产生纵向应变图或纵向应力图。在多个方面中，此类纵向应变图或纵向应力图可导致纵向应变或纵向应力沿着换能器基板、波导和/或末端执行器的长度以正弦(或大致正弦)方式变化。在至少一个方面中，例如，纵向应变图可具有最大峰和零点，其中在这样的峰和零点之间应变值可以非线性方式变化。在如图1所示的常规D33超声换能器架构中，螺栓提供将压电元件环声学联接到超声波导的压缩。
图4是根据本公开的一个方面的被配置成能够以D33操作模式操作的换能器组件6800的透视图。换能器组件6800包括换能器6818、压电元件6808a-6808f、喇叭形部分6802、以及用于连接到超声波导的螺纹连接(诸如螺柱6804)。换能器6818包括压电元件6808a-6808f。如上所述，换能器6800可以被配置为“Langevin”堆叠(例如，具有矩形截面)，其中压电元件6808a-6808f和对应激活电极6810a-c是交错的。在一个方面中，激活电极6809a-6809g可以是导电金属(诸如铝、银、金、铜和/或其合金)的薄片材。激活电极6809a-g各自经由导电元件6810a-6810f电连接到超声信号发生器。导电元件6810a、6810b、6810c可以形成到发生器的极(例如，正极)的路径。导电元件6810d、6810e、6810f、6810g可以形成到发生器的相对极(例如，负极)的另一个路径。导电元件6810a-6810g可以是看起来类似于支架的U形短路帽。如图4所示，短路帽6810a-6810c位于压电元件6808a-f上方。在各个方面中，并非采用螺栓将压电元件6808a-6808f压缩和声学联接到超声波导，而是换能器组件6800采用楔形物6806a-6806b来抵靠压缩板6816进行压缩。进而，压缩板6816将压电元件6808压缩并声学联接到超声波导。压电元件6808a-6808f的这种压缩对于换能器6800堆叠的操作可以是有用的。压缩板6816可以由导电金属(例如钢)制成。楔形物6806a、6806b可以由导电金属(例如钢)制成。
在一个方面中，楔形物6806a(图4中未示出)、6806b可以被机加工并通过合适的成形压力来插入。附加地，楔形物6806a、6806b可以通过导电粘结材料或粘合剂来固定。除了压电元件6808，楔形物6806a、6806b，电极6809a-6809g和短路帽6810a-6810g之外，换能器组件6800包括位于换能器组件6800的相对侧上的凸缘6812a、6812b，诸如换能器组件6800的节点位置。凸缘6812a、6812b可以被配置成能够容纳在超声外科器械的壳体(未示出)的保持器内以用于将换能器组件6800牢固地附接到壳体。用楔形物6806a、6806b替换螺栓可能是有利的，这是因为换能器6800堆叠的更容易的机加工和组装。楔形配置的附加优点包括通过用楔形物6806a、6806b和压电元件6808a-6808f的相对便宜的廉价的几何形状调制换能器6800中的张力来调谐换能器组件6800的声学组件的能力。
图5A-5B示出了根据本公开的一个方面的采用楔形配置的超声换能器组件6800的截面视图，其中图5A是沿图4所示的剖面线5A-5A截取的剖视图，并且图5B是沿图4所示的剖面线5B-5B截取的剖视图。在图5A-5B中，楔形物6806a、6806b各自具有不规则的四边形或四角形形状。如果楔形物6806a、6806b的各个形状横向组合，则该组合具有正方形形状。如上所述，楔形物6806a、6806b被构造成能够通过螺柱6804将压电元件6808a-6808f压缩并声学联接到超声波导。
通过从穿过换能器组件6800的中心的纵向轴线开始并沿对应箭头5A的方向继续向右获得图5A的面向右截面图，如图4所描绘的。如在图5A中可以看到的，在一个方面中，第一对短路帽6810a-6810c可能以偏移方式连接。具体地，短路帽6810c可以在一端连接到超声波信号发生器的极并且在另一端连接到激活电极6809b。类似地，短路帽6810a可以在一端连接到激活电极6809b并且在另一端连接到激活电极6809d。短路帽6810b可以在一端连接到激活电极6809d并且在另一端连接到激活电极6809f。因此，短路帽6810a-6810c被配置成能够提供闭合将发生器连接到压电元件6808a-6808f和电极6809a-6809g的电路的安全装置。如在图5A中可以看到的，短路帽6810a位于换能器组件6800的上侧，而短路帽6810b-6810c位于换能器组件6800的下侧。
通过从穿过换能器组件6800的中心的纵向轴线开始并沿对应箭头5B的方向继续向左获得图5B的面向左截面图，如图4所描绘的。在另一方面中，如在图5B中可以看到的，第二对短路帽6810a-6810c可能以相对偏移方式连接。具体地，短路帽6810g可以在一端(与短路帽6810c连接的极相对)连接到超声波信号发生器的极，并且在另一端连接到激活电极6809a。类似地，短路帽6810d可以在一端连接到激活电极6809a并且在另一端连接到激活电极6809c。短路帽6810f可以在一端连接到激活电极6809c并且在另一端连接到激活电极6809e。短路帽6810e可以在一端连接到激活电极6809e并且在另一端连接到激活电极6809g。因此，短路帽6810d-6810g被配置成能够提供闭合将发生器连接到压电元件6808a-6808f和电极6809a-6809g的电路的安全装置。如在图5B中可以看到的，短路帽6810g和6810f位于换能器组件6800的下侧，而短路帽6810d-6810e位于换能器组件6800的上侧。
图5C-5D示出了根据本公开的一个方面的如图5A和图5B所示的沿类似剖面线截取的采用另一种楔形配置的超声换能器组件6805的截面视图。在图5C-5D中，楔形物6807a、6807b具有与图5A-5B中的楔形物6806a、6806b的形状不同的不规则四边形或四角形形状。如果楔形物6807a、6807b的各个形状纵向组合，则该组合具有正方形形状。如上所述，楔形物6807a、6807b被构造成能够通过螺柱6804将压电元件6808a-6808f压缩并声学联接到超声波导。图5C描绘了如结合图5A描述的短路帽6810a-6810c的相同配置。类似地，图5D描绘了结合图5B描述的短路帽6810d-6810g的相同配置。
图6是根据本公开内容的一个方面的类似于超声外科器械6800的超声换能器组件6850的透视图，除了换能器组件6850包括换能器6819，该换能器采用螺钉6852以抵靠压缩板6816进行压缩以将压电元件6808a-6808f压缩和声学联接到超声波导。图7是根据本公开的一个方面的沿图6所示的剖面线7-7截取的超声换能器组件6850的剖视图。现在参考图6-7，在一个方面中，在超声外科器械6850中没有使用楔形物，如图6的透视图所示。相反，螺钉6852可以紧固到压缩板6816中以抵靠压缩板6816施加压缩力，诸如通过将螺钉6852的尖头点或尖端6854(和螺纹的近侧部分)向远侧拧入压缩板6816中。如在图7的剖视图中可以看到的，螺钉6852的尖头端6854与压电元件6808的最近侧接触。螺纹6856的远侧部分和螺钉6852的头部6858从压缩板6816向远侧延伸。这种螺杆配置的优点包括避免使用中心螺栓以进行压缩和联接，以及通过用螺杆6852调节换能器6819中的张力来调节换能器组件6850的声学组件的能力。与具有中心螺栓的换能器组件相比，具有螺钉6852的换能器组件6850更容易机加工，因为螺钉6852的螺纹6856的远侧部分被简单地固定到压缩板6816中。图8是根据本公开的一个方面的螺钉6852的透视图。
图9示出了根据本公开的一个方面的被配置成能够以D31操作模式操作的超声外科器械6900。超声外科器械6900包括换能器组件6902和超声波导6904。换能器组件6902包括喇叭形部分6908，压电元件6906a、6906b，以及用于连接到超声波导6904的螺纹连接(诸如螺柱6804)。如图10所示，换能器组件6902被配置成能够在每个压电元件6906a、6906b与波导6904之间产生强机械粘结。图10是根据本发明的一个方面的换能器组件6902的剖视图，该换能器组件包括位于波导6904的第一侧上的第一压电元件6906a和位于波导6904的第二相对侧(与第一侧相对)的第二压电元件6906b。在一个方面中，波导6904包括用于分别插入压电元件6906a、6906b的第一内部凹陷部6908a和第二内部凹陷部6908b。如图10所示，相应地，第一内部凹陷部6908a可以从内部顶表面延伸到波导6904中，并且第二内部凹陷部6908a可以从内部底表面延伸到该波导中。第一凹陷部6908a和第二凹陷部6908b的深度可以分别等于或基本上等于压电元件6906a、6906b的高度。
因此，当压电元件6906a、6906b插入凹陷部6908a、6908b中时，压电元件6906a、6906b可以与波导6904齐平(即，水平或基本水平)。换句话说，压电元件6906a的最高点或部分与波导6904的外部顶表面对准。类似地，压电元件6906b的最低点或部分与波导6904的外部底表面对准。因此，压电元件6906a、6906b都不突出超过波导6904的外部顶或底表面。在另一个方面中，每个内部凹陷部6908a、6908b的长度大于每个压电元件6906a、6906b的相应长度。因此，当压电元件6906a、6906b插入相应的内部凹陷部6908a、6908b中时，存在凹陷部6908a、6908b的近侧和远侧间隙部分6910a、6910b。将诸如固化环氧树脂粘合剂6912a、6912b的粘结材料(例如，导电粘合剂)施加到间隙部分6910a、6910b中的每一个。
因此，在每个压电元件6906a、6906b与波导6904之间产生了牢固且持久的机械粘结，因为在换能器6902的操作期间环氧树脂粘合剂6912a、6912b粘结失效的风险较低。具体地，环氧树脂的拉伸强度可以显著大于环氧树脂的剪切强度。在换能器6902的操作期间，环氧树脂粘合剂6912a、6912b可能经历高程度的剪切载荷，这可能致使环氧树脂粘合剂6912a、6912b的粘结例如经由分层而失效。然而，如图10的换能器组件6902所示，环氧树脂粘合剂6912a、6912b以拉伸配置加载，这可导致较低的粘合失败率。因此，图10的换能器配置的优点包括每个压电元件6906a、6906b与波导6904之间的强机械联接。在另一个方面中，没有粘结材料可以施加到压电元件6906a、6906b的与波导6904接触的表面。
根据本发明的一个方面的D31架构250采用各种不同技术来将压电元件254a，254b电联接和热联接到超声波导252。以下公开了这些技术。图11是根据本公开的一个方面的被配置成能够以D31操作模式操作的超声外科器械6000的剖视图。超声外科器械6000包括通过粘结材料附接到超声波导6014的超声换能器6012。超声外科器械6000包括波导6014，第一电压元件6004a和第二压电元件6004b，第一导电元件6006a和第二导电元件6006b，以及包覆模制的壳体6010。换能器6012的部件包括通过诸如第一导电粘合剂6008a和第二导电粘合剂6008b的粘结材料附接到波导6014的相对侧的第一电压元件6004a和第二压电元件6004b。例如，第一导电粘合剂6008a和第二导电粘合剂6008b可以是导电环氧树脂粘合剂。
如图11所示，压电元件6004a的下表面通过导电粘合剂6008a联接到波导6014，并且压电元件6004b的上表面通过导电粘合剂6008b联接到波导6014。下表面和上表面可以是相对的。包覆模制的壳体6010可以通过合适的包覆模制过程(诸如低压热熔粘合剂模制过程)来形成。例如，加利福尼亚州尔湾市的Henkel Electronic Materials LLC的模制过程可以与合适的聚酰胺或聚烯烃一起使用以形成包覆模制的壳体6010。包覆模制的壳体6010被构造成能够包围超声外科器械6000的至少一部分。在一个方面中，包覆模制的壳体6010包围换能器6012和波导6014的近侧部分。通过包围第一电压元件6004a和第二压电元件6004b和波导6014的近侧部分，包覆模制的壳体6010可以确保压电元件6004a、6004b与波导6014之间的持久且一致的附接或联接。
具体地，包覆模制的壳体6010可以被构造成能够将第一电压元件6004a和第二压电元件6004b压靠在波导6014或者以摩擦配合保持元件6004a、6004b和波导6014。附加地，包覆模制的壳体6010可以形成为包括用于导电元件6006a、6006b的非模制部分以从包覆模制的壳体6010突出。如图11所示，引线6006a、6006b从壳体6014向近侧突出以将第一电压元件6004a和第二压电元件6004b电联接到超声信号发生器。在一个方面中，第一电压元件6004a和第二压电元件6004b电联接到超声信号发生器的正极。如图11所示，波导6002可以向远侧逐渐变细。压电元件6004a、6004b可以由陶瓷材料(诸如PZT)构成。导电元件6006a、6006b可以是电连接器，诸如导线、引线、金属导电焊盘(例如，焊接掩模限定焊盘(SMD)或非焊接掩模限定焊盘(NSMD))，或其他合适的电连接器。
图12是根据本公开的一个方面的被配置成能够以D31操作模式操作的超声外科器械6100的分解图。超声外科器械6100包括多个板部件，包括第一电极板6102a和第二电极板6102b，第一压电板6104a和第二压电板6104b，换能器基板6106(例如，换能器安装部分)，导电元件(诸如导线环6112)和波普空心铆钉6114。在一个方面中，板6102a、6102b、6104a、6104b、6106中的每一个板各自包括带槽的接收孔6118，其可以通过合适的机械加工过程来形成。每个带槽的接收孔6118可以被配置成能够接收导线环6112以电联接板6102a、6102b、6104a、6104b、6106。具体地，当与波普空心铆钉6114结合时，导线环6112可以联接到电压或能量源(例如，超声信号发生器)的正极。换能器基板6106可以用作使电流流过导线环6112的电接地。可以通过换能器基板6106的接地导线6110来实现与电接地的连接。
在另一方面中，接地导线6110经由合适的装置来焊接、机械环绕或以其他方式联接到换能器基板6106。除了带槽的接收孔6118和接地导线6118之外，换能器基板6106包括凸缘6108a、6108b，该凸缘6108a、6108b可以被配置成能够容纳在超声外科器械6100的壳体(未示出)的保持器内以用于将换能器基板6106牢固地附接到壳体。在另一方面中，波普空心铆钉6114被构造成能够通过穿过6102a、6102b、6104a、6104b、6106中的每一个和导线环6112插入，使得波普空心铆钉6114压缩电极板6102a、6102b，其进而压缩压电板6104a、6104b。与图11所示的方面不同，例如，超声外科器械6100可以不需要使用环氧树脂来进行电联接。相反，波普空心铆钉6114通过电极板6102a、6102b提供压缩以将压电板6104a、6104b电联接到超声外科器械6100的波导。波普空心铆钉6114配置的优点可以包括减少的组装时间、改进的电联接(基于所提供的压缩)和降低的成本(例如，不需要环氧树脂)。
图13A是根据本公开的一个方面的被配置成能够以D31操作模式操作的超声外科器械6200的侧视图。超声手术器械6200包括超声波导6202，压电元件6204a、6204b、6204c(以虚线示出)和电极垫片6206a、6206b。超声波导6202包括压电元件6204c可以插入其中的凹陷或“切出”部分。压电元件6204c可以具有比压电元件6204a、6204b更小的表面积。在一个方面中，电极垫片6206a、6206b是扁平电极，其被配置成能够将压电元件6204a、6204b、6204c彼此电联接并将其电联接到电压或能量源(例如，超声信号发生器)。电极垫片6206a可以包括各自压靠压电元件6204a的表面的三个部分。例如，如图13A所示，电极垫片6206a的一部分被包裹到(即，在朝向超声波手术器械6200的内部部分的侧向方向上延伸以接触)压电元件6204c中，该压电元件插入波导6202的凹陷部分内以用于压电元件6204a、6204b、6204c的电联接。
附加地，如图13A中的虚线所示，电极垫片6206b也被包裹到(即，在朝向超声外科器械6200的内部部分的侧向方向上延伸以接触)压电元件6204c中以用于压电元件6204a、6204b、6204c的电联接。电极垫片6206a、6206b可以相反方向包裹到压电元件6204c中。在另一个方面中，压电元件6204a包括连接部分6208a以电联接到能量源的正极，并且压电元件6204b包括连接部分6208b以电联接到能量源的负极。因此，电流可以通过压电元件6204a、6204b、6204c和超声波导6202流过电连接部分6208a、6208b，其中超声波导6202作为电接地。
图13B是根据本公开的一个方面的超声外科器械6200的侧面的剖视图。如在图13B中可以看到的，每个电极垫片6206a、6206b的一端与压电元件6204c接触。现在参考图13A和图13B，可以使用诸如塑料或聚酰胺绝缘体6210a、6210b的电绝缘来减少或防止电短路的风险。绝缘体6210a、6210b可以位于电极垫片6206a、6206b或波导6202上，使得电流可以仅流过位于压电元件6204a、6204b之一与波导6202之间的区域的一部分。在另一个方面中，类似于压电元件6004a、6004b，压电元件6204a、6204b可以通过诸如导电环氧树脂粘合剂的粘结材料来附接到波导6202的相对侧。图14是根据本公开的一个方面的超声外科器械6200的顶视图。
在图14中，仅可见压电元件6204a。如图14所示，电极垫片6206a的第一部分6212a定位在压电元件6204a的顶表面上或包裹到该压电元件的顶表面中。电极垫片6206a的第二部分6212b位于压电元件6204a的第一侧表面上。在一个方面中，另一个电极垫片6206b的第二部分位于压电元件6204a的第二侧表面上。压电元件6204a的第一侧表面和第二侧表面是相对的。电极垫片6206a的第三部分(未示出)朝向超声外科器械6200的内部侧向延伸，使得第三部分接触压电元件6204c。位于超声外科器械6200的相对表面上的每个电绝缘体6210a、6210b的一部分可以在图14图中看到。图15是根据本公开的一个方面的超声外科器械6200的后剖视图。如在图15可以看到的，绝缘体6210a可以从压电元件6204a、6204b的侧表面延伸到波导6202与压电元件6204b之间的区域中。类似地，绝缘体6210b可以从压电元件6204a、6204b的侧表面延伸到波导6202和压电元件6204a之间的区域中。
图16A是根据本公开的一个方面的以平坦配置的电极垫片6206a的平面图。图16B是根据本公开的一个方面的以折叠配置的图16所示的电极垫片6206a的透视图。如上所述，电极垫片6206a包括第一部分6212a、第二部分6212b和第三部分6212c。此外，电极垫片6206a包括连接部分6208a以连接到例如能量源的正极。根据本公开的一个方面，图16A示出了电极垫片6206a，其可以由铜派彩制成扁平电极并可以弯曲成三个部分。第一部分6212a可以具有与波导6202相同或基本相同的长度L1。第二部分6212a可以具有与波导6202相同或基本相同的长度L2。第三部分6212a可以具有波导6202的长度L3的三分之二。除了电极垫片6206b沿相反方向定向之外，电极垫片6206b可以与电极垫片6206a相同或基本相似。图16B是根据本公开的一个方面的以弯曲配置的电极垫片6206a的透视图。
图17A-17B是根据本公开的一个方面的具有酰亚胺膜材料涂层(诸如可从特拉华州威尔明顿市的Idu Pont de Nemours and Company获得的聚酰亚胺膜)作为位于电极垫片6206a上的绝缘体6210a的超声外科器械6200的一部分的视图。如图17A所示，在一个方面中，Kapton绝缘体6210a可以涂覆到第二部分6212b和第三部分6212c之间的弯曲部分上，使得Kapton绝缘体6210a位于电极垫片6206a与波导1602之间。在另一个方面中，如图17B所示，Kapton绝缘体6210a可以被施加在第二部分6212b上，使得Kapton绝缘体6210a沿着压电元件6204a和波导6202延伸。
图18是根据本公开的一个方面的被配置成能够以D31操作模式操作的超声外科器械6300(可以被称为一对超声波剪切器或镊子)的透视图。剪切器6300包括通过紧固件6306可枢转地连接到第二臂6304的第一臂6302。第一臂6302包括位于其远端的钳口6008或夹具，该钳口6008或夹具被构造成能够与从第二臂6304向远侧延伸的末端执行器9054配合。在第一方向致动第一臂6302致使钳口6308朝向末端执行器6310枢转，并且沿第二方向致动第一臂6302致使钳口6308远离末端执行器6310枢转。在一个方面中，超声外科器械6300包括换能器组件6312，诸如换能器组件6902。换能器组件6312包括封闭第一电压元件6316a和第二压电元件6316b的壳体6314和超声波导6320。第一电压元件6316a和第二压电元件6316b通过粘结材料附接到波导6320的相对侧。换能器6318包括第一电压元件6316a和第二压电元件6316b。换能器组件6312包括凸缘6322a、6322b，该凸缘6322a、6322b可被配置成能够接收在壳体6314的保持器内以用于将换能器6318牢固地附接到壳体6314。换能器组件6312包括凹陷接收部分，该凹陷接收部分被配置成能够接收用于压缩压电元件6316a、6316b的电极。
图19是根据本公开的一个方面的超声外科器械6300的这种电极6322a的透视图。电极6322a包括基部6324和突出部分6325。图20是根据本公开的一个方面的换能器组件6312的平面图，该换能器组件包括被配置成能够接收诸如电极6322a的电极的凹陷接收部分6326a。在图20可见凹陷接收部分6326a的基部和电极6322a。如下面进一步详细描述的，电极6322a可以经由过盈配合或几何配合来定位到由基部限定的接收区域中。电极(例如，导电泡沫)6322被配置成能够压缩压电元件6316a以维持压电元件6316a与波导6320之间的电接触。在一个方面中，模制互连焊盘6328用于电联接到连接到超声信号发生器的电连接器(例如，导线)。在另一个方面中，导电粘结材料(诸如电油脂粘合剂)被施加在电极6322a与压电元件6316a之间以实现更强的电连接。
图21A是根据本公开的一个方面的换能器组件6312的纵向剖视图，其示出了电极6322a的一部分、模制互连焊盘6328、接收区域6330和凹入接收部分6326a的一部分。基于从轴线AA开始并在所描绘的对应箭头的方向上继续的截面获得纵向剖视图。图21B是根据本公开的一个方面的换能器组件6312的横向剖视图，其示出了电极6322a的一部分、模制互连焊盘6328、接收区域6330和凹入接收部分6326a。基于从轴线BB开始并在所描绘的对应箭头的方向上继续的截面获得横向剖视图。
图22A-22C示出了根据本公开的一个方面的将电极6322a组装到凹陷接收部分6326a中的过程。图22A示出了电极6322a的侧视图，该电极以一角度定位，使得基部6324的一端位于接收区域6330内，而基部6324的另一端位于接收区域6330外。如图22A所示，另一端和突出部分6325两者远离凹陷接收部分6326a突出。附加地，电极6322a不与模制的互连焊盘6328接触。图22B示出了基部6324的一端定位在接收区域6330中，使得该一端以略微过盈配合接合凹陷接收部分6326a的第一侧壁和臂6332(在第一壁近侧)。如在图22B中可以看到的，电极6322a从初始成角度位置过渡到基本平坦或水平位置，并且朝向第一侧壁移动。基部6324的另一端远离第二侧壁和另一臂6332(在第二侧壁近侧)定位。突出部分6325保持远离凹陷接收部分6326a突出。在一个方面中，臂6332从凹陷接收部分6326a的相对侧壁延伸。图22C示出了处于最终位置以用于基于朝向第二侧壁的相反方向移动来压缩压电元件6316a的电极6322a。在最终位置中，基部6324的两端的顶侧的部分与相应的臂6332接合。基部6324的两端的顶侧的剩余部分是未接触的。此外，基部6324的任一端都不与第一侧壁或第二侧壁中的任一个接触。突出部分6325保持远离凹陷接收部分6326a突出。如图22B-22C的方面所示，模制互连焊盘6328电联接到电极6322a。
图23A-23B示出了根据本公开的一个方面的换能器组件6312的组装过程，其中电极6322a、6322b相对于压电元件6316a、6316b从初始未压缩状态组装到最终压缩状态。如图23A所示，在一个方面中，换能器组件6312包括被配置成能够分别压缩压电元件6316a、6316b的两个电极6322a、6322b。两个电极6322a、6322b中的每一个电极插入凹陷接收部分6326a、6326b的接收区域6330中，如结合图22A-22C所述。处于如图23A所示的初始未压缩状态的两个凹陷的接收部分6326a、6326b可以组合以形成处于最终压缩状态的整体组装部件。具体地，凹陷接收部分6326a的侧壁压靠凹陷接收部分6326b的侧壁或与该侧壁结合。凹陷接收部分6326a在朝向压电元件6316a的方向上过渡，并且凹陷接收部分6326b在朝向压电元件6316b的方向上过渡。图23B示出了具有整体组装部件的换能器组件6312。
如在图23B中可以看到的，两个凹陷接收部分6326a、6326b的第一侧壁组合以形成整体组装部件的一个连接侧壁。类似地，两个凹陷接收部分6326a、6326b的第一侧壁组合以形成整体组装部件的另一个连接侧壁。在图23B中描绘的最终压缩状态中，电极6322a、6322b的每个电极突出部分6325的顶表面分别压靠压电元件6316a、6316b的相应表面。换能器组件6312的压缩电极配置的优点可以包括减少的组装时间、步骤和成本。附加地，该配置可以导致压电元件6316a、6316b和波导6320之间的电连接得到改善。
图24示出了根据本公开的一个方面的被配置成能够以D31操作模式操作的超声外科器械6400的方面。超声手术器械6400可以与超声手术器械6300相同或基本相似。如在图24的侧剖视图中可看到的，超声外科器械6400包括波导6402，压电元件6404a、6404b，散热器6406a、6406b，以及诸如导线6412的电连接器。在一个方面中，散热器6406a、6406b包括具有两个散热器部件半部的金属壳体。上散热器半部6406a可以定位在波导6402的顶表面上，而下散热器半部6406b可以定位在波导6402的底表面上。金属壳体可以由合适的金属(诸如铝或钢)制成。每个散热器半部6406a、6406b包括肋6408a、6408b和多个翅片6410a、6410b。合适的粘结材料(诸如导电泡沫或油脂6422a、6422b)可以用于将每个肋6408a、6408b分别热联接和电联接到压电元件6404a、6404b。附加地，导电泡沫或油脂6422a、6422b是粘合剂以将肋6408a、6408b牢固地粘附到压电元件6404a、6404b。在另一个方面中，在压电元件6404a、6404b的操作期间产生的热能或热量可以通过多个翅片6410a、6410b消散。具体地，散热器6406a、6406b基于通过对应肋6408a、6408b并经由相应的翅片6410a、6410b中的一个或多个远离超声外科器械6400从压电元件6404a中的任一个产生的传导热而起作用。多个翅片6410a、6410b中的每一个翅片可能以预定间隔隔开。具体地，除了位于散热器半部6406a、6406b的一端的散热片6410a、6410b之外，在相邻的散热片6410a、6410b之间可以存在凹陷空间。
在又另一个方面中，如图24所示，导线6412定位或楔入散热器半部6406a、6406b之间，并被配置成能够电连接到超声信号发生器。图25是根据本公开的一个方面的沿图24所示的剖面线25-25截取的超声外科器械6400的剖视图。如图25所示，在一个方面中，上散热器半部6406a包括位于近端的接收部分6416。下散热器半部6406b包括位于近端的插入部分6418。插入部分6418被配置成能够以过盈配合接合或插入到接收部分6416中以将下散热器半部6406a和上散热器6406b彼此联接。在另一个方面中，紧固件装置6414(诸如锁定螺钉或波普空心铆钉)用于将两个散热器半部6406a、6406b固定在一起，使得半部6406a、6406b形成散热器6406a、6406b的整体金属外壳。
图26是根据本公开的一个方面的上散热器半部6406a的透视图。在一个方面中，如图26所示，接收部分6416在朝向波导6402的方向上延伸，使得接收部分6416限定用于插入部分6418的空间。如在图26中可以看到的，上散热器半部6406a包括基部6422，该基部被从压电元件6404a向外(即，向上)延伸的突出部分6424中断。突出部分6424包括多个翅片6410a，其可以安装到突出部分6424的顶表面或从该顶表面延伸。如上所述，多个翅片6410a可能以预定间隔隔开。如图26所示，基部6422和突出部分6424经由互连部分形成上散热器半部6406a的互连部件。肋6408a(图26中未示出)可以联接到突出部分的底表面并通过导电泡沫或油脂6422a来连接到压电元件6404a，如上所述。在另一个方面中，下散热器半部6406b可以类似于上散热器半部6406a，除了下散热器半部6406b的基部可以被从压电元件6404b向外(即，向下)延伸的突出部分中断。突出部分可以包括多个翅片6410b。
图27是根据本公开的一个方面的被配置成能够以D31操作模式操作的超声外科器械6500的透视图。超声外科器械6500包括波导6502，压电元件6504a、6504b，导电桥6506，散热器6508，压接连接器6516和导线6518。压电元件6504a、6504b位于波导6502的相对表面上。在一个方面中，导电桥6506既导热又导电。导电桥6506可以是由泡沫芯上的石墨片材构成的热泡沫垫圈(TFG)。例如，石墨片材可以由合适的石墨材料形成，诸如SPREADERSHIELDTM或 HITHERMTM柔性石墨热界面材料(TIM)，两者均可从俄勒冈州布鲁克林高地的GrafTech International Holdings Inc.获得。石墨片材可以包裹或定位在泡沫芯的多个表面上。SPREADERSHIELDTM柔性石墨的面内导热系数范围为例如300至1500瓦/米开尔文(W/mK)。相比之下，铝的导热率范围为约200至250W/mK。泡沫芯可以由合适的热塑性弹性体(TPE)形成，诸如可从宾夕法尼亚州费城的Stockwell Elastomerics,Inc.获得的热塑性聚氨酯或导热硅氧烷间隙填料。泡沫芯也可以由镍和铜(Ni/Cu)金属化聚氨酯导电泡沫制成。类似地，导电泡沫的顶表面和底表面可以由Ni/Cu编织聚酯网制成。
在其他方面中，导电桥6506可以是泡沫垫圈上的箔，诸如购自俄亥俄州克利夫兰的Parker Hannifin Corporation的SOFT-SHIELD4000系列电磁干扰(EMI)垫圈(包括PORON1聚氨酯泡沫芯)，或者购自俄亥俄州沃伦的Laird Technologies的泡沫垫圈上的合适金属化织物。在另一个方面中，导电桥6506被配置成能够电联接到金属电极垫片6508，诸如以电桥接或传导从垫片6508穿过桥6506到压电元件6504a的信号(例如，由超声信号发生器产生)。垫片6508被配置成能够将压电元件6504a压靠在波导6502上。如图27所示，垫片6508包括被导电部分6510中断的两个涂覆的非导电部分6512。垫片6508的导电部分6510被配置成能够定位在导电桥6506上方，使得导电部分6510的底表面与导电桥6506的顶表面电接触和热接触。而且，导电桥6506的底表面可以定位在压电元件6504a上。因此，压电元件6504a、导电桥6506和垫片6508都彼此热联接和电联接。
因此，垫片6508用作超声波手术器械6500的散热器和压缩电极。具体地，在压电元件6504a的操作期间产生的热能或热量可以通过导电桥6506传导以被垫片6508散热器吸收和消散。附加地，电能可以从发生器通过垫片6508的导电部分6510和导电桥6506传导到压电元件6504a。在一个方面中，压电元件6504a、6504b的安全操作温度低于150摄氏度(即确保防止对压电元件6504a、6504b造成损坏的温度)。凸缘或附接部件6514可以被构造成能够接收在压接连接器6516的接收部分内。压接连接器6516可以电联接到导线6518，该导线可以连接到发生器。在各个方面中，第二导电桥6506和垫片6508可能以与上述配置类似但对称的配置位于压电元件6504b的底表面下方(即，导电桥6506和垫片6508位于压电元件6504a上方)。具体地，第二导电桥6506的顶表面可以位于压电元件6504b的底表面下方，并且第二垫片6508的第二导电部分6510的顶表面可以位于第二导电桥6506的底表面下方。超声外科器械6500的桥和垫片构型的优点可以包括降低成本，更容易制造和组装，以及基于使用垫片6508散热器作为电连接的效率。
图28示出了根据本公开的一个方面的超声外科器械6600，其包括通过粘结材料附接到超声波导6602的超声换能器6610，其中超声外科器械6600被配置成能够以D31模式操作。超声换能器6610包括通过粘结材料附接在超声波导6602的相对侧上的压电元件6606a、6606b。在一个方面中，粘结材料是导电粘合剂6608。根据本公开的一个方面中，导电板6604a、6604b分别通过粘结材料(诸如导电粘合剂6608)来附接到压电元件6606a、6606b。电连接方法包括在一侧将压电元件6606a、6606b直接焊接到导电板6604a、6604b(例如，铜板或铜片)的内表面并且在另一侧上焊接到超声波导6602。导电环氧树脂6608施加在导电板6604a、6604b与压电元件6606a、6606b的自由端之间。导电环氧树脂6608也施加在压电元件6606a、6606b的固定端和超声波导6602之间。导电元件(诸如导线)可以连接到导电板6606a、6606b和超声波导6602。在一个方面中，超声波导6602可以通过冲压形成，并且电连接特征可以被添加到超声波导6602。导电板6606a、6606b可以由铜片形成并且组装到电缆上的阴电连接器。压接连接可以冲压或形成在超声波导6602和导电板6606a、6606b(例如铜板)上。在组装期间，可以压接与导线的连接。在各个方面中，电连接过程可以包括以上的任何组合。
图29是根据本公开的一个方面的被配置成能够以D31操作模式操作的超声外科器械6700的透视图。超声手术器械6700包括超声波导6702和压电元件6704a、6704b。超声手术器械6700包括超声换能器6706，其包括压电元件6704a、6704b。如图14所示，使用粘结材料(诸如导电环氧树脂粘合剂6708)将压电元件6704a、6704b附接到超声波导6702以将压电元件6704a、6704b粘结到超声波导6702。具体而言，将环氧树脂粘结剂6708施加到第一压电元件6704a的底表面与超声波导6702的顶表面之间的区域。类似地，将环氧树脂粘合剂6708施加到超声波导6702的底表面与第二压电元件6704b的顶表面之间的区域。在一个方面中，使用环氧树脂粘合剂6708在压电元件6704a、6704b与超声波导6702之间产生牢固的电连接。如上所述，可以对超导波导6702进行电接地连接，该超声波导是导电的。
如图29所示，描绘了多个节点和波腹的位置。虚线“PN”和“DN”分别指示近侧节点和远侧节点。每条虚线“AN”表示反节点。如上所述，振动运动驻波中的最小或零交点通常称为波节，驻波中的最大绝对值或峰值通常称为波腹。通常，电接地连接在近侧节点处进行，其在图29中用虚线“PN”表示。近侧节点的位置可以由延伸通过压电元件6704a、6704b和超声波导6702的中心部分的纵向线表示。此外，近侧节点代表高电压电位的位置，其使得能够基于压电元件6704a、6704b与超声波导6702之间的电接触对超声波导6702进行电接地连接。在另一个方面中，使用环氧树脂粘合剂6708可以使得超声波导6702能够在替代节点(诸如远侧节点)而不是近侧节点处进行电接地连接。可以使用替代节点，因为使用环氧树脂粘合剂6708在压电元件6704a、6704b与超声波导6702之间产生牢固的电接触。
图30是具有导电电极6710的超声手术器械6700的剖视图，该导电电极分别被配置成能够压缩压电元件6704a、6704b和超声波导6702。导电电极6710各自包括柔顺构件部分6712和薄金属部分6714。在一个方面中，两个导电电极6710位于超声波导6702的每一侧上。在近侧节点处，第一上导电电极6710的薄金属部分6714包括窄尖端以压缩压电元件6704a。类似地，在近侧节点处，第一下导电电极6710的薄金属部分6714包括窄尖端以压缩压电元件6704a。在远侧节点处，第二上导电电极6710的薄金属部分6714包括窄尖端以压缩超声波导6702。类似地，在远侧节点处，第二下导电电极6710的薄金属部分6714包括窄尖端以压缩超声波导6702。在另一个方面中，基于第二上导电电极6710和第二下导电电极6710，可以在远侧节点处将电接地连接施加到超声波导。该构型的优点可以包括减小超声外科器械6700的制造复杂性。
图31A-31C示出了超声外科器械6800，其包括通过粘结材料附接到超声换能器6812的超声波导6802，其中超声外科器械6800被配置成能够以D31模式操作。超声换能器6812包括通过粘结材料附接到超声波导6802的相对侧的第一和第二未极化压电元件6804a、6804b。图31A示出了根据本公开的一个方面的在组装和极化之前的超声外科器械6800。超声外科器械6800包括金属超声波导6802(例如，钛/钛合金)。粘结材料(诸如焊膏6806)被施加到第一未极化压电元件6804a和第二未极化压电元件6804b的一个表面上。焊膏6806是焊剂和微小焊料颗粒的粘性混合物，并且可以使用丝网印刷过程通过不锈钢或镍模板来施加到压电元件6804a、6804b。焊膏6806也可以通过喷射印刷机构(类似于喷墨打印机)来施加到压电元件6804a、6804b。在粘贴之后，压电元件6804a、6804b行进到拾取和放置机器或手动放置过程，以用于将压电元件6804a、6804b固定到超声波导6802。
图31B示出了根据本公开的一个方面的在极化之前的图31A的超声外科器械6800以及以D31配置固定到超声波导6802的第一和第二未极化压电元件6804a、6804b。在粘贴之后，使用自动或手动过程将压电元件6804a、6804b固定到超声波导6802。在将固定的压电元件6804a、6804b和超声波导6802组件传送到回流焊炉之前，可以采用绝缘夹具来固定第一未极化压电元件6804a和第二未极化压电元件6804b。一旦进入焊炉，使焊膏6806回流以将第一未极化压电元件6804a和第二未极化压电元件6804b粘结到超声波导6802。
图31C示出了根据本公开的一个方面的在回流焊接之后并在对以D31配置附接到超声波导6802的第一未极化压电元件6804a和第二未极化压电元件6804b进行极化之前的图31B的超声器械6800。一旦将固定的压电元件6804a、6804b和超声波导6802组件传送到回流焊炉，焊膏6806就回流以在第一未极化压电元件6804a和第二未极化压电元件6804b与超声波导6802之间建立粘结。可以使用标准表面安装技术使焊膏6806回流。存在许多用于使焊料6806回流的技术。一种技术采用红外灯并称为红外回流。另一种技术采用了使用标准空气或氮气的热气对流。另一种表面安装技术采用具有高沸点的特殊碳氟化合物液体，其使用称为气相回流的方法。每种方法都有其优点和缺点。
在使用回流焊接技术将第一和第二未极化压电元件6804a、6804b附接到超声波导6802之后，整个超声器械6800组件被极化。极化过程可以通过特殊夹具夹持在油浴中进行。压电效应的性质与固体中的电偶极矩的出现密切相关。后者可以在具有不对称电荷环境的晶格位置处被引发，如在压电元件中那样。可以通过对每单位体积的晶体晶胞的偶极矩求和来计算偶极子密度或极化(维数(C·m/m3))。由于每个偶极子是矢量，偶极子密度P是矢量场。彼此附近的偶极子倾向于在称为Weiss域的区域中对齐。这些域通常是随机定向的，但可以使用极化过程(与磁极化不同)进行对准，通常在高温下通过该过程在材料上施加强电场。并非所有的压电材料都可以被极化。压电元件6804a、6804b的极化轴线(P)分别由方向箭头6808a、6808b指示。响应于压电元件6804a、6804b的激励的超声波导6802的运动轴线由超声波导6802的远端处的运动箭头6810示出，该远端通常称为超声波导6802的超声刀片部分。运动轴线6810与极化轴线(P)6808a、6808b正交。
压电效应是在施加机械应力下的极化P的改变。这可能是由于偶极子引发周围环境的重新配置或者通过在外部机械应力的影响下的分子偶极矩的重新定向而引发的。压电性可能以各种方式进行表现，包括极化强度、其方向或两者的变化，其中细节取决于：晶体内的P的定向；晶体对称；和所施加的机械应力。P的改变表现为晶面上的表面电荷密度的变化，即作为由体块中的偶极子密度的改变引起的在面间延伸的电场的变化。例如，正确施加2kN(500lbf)的力的1cm3的石英立方体可以产生12500V的电压。
本文所公开的装置可被设计成在单次使用后废弃，或者其可被设计成多次使用。然而无论是哪种情况，该装置都可在至少使用一次后经过修整再行使用。修整可包括拆卸装置、之后清洁或替换特定零件以及后续重新组装步骤的任意组合。具体地，该装置可拆卸，而且可以任意组合选择性地替换或移除该装置的任意数目的特定零件或部件。在清洁和/或替换特定部件后，可对该装置进行重新组装，以便随后在修整设施处使用或就在外科手术之前由手术团队使用。本领域的技术人员将会理解，修整装置可利用多种技术来进行拆卸、清洁/替换和重新组装。此类技术的使用以及所得的修整装置均在本申请的范围内。
虽然本文已描述了各种方面，但是可以对那些方面实施多种修改和变型。例如，可以采用不同类型的端部执行器。另外，在公开了用于某些部件的材料的情况下，也可使用其它材料。上述具体实施方式和下述权利要求旨在涵盖所有此类修改和变型。
以引用方式全文或部分地并入本文的任何专利、公布或其他公开材料均仅在所并入的材料不与本发明所述的现有定义、陈述或其他公开材料相冲突的范围内并入本文。因此，并且在必要的程度下，本文明确列出的公开内容代替以引用方式并入本文的任何冲突材料。据称以引用方式并入本文但与本文列出的现有定义、陈述或其他公开材料相冲突的任何材料或其部分，将仅在所并入的材料与现有的公开材料之间不产生冲突的程度下并入。
本文所述主题的各个方面在以下编号的实施例中陈述：
实施例1.一种超声外科器械，包括：换能器基板，其包括第一面和第二面；第一压电元件，所述第一压电元件位于所述第一面上；第二压电元件，所述第二压电元件位于所述第二面上，其中所述第一电压元件和所述第二压电元件各自被配置成能够相对于联接到所述换能器基板的波导的纵向轴线以D31模式操作，其中所述波导通过导电粘合剂来电联接到所述第一压电元件和所述第二压电元件；电极，所述电极被配置成能够将所述第一电压元件和所述第二压电元件电联接到超声信号发生器；和热导体，所述热导体被配置成能够传导热能远离所述第一电压元件和所述第二压电元件。
实施例2.根据实施例1所述的超声外科器械，其中，所述第一压电元件具有位于从所述第一压电元件的第一侧到第二侧的方向上的极化轴线，并且所述第二压电元件具有位于从所述第二压电元件的第一侧到第二侧的方向上的极化轴线，以便以D31模式操作。
实施例3.根据实施例1或实施例2所述的超声外科器械，其中，所述超声波导的运动轴线与所述第一电压元件和所述第二压电元件的极化轴线正交。
实施例4.根据实施例1至3中的一项或多项所述的超声外科器械，其中，所述导电粘合剂为焊料粘结材料。
实施例5.根据实施例1至实施例4中的一项或多项所述的超声外科器械，还包括电连接器，所述电连接器位于所述超声外科器械的多个节点中的一个节点处，其中所述波导联接到所述电连接器以提供电接地。
实施例6.根据实施例1至实施例5中的一项或多项所述的超声外科器械，还包括：第一导电板，所述第一导电板通过第二粘结材料附接到所述第一压电元件的第二面；和第二导电板，所述第二导电板通过所述第二粘结材料附接到所述第二压电元件的第二面。
实施例7.根据实施例1至实施例6中的一项或多项所述的超声外科器械，其中：所述热导体是包括金属壳体的散热器，所述金属壳体包括至少一个翅片，所述金属壳体包括通过所述波导互连的两个部分，并且所述至少一个翅片被配置成能够通过所述散热器的肋传导热能远离所述第一电压元件和所述第二压电元件。
实施例8.根据实施例7所述的超声外科器械，其中，连接到所述超声信号发生器的电连接器楔入所述两个部分之间。
实施例9.一种制造超声外科器械的方法，包括：从扁平金属原料的一部分加工换能器基板，其中所述换能器基板包括第一面和第二面；将第一压电元件定位在所述第一面上；将第二压电元件定位在所述第二面上，其中所述第一电压元件和所述第二压电元件各自被配置成能够相对于联接到所述换能器基板的波导的纵向轴线以D31模式操作；通过第一导电粘合剂将所述波导联接到所述第一压电元件和所述第二压电元件；通过电极来抵靠所述第一电压元件和所述第二压电元件进行压缩，以将所述第一电压元件和所述第二压电元件电联接到超声信号发生器；以及通过热导体远离所述第一电压元件和所述第二压电元件传导热量。
实施例10.根据实施例9所述的方法，还包括：形成所述热导体的多个翅片和肋，其中所传导的热量通过所述肋来传导。
实施例11.根据实施例10所述的方法，还包括：在所述热导体的第一部分、所述波导和所述热导体的第二部分之间形成互连。
实施例12.根据实施例11所述的方法，其中，所述多个翅片中的第一翅片位于所述第一部分上，并且所述多个翅片中的第二翅片位于所述第二部分上。
实施例13.根据实施例9至实施例12中的一项或多项所述的方法，还包括：在所述电极与所述第一电压元件和所述第二压电元件之间施加第二导电粘合剂。
实施例14.一种换能器基板，包括：第一面和第二面，其中第一压电元件位于所述第一面上并且第二压电元件位于所述第二面上，并且其中所述第一电压元件和所述第二压电元件各自被配置成能够相对于联接到所述换能器基板的波导的纵向轴线以D31模式操作；导电粘合剂，所述导电粘合剂用于将所述第一电压元件和所述第二压电元件电联接到所述波导；电极，所述电极被配置成能够将所述第一电压元件和所述第二压电元件电联接到超声信号发生器；和热导体，所述热导体被配置成能够远离所述第一电压元件和所述第二压电元件传导热量。
实施例15.根据实施例14所述的换能器基板，还包括：第三压电元件，所述第三压电元件位于所述波导的凹陷部中；绝缘体，所述绝缘体位于所述电极的第一部分上，其中所述电极的第二部分被配置成能够将所述第一压电元件、第二压电元件和第三压电元件电联接到所述超声信号发生器。
实施例16.根据实施例15所述的换能器基板，其中，所述电极包括所述第一部分、所述第二部分和第三部分。
实施例17.根据实施例14至实施例16中的一项或多项所述的换能器基板，其中，所述导电粘合剂包括位于所述第一电压元件和所述第二压电元件的近端处的第一部分以及位于所述第一电压元件和所述第二压电元件的远端处的第二部分。
实施例18.根据实施例14至实施例17中的一项或多项所述的换能器基板，还包括用于接收所述第一压电元件的第一凹陷部和用于接收所述第二压电元件的第二凹陷部，其中所述第一凹陷部的长度大于所述第一压电元件的长度，从而设置所述第一凹陷部的间隙，并且所述第二凹陷部的长度大于所述第二压电元件的长度，从而设置所述第二凹陷部的间隙。
实施例19.一种超声换能器组件，包括：多个压电元件的堆叠，其中所述堆叠被配置成能够相对于联接到所述换能器基板的波导的纵向轴线以D33模式操作；压缩板，所述压缩板用于压缩所述多个压电元件的堆叠以将所述压电元件的堆叠联接到波导；和压缩元件，所述压缩元件用于抵靠所述压缩板施加压缩力。
实施例20.根据实施例19所述的超声换能器组件，其中，所述压缩元件为紧固到所述压缩板的螺钉。
实施例21.根据实施例19所述的超声换能器组件，其中，所述压缩元件为楔形元件。
Claims (21)
1.一种超声外科器械，包括：
换能器基板，所述换能器基板包括第一面和第二面；
第一压电元件，所述第一压电元件位于所述第一面上；
第二压电元件，所述第二压电元件位于所述第二面上，其中所述第一压电元件和所述第二压电元件各自被配置成能够相对于联接到所述换能器基板的波导的纵向轴线以D31模式操作，其中所述波导通过导电粘合剂来电联接到所述第一压电元件和所述第二压电元件；
电极，所述电极被配置成能够将所述第一压电元件和所述第二压电元件电联接到超声信号发生器；和
热导体，所述热导体被配置成能够传导热能远离所述第一电压元件和所述第二压电元件。
2.根据权利要求1所述的超声外科器械，其中，所述第一压电元件具有位于从所述第一压电元件的第一侧到第二侧的方向上的极化轴线，并且所述第二压电元件具有位于从所述第二压电元件的第一侧到第二侧的方向上的极化轴线，以便以D31模式操作。
3.根据权利要求2所述的超声外科器械，其中，所述超声波导的运动轴线与所述第一电压元件和所述第二压电元件的极化轴线正交。
4.根据权利要求1所述的超声外科器械，其中，所述导电粘合剂为焊料粘结材料。
5.根据权利要求1所述的超声外科器械，还包括：
电连接器，所述电连接器位于所述超声外科器械的多个节点中的一个节点处，其中所述波导联接到所述电连接器以提供电接地。
6.根据权利要求1所述的超声外科器械，还包括：
第一导电板，所述第一导电板通过第二粘结材料附接到所述第一压电元件的第二面；和
第二导电板，所述第二导电板通过所述第二粘结材料附接到所述第二压电元件的第二面。
7.根据权利要求1所述的超声外科器械，其中：
所述热导体是包括金属壳体的散热器，所述金属壳体包括至少一个翅片，
所述金属壳体包括通过所述波导互连的两个部分，并且
所述至少一个翅片被配置成能够通过所述散热器的肋传导热能远离所述第一电压元件和所述第二压电元件。
8.根据权利要求1所述的超声外科器械，其中，连接到所述超声信号发生器的电连接器楔入所述两个部分之间。
9.一种制造超声外科器械的方法，包括：
从扁平金属原料的一部分加工换能器基板，其中所述换能器基板包括第一面和第二面；
将第一压电元件定位在所述第一面上；
将第二压电元件定位在所述第二面上，其中所述第一电压元件和所述第二压电元件各自被配置成能够相对于联接到所述换能器基板的波导的纵向轴线以D31模式操作；
通过第一导电粘合剂将所述波导联接到所述第一压电元件和所述第二压电元件；
通过电极来抵靠所述第一电压元件和所述第二压电元件进行压缩，以将所述第一电压元件和所述第二压电元件电联接到超声信号发生器；以及
通过热导体传导热量远离所述第一电压元件和所述第二压电元件。
10.根据权利要求9所述的方法，还包括：
形成所述热导体的多个翅片和肋，其中所传导的热量通过所述肋来传导。
11.根据权利要求10所述的方法，还包括：
在所述热导体的第一部分、所述波导和所述热导体的第二部分之间形成互连。
12.根据权利要求11所述的方法，其中，所述多个翅片中的第一翅片位于所述第一部分上，并且所述多个翅片中的第二翅片位于所述第二部分上。
13.根据权利要求9所述的方法，还包括：
在所述电极与所述第一电压元件和所述第二压电元件之间施加第二导电粘合剂。
14.一种换能器基板，包括：
第一面和第二面，其中第一压电元件位于所述第一面上并且第二压电元件位于所述第二面上，并且其中所述第一电压元件和所述第二压电元件各自被配置成能够相对于联接到所述换能器基板的波导的纵向轴线以D31模式操作；
导电粘合剂，所述导电粘合剂用于将所述第一电压元件和所述第二压电元件电联接到所述波导；
电极，所述电极被配置成能够将所述第一电压元件和所述第二压电元件电联接到超声信号发生器；和
热导体，所述热导体被配置成能够传导热量远离所述第一电压元件和所述第二压电元件。
15.根据权利要求14所述的换能器基板，还包括：
第三压电元件，所述第三压电元件位于所述波导的凹陷部中；
绝缘体，所述绝缘体位于所述电极的第一部分上，其中所述电极的第二部分被配置成能够将所述第一压电元件、第二压电元件和第三压电元件电联接到所述超声信号发生器。
16.根据权利要求15所述的换能器基板，其中，所述电极包括所述第一部分、所述第二部分和第三部分。
17.根据权利要求14所述的换能器基板，其中，所述导电粘合剂包括位于所述第一电压元件和所述第二压电元件的近端处的第一部分以及位于所述第一电压元件和所述第二压电元件的远端处的第二部分。
18.根据权利要求14所述的换能器基板，还包括用于接收所述第一压电元件的第一凹陷部和用于接收所述第二压电元件的第二凹陷部，其中所述第一凹陷部的长度大于所述第一压电元件的长度，从而设置所述第一凹陷部的间隙，并且所述第二凹陷部的长度大于所述第二压电元件的长度，从而设置所述第二凹陷部的间隙。
19.一种超声换能器组件，包括：
多个压电元件的堆叠，其中所述堆叠被配置成能够相对于联接到所述换能器基板的波导的纵向轴线以D33模式操作；
压缩板，所述压缩板用于压缩所述多个压电元件的堆叠以将所述压电元件的堆叠联接到波导；和
压缩元件，所述压缩元件用于抵靠所述压缩板施加压缩力。
20.根据权利要求19所述的超声换能器组件，其中，所述压缩元件为紧固到所述压缩板的螺钉。
21.根据权利要求19所述的超声换能器组件，其中，所述压缩元件为楔形元件。
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