CN110191683A - 超声换能器到波导的声学联接、连接和配置 - Google Patents

超声换能器到波导的声学联接、连接和配置 Download PDF

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CN110191683A
CN110191683A CN201780052270.9A CN201780052270A CN110191683A CN 110191683 A CN110191683 A CN 110191683A CN 201780052270 A CN201780052270 A CN 201780052270A CN 110191683 A CN110191683 A CN 110191683A
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piezoelectric element
ultrasonic
waveguide
ultrasound
surgical instrument
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J·D·梅瑟利
B·D·迪克森
R·J·R·奥蒂兹
R·M·亚瑟
J·D·丹尼斯
B·D·布莱克
C·T·戴维斯
M·E·特比
I·V·尼科拉埃斯库
F·埃斯特拉
W·A·奥尔森
A·皮尔斯
J·威尔逊
W·D·丹纳尔
张法建
F·B·斯图伦
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Angiotech Pharmaceuticals Inc
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Angiotech Pharmaceuticals Inc
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Abstract

本发明公开了各种超声器械。所述超声器械包括声学联接到超声换能器的超声波导。本发明公开了几种用于将所述超声换能器声学联接到所述超声波导的技术。

Description

超声换能器到波导的声学联接、连接和配置
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端部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端部执行器时，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分离。由于通过波导从超声转换器可传输至外科端部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。
以超声频率激活或激励此类器械的端部执行器(例如，切割刀)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端部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端部执行器的超声波导传输至外科端部执行器。波导和端部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。
端部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为2π乘以循环频率f的角频率f；和
A＝零至峰的幅值。
将端部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，端部执行器可包括刀，由于所述纵向偏移，该刀可切割和/或凝结组织。2001年9月4日发布并且名称为“METHOD OF BALANCING ASYMMETRIC ULTRASONIC SURGICALBLADES”的美国专利6,283,981；2001年10月30日发布并且名称为“CURVED ULTRASONICWAVEGUIDE HAVING A TRAPEZOIDAL CROSS SECTION”的美国专利6,309,400；以及2002年8月20日发布并且名称为“BALANCED ULTRASONIC WAVEGUIDE INCLUDING A PLURALITY OFBALANCE ASYMMETRIES”的美国专利6,436,115公开了各种超声外科器械，其全部公开内容以引用方式并入本文。
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，所述换能器被构造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，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，外科工具包括具有近侧端部和远侧端部的主体，其中远侧端部可通过换能器所产生的振动相对于纵向轴线移动，并且近侧端部机械地联接到换能器。
在一个方面，提供了一种压缩超声换能器组件。压缩超声换能器组件包括：金属外壳，其限定开口；至少两个压电元件，其设置在所述开口内并受到压缩力的压缩，其中所述至少两个压电元件被构造成能够以D33模式工作；以及金属塞，其结合到所述金属外壳以封闭所述开口并使所述至少两个压电元件在所述金属外壳内保持在压缩状态。
在另一个方面，提供了一种超声外科器械。超声外科器械包括：超声波导；超声换能器，其安装到超声波导并被构造成能够以D31模式操作，超声换能器包括：第一陶瓷压电元件，其第一侧通过第一粘结材料附接到超声波导的第一侧；以及第二陶瓷压电元件，其第一侧通过第一粘结材料附接到超声波导的第二侧，其中超声波导的第一侧与超声波导的第二侧相对。
在另一个方面，提供了一种超声外科器械。超声外科器械包括：超声波导，其包括：基部部分；从基部部分的一侧延伸的第一壁和第二壁；以及从对应的第一壁和第二壁突出的第一凸缘和第二凸缘，其中第一空间限定在第一凸缘与基部部分之间，并且其中第二空间限定在第二凸缘与基部部分之间；以及附接到超声波导的超声换能器，其中超声换能器包括可滑动地设置在所述第一空间与所述第二空间之间并固定在其中的至少一个压电元件。
在另一个方面，提供了一种超声外科器械。超声外科器械包括：超声波导；以及附接到所述超声波导的超声换能器；其中所述超声波导包括音叉状框架，所述音叉状框架包括：上叉臂；和下叉臂，在所述上叉臂和下叉臂之间限定U形孔，所述U形孔被构造成能够在其中接纳所述超声换能器。
附图说明
各种方面的特征部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各个方面(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4A-4C示出了根据本公开的一个方面的具有调节压缩的以D33配置的压缩超声换能器组件。
图5是根据本公开的一个方面的超声外科器械的透视图。
图6是根据本公开的一个方面的用于与图5所示的超声外科器械一起使用的压电元件的透视图。
图7是根据本公开的一个方面的图5所示的超声波外科器械的剖视图。
图8示出了根据本公开的一个方面的金属与金属合金焊料之间的粘合剂粘结的示例。
图9示出了根据本公开内容的一个方面的由金属合金焊料形成的陶瓷与金属之间的粘合剂粘结。
图10示出了根据本公开的一个方面的冶金/化学粘结的示例。
图11是根据本公开的一个方面的陶瓷和金属合金焊料化学粘结的微结构图示。
图12A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12B示出了根据本公开的一个方面的在极化之前的图12A的超声外科器械以及以D31配置固定到超声波导的第一和第二未极化压电元件。
图12C示出了根据本公开的一个方面的在极化之前的图12B的超声器械以及以D31配置固定到超声波导的第一和第二未极化压电元件。
图13A示出了根据本公开的一个方面的超声外科器械，其包括被构造成能够使用粘结材料来保持压电元件的超声波导。
图13B示出了根据本公开的一个方面的超声外科器械，其包括被构造成使用偏压力来保持压电元件的超声波导。
图13C示出了根据本公开的一个方面的超声外科器械，其包括被构造成能够使用粘结材料和偏压力的组合来保持压电元件的超声波导。
图14示出了根据本公开的一个方面的超声外科器械，其包括固定到以D31布置的压电元件的超声波导。
图15示出了根据本公开的一个方面的在粘结阶段期间将电压V施加到压电元件的图14所示的超声外科器械。
图16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17示出了根据本公开的一个方面的超声外科器械，其包括单个中平面超声换能器和具有音叉状框架的超声波导。
图18是根据本公开的一个方面的图17所示的超声外科器械的剖视图，其中超声换能器插入超声波导的音叉状框架中。
图19A和图19B示出了根据本公开的一个方面的D33超声换能器配置。
图20示出了根据本公开的一个方面的D33超声换能器配置。
图21示出了根据本公开的一个方面的D33超声换能器配置。
图22A-D示出了根据本公开的一个方面的D33超声换能器配置。
图23示出了根据本公开的一个方面的D33超声换能器配置。
图24A示出了根据本公开的一个方面的沿线24A-24A的D31超声换能器配置的剖视图。
图24B示出了根据本公开的一个方面的D31超声换能器配置。
图24C示出了根据本公开的一个方面的图24A-B所示的D31超声换能器配置的外壳的形状变化。
图25A-E示出了根据本公开的一个方面的D33超声换能器配置。
图26A示出了根据本公开的一个方面的D33超声换能器配置。
图26B示出了根据本公开的一个方面的图26A所示的超声换能器配置的塞。
图26C-D示出了根据本公开的一个方面的安装图26A所示的D33超声换能器配置的方法。
图27示出了根据本公开的一个方面的D31超声换能器配置。
图28示出了根据本公开的一个方面的D31超声换能器配置。
图29A-B示出了根据本公开的一个方面的D31超声换能器配置。
图30A示出了根据本公开的一个方面的D31超声换能器配置。
图30B示出了根据本公开的一个方面的30A所示的D31超声换能器配置的分解图。
图30C示出了根据本公开的一个方面的D31超声换能器配置。
图30D示出了根据本公开的一个方面的30C所示的D31超声换能器配置的分解图。
图31示出了根据本公开的一个方面的D33超声换能器配置。
图32A-B示出了根据本公开的一个方面的具有可不对称激励的压电换能器组件的D31超声换能器配置。
图33A-C示出了根据本公开的一个方面的具有可不对称激励的压电换能器组件的D31超声换能器配置。
图34A-B示出了根据本公开的一个方面的D31超声换能器配置，其中压电元件相对于彼此偏移。
图34C-D示出了根据本公开的一个方面的分别经历纵向和非纵向运动的外科器械的端部执行器的平面图。
图35A示出了根据本公开的一个方面的具有复杂特征部的外科器械的波导的远侧端部的透视图。
图35B-E示出了根据本公开的一个方面的制造图35A所示的外科器械的过程。
图36A示出了根据本公开的一个方面的被构造成能够产生非纵向运动的D31超声换能器配置的透视图。
图36B示出了根据本公开的一个方面的图36A所示的D31超声换能器配置的电极的透视图。
图36C示出了根据本公开的一个方面的沿线36C-36C的图36A所示的D31超声换能器配置的剖视图。
图36D示出了根据本公开的一个方面的图36A所示的D31超声换能器配置的电极和压电换能器组件的侧视图。
图37示出了根据本公开的一个方面的用于外科器械的超声信号发生器的电连接器的透视图。
图38示出了根据本公开的一个方面的D33超声换能器配置的分解图。
图39示出了根据本公开的一个方面的图38的D33超声换能器配置的透视图。
图40示出了根据本公开的一个方面的图38的D33超声换能器配置的透视剖视图。
图41示出了根据本公开的一个方面的图38的D33超声换能器配置的平面剖视图。
具体实施方式
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、变型和修改结合在一起实施，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，以提供对本文所公开的装置和方法的结构、功能、制造和用途的原理全面理解。这些方面的一个或多个示例在附图中示出。本领域普通技术人员将理解，本文具体描述并在附图中示出的设备和方法是非限制性示例性方面，并且各个方面的范围仅由权利要求限定。结合一个方面示出或描述的特征部可与其他方面的特征部结合。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大体涉及超声外科器械以及与其一起使用的刀。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的示例，其中所述专利的全部公开内容以引用方式并入本文。
根据各个方面，一种包括具有端部执行器(诸如刀)的外科工具的超声器械对于希望去除皮质骨和/或组织，同时控制出血的整形手术可具有特别的有益效果。由于其切割和凝结特性，超声外科器械的刀可适用于一般的软组织切割和凝结。在某些情况下，根据各个方面的刀可适用于同时切割和止血密封或烧灼组织。刀可为直的或弯曲的，并适用于开放式或腹腔镜式用途。根据各个方面的刀可适用于脊椎外科手术，特别是在从骨骼上去除肌肉时帮助从背部进入。
本申请的申请人拥有于与其同时提交并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日提交的名称为“UltrasonicTransducer Techniques for Ultrasonic Surgical Instrument”的代理人案卷号END7919USNP/160045M，
发明人Jeffrey Messerly等人在2017年8月17日提交的名称为“UltrasonicTransducer For Surgical Instrument”的代理人案卷号END7919USNP1/160045-1，
发明人Jeffrey Messerly等人在2017年8月17日提交的名称为“Electrical AndThermal Connections For Ultrasonic Transducer”的代理人案卷号END7919USNP2/160045-2，
发明人Jeffrey Messerly等人在2017年8月17日提交的名称为“UltrasonicTransducer to Waveguide Joining”的代理人案卷号END7919USNP4/160045-4，
发明人Jeffrey Messerly等人在2017年8月17日提交的名称为“Tissue LoadingOf A Surgical Instrument”的代理人案卷号END7919USNP5/160045-5。
图1示出了超声系统10的一个方面。超声系统10的一个方面包括连接到超声换能器14的超声信号发生器12、手柄组件60(包括手柄外壳16)以及端部执行器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。在各个方面，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)，如下面所详细描述的。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“近侧”和“远侧”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，外科器械在许多方向和位置中使用，并且这些术语并非限制性的和绝对的。
端罩20的远侧端部连接至换能部分18的近侧端部，并且前罩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，所述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从其近侧端部到其远侧端部向内成锥形，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。
再次参照图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接合。在各个方面，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，诸如例如锆钛酸铅、偏铌酸铅、钛酸铅和/或任何合适的压电晶体材料。
在各个方面，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，该电极可被构造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中的每一个可以包括延伸穿过中心的穿孔，该穿孔可被构造成能够接纳端罩20的螺纹构件。
在各个方面，正电极34和负电极36分别电连接至导线38和40，其中导线38和40可包裹在缆线42内，并可电连接至超声系统10的超声信号发生器12。
在各个方面，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14和端部执行器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，振动运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30-70kHz，并且一个示例性的操作振动频率可为大约55.5kHz。
沿声学组件24的任何点处的振动运动的振幅可取决于沿声学组件24测量振动运动的位置。振动运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。
在各个方面，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传输至端部执行器50。为了使声学组件24将能量递送到端部执行器50，声学组件24的部件与端部执行器50声学联接。例如，超声换能器14的远侧端部可在表面30处通过螺纹连接(例如，螺柱48)与超声传输波导46的近侧端部声学联接。
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。超声端部执行器50的远侧端部52可设置在波腹处(或至少其附近)，以便提供远侧端部的最大(或至少接近最大)纵向偏移。在各个方面，当换能器组件通电时，超声端部执行器50的远侧端部52可被构造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，超声端部执行器50可联接到超声传输波导46。在各个方面，如图所示的超声端部执行器50和超声传输波导46由适合超声能量传输的材料以单一单元制成，该材料为例如Ti6Al4V(含铝和钒的钛合金)、铝、不锈钢和/或任何其他合适的材料。另选地，超声端部执行器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联接在一起。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，超声传输波导46包括设置在多个波节处(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端部执行器50的远侧端部52。
如图1所示，护套58可联接至手柄组件60的远侧端部。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连接到适配器62和/或从其延伸，并具有纵向贯穿其中的开口。在各个方面，护套58可通过螺纹连接或按扣到外壳16的远侧端部上。在至少一个方面，超声传输波导46延伸穿过管状构件64的开口，并且硅树脂环56可接触所述开口的侧壁并隔离其中的超声传输波导46。在各个方面，护套58的适配器62优选由例如构造而成，并且管状构件64由例如不锈钢加工而成。在至少一个方面，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，并且在各个方面，电势可以与具有包括例如换能器14、波导46和端部执行器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，在各个方面，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，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联接到端部执行器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及其激活电极34和36(一起，换能器14)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低于居里温度，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。虽然非极化的压电元件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可以通过沿着d3轴线膨胀同时沿着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可以通过沿着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将机械振动传输到端部执行器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(即压电元件沿长度维度的膨胀)和ΔW(即压电元件沿宽度维度的膨胀)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，如下所述，超声医疗装置可以包括：换能器，其被构造成能够产生纵向振动；以及外科工具，其具有可操作地联接到换能器的换能器基板(例如，换能器安装部分)、端部执行器以及其间的波导。在一些方面，也如以下所述，换能器可生成能够传输至端部执行器的振动，其中振动可以谐振频率(或接近谐振频率)驱动换能器基板、波导、端部执行器和/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/或端部执行器中产生纵向应变图或纵向应力图。在各个方面，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/或端部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，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被构造成能够以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结合部258a、258b电联接到超声波导252。在一个方面，导电板256a、256b联接到电压源的正极，并且导电结合部258a、258b通过金属超声波导252电联接到接地电位。在一个方面，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，所述化合物的化学式为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的远侧端部处的运动箭头262示出，该远侧端部通常称为超声波导252的超声刀部分。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32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、导电的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，可以采用金属弹簧接触件来形成与压电元件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，如下所述，超声医疗装置可以包括：换能器，其被构造成能够产生纵向振动；以及外科器械，其具有可操作地联接到换能器的换能器基板、端部执行器和其间的波导。在一些方面，也如以下所述，换能器可生成能够传输至端部执行器的振动，其中振动可以谐振频率(或接近谐振频率)驱动换能器基板、波导、端部执行器和/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/或端部执行器中产生纵向应变图或纵向应力图。在各个方面，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/或端部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，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。根据本公开的一个方面的D31架构250采用各种不同的技术来将压电元件254a、254b声学联接到超声波导252。以下公开了这些技术。
图4A-4C示出了根据本公开的一个方面的具有调节压缩的以D33配置的压缩超声换能器组件7000。在一个方面，超声换能器组件7000包括压缩在由外壳7004或外壳限定的开口7014中的一个或多个压电元件7002a、7002b、7002c、7002d(例如，PZT)。一旦超声换能器组件7000被完全压缩，就将其提供给另一组装过程，其中例如，组件7000中的压电元件7002a-d之一的表面附接到金属超声波导或波导。在压电元件7002a-d上施加压缩(特别是在联接应变的方向上)提供了驱动更大负载的更高效率和增加的能力。因为压缩超声换能器组件7000不包括轴向压缩元件，所以压电元件7002a-d沿振动轴线LA被压缩并然后锚定就位。围绕压电元件7002a-d设置的外壳7004或带被压缩，并且组件如下所述地锚定就位。
图4A示出了处于预压缩状态的超声换能器组件7000的安装阶段。一个或多个压电元件7002a-d堆叠在外壳7004内。塞7006与压电元件7002a-d的堆叠对齐。外壳7004和塞7006元件由金属材料制成。塞7006和压电元件7002a-d的堆叠与振动轴线LA对齐。压电元件7002a-d的堆叠在压缩前的长度标记为d0。
图4B示出了压缩超声换能器组件7000的初始压缩状态。将目标初始力Fi施加到塞7006以将塞7006压缩到压电元件7002a-d的堆叠上。
图4C示出了压缩超声换能器组件7000的最终压缩状态。如图4C所示，在将最终压缩力Ff施加到压电元件7002a-d的堆叠之后，外壳7004和塞通过锚定件7008a、7008b锚定在一起，同时压电元件7002a-d的堆叠处于压缩状态。压电元件7002a-d的堆叠的压缩长度被标记为d1，其中d1<d0。锚定件7008a、7008b可以是用于将塞7006抵靠压电元件7002a-d在适当位置牢固地结合到外壳7004以使压电元件7002a-d的堆叠保持在压缩下的任何合适元件。因此，锚定件7008a、7008b可以由通过熔焊、焊接、硬钎焊、环氧树脂、型锻或其任何组合形成的结合部附接或固定。
在另一方面，锚定件7008a、7008b可以通过螺纹连接来附接到金属外壳7004。在螺纹连接配置中，金属外壳7004和金属塞7006各自包括螺纹端部，并且部件螺纹联接。在一个方面，金属塞7006包括外部阳螺纹，并且外壳7004包括内部阴螺纹以通过螺纹接合塞7006的阳螺纹，并且塞7006被拧入外壳7004的内部。在另一个方面，塞7006包括内部阴螺纹，并且外壳7004包括外部阳螺纹以通过螺纹接合塞7006的阴螺纹，并且塞7006被拧到外壳7004的外部上。在后一种配置中，塞7006的内部包括凸台或塞7006内的其他突出特征以接触和压缩压电元件7002a-c的堆叠。在螺纹锚定配置中，旋转力施加到塞7006，该旋转力在塞7006与外壳7004通过螺纹接合时将压缩力施加到压电元件7002a-d的堆叠。
一旦换能器组件7000被完全压缩并且施加锚定件7008a、7008b，就准备好组装换能器组件7000。在一个方面，超声波导声学联接到换能器组件7000的第一表面7010，并且在另一个方面，超声波导声学联接到换能器组件7000的第一表面7010。在其他方面，塞7006可以是超声波导的部件。
说明书现在转向用于以D31配置将陶瓷压电元件声学联接到由钛或钛合金(即Ti6Al4V)制成的超声波导的技术。本文描述的D31声学联接技术的优点包括低成本、低构型、易于制造和组装。附加的优点包括压缩压电元件(特别是在联接应变方向上)以提供更高效率和驱动大负载的能力。在D31声学系配置中，用于电连接的电接触件设置在陶瓷压电元件的两侧上。如果存在从陶瓷压电元件到超声波导的电接触，则可以将电接地连接施加到超声波导。在一个方面，采用低温声联接技术来最小化或防止对陶瓷压电元件的损坏(<150℃)。电连接也可以用作散热器。下面结合图5-11描述用于以D31配置将陶瓷压电元件声学联接到钛/钛合金超声波导的若干技术。
图5是根据本公开的一个方面的超声外科器械7100的透视图。超声外科器械7100包括通过粘结材料附接到超声波导7102的超声换能器7118，其中超声外科器械7100被构造成能够以D31模式操作。图6是根据本公开的一个方面的用于与图5所示的超声外科器械7100一起使用的压电元件7104的透视图。超声换能器7118包括通过粘结材料附接到超声波导7102的相对侧的第一压电元件7104a和第二压电元件7104b。压电元件7104a-b可以是使用下文所述的陶瓷-金属粘结技术来附接到金属超声波导7102的PZT陶瓷元件。
图7是根据本公开的一个方面的图5所示的超声波外科器械7100的剖视图。超声外科器械7100包括通过粘结材料附接到超声波导7102的超声换能器，其中超声外科器械7100被构造成能够以D31模式操作。超声换能器包括第一陶瓷压电元件7104a和第二陶瓷压电元件7104b，其通过粘结材料附接到超声波导7102的相对侧。粘结材料用于附接陶瓷-金属连接以将陶瓷压电元件7104a、7104b粘结到金属超声波导7102。在图7所示的示例中，顶部压电元件7104a的底表面通过诸如金属合金焊料7106a的金属粘结材料附接到超声波导7102的一侧。类似地，底部压电元件7104b的底表面通过诸如金属合金焊料7106b的金属粘结材料附接到超声波导7102的相对侧。金属合金焊料7106a、7106b可以用于将由PZT材料(即Pb[ZrxTi1-x]O3)制成的陶瓷压电元件7104a、7104b粘结到由钛或钛合金(即Ti6Al4V)制成的金属超声波导7102，而不使用助焊剂或预涂覆压电元件7104a、7104b。可以在低于陶瓷的居里温度的温度下施加金属合金焊料。金属合金焊料7106a、7106b结合部是导热和导电的，提供气密密封，并且具有高剪切强度。取决于结合过程，金属合金焊料7106a、7106b可以在压电元件7104a、7104b和超声波导7102的表面之间形成化学粘结。
此外，金属粘结材料(诸如金属合金焊料7108a)也可以用于将薄导电金属元件7110a粘结到顶部压电元件7104a的顶表面。类似地，金属粘结材料(诸如金属合金焊料7108b)可以用于将薄导电金属元件7110b粘结到底部压电元件7104b的顶表面。导电金属元件7110a、7110b适合于经由焊接线、压接连接或铲形连接与压电元件7104a、7104b进行正电连接。在低于压电元件7104a、7104b的居里温度的温度下，可以在对压电元件7104a、7104b进行极化之后执行粘结。在压电元件7104a、7104b的居里温度或高于该居里温度的温度下，压电元件7104a、7104b可以在将超声外科器械7100的部件作为组件粘结之后被极化。
在一个方面，例如，可以从S-Bond Technologies获得适合于陶瓷-金属粘结的金属粘结材料，例如金属合金焊料7106a、7106b、7108a、7108b。活性金属合金焊料可用于陶瓷-金属粘结。此类焊料合金包括活性元素(诸如钛和铈)，其被添加到SnAg、SnInAg和SnBi合金以产生可在粘结之前直接与陶瓷表面反应的焊料合金。焊料合金可以与所有金属(例如包括钢、不锈钢、钛、镍合金、铜和铝合金)产生可靠的密封结合部。陶瓷通常与直接润湿过程(熔融金属层粘附)不相容，并且陶瓷和金属具有非常不同的热膨胀系数(CTE)。根据定义，焊料合金熔化并且因此在低于840℉并通常接近480℉(250℃)的温度下结合。因此，焊接结合部在将陶瓷结合到金属方面要好得多，因为结合应力要低得多，这是由于固化来自比钎焊结合部低得多的温度。有关常规焊料的警告仍然是必须首先将粘附金属层放置在陶瓷表面上，然后进行焊剂过程，以破坏陶瓷上的金属和金属涂层上形成的氧化物，因为它们在焊料结合过程中被加热。以商品名S-BOND已知的金属合金焊料是一种活性焊料，其适合于通过将陶瓷直接粘结到金属而将金属合金结合到陶瓷上，从而在无需使用焊剂步骤以及无需预涂陶瓷步骤的情况下形成结合部。该过程消除了多步涂覆过程，并且可以在低于400℉的温度下应用，从而防止金属变形和软化并防止陶瓷破裂。所产生的结合部是密封的、通过<10-9atm-cc/sec、较强(>5,000psi剪切)、延展性、基于SnAg或SnIn合金以及导热。
压电元件7104a、7104b的极化轴线(P)分别由方向箭头7114a、7114b指示。响应于压电元件7104a、7104b的激励的超声波导7102的运动轴线由超声波导7102的远侧端部处的运动箭头7116示出，该远侧端部通常称为超声波导7102的超声刀部分。运动轴线7116与极化轴线(P)7114a、7114b正交。
图8-11示出了根据本公开的一个方面的适用于如图7所示的陶瓷-金属粘结的示例性金属合金焊料结合部7106a、7106b、7108a、7108b的剖视图。两种不同的过程可以用于陶瓷-金属粘结。图8和图9所示的“机械激活”结合过程可以在金属合金焊料熔化温度(例如，对于S-Bond 220为250℃)或其附近进行。
图8示出了根据本公开的一个方面的在金属合金焊料7122与金属7124之间形成的粘合剂粘结7120的示例。粘结7120可以通过将熔融合金涂抹、摩擦或刷涂到受热表面上并以一定方式装配“热”来进行，使得金属合金焊料7122的表面被充分搅拌以破坏在熔融时形成的薄氧化物皮。如图8所示，金属7124中的Al、Cr或Ti原子7128和金属合金焊料7122中的Ti或Ce原子7130在界面7126处形成粘合剂粘结。
图9示出了由金属合金焊料7146形成的陶瓷7142(例如，PZT)与金属7144(例如，钛合金钢)之间的粘合剂粘合7140的示例。金属合金焊料7146的合金可以粘结，但结合部强度在剪切下的标称值低于3,000psi。陶瓷7142和许多金属7144上的此类结合部是粘合剂，但没有化学粘结。
图10示出了根据本公开的一个方面的冶金/化学粘结7150的示例。另一种金属合金焊料7154结合过程采用热激活过程，其制备陶瓷7152表面并通过金属合金焊料7154中的活性元素的反应与表面形成化学粘结。这些结合部开始于在保护气氛炉中进行高温处理，其中金属合金焊料7154放置在待结合的陶瓷7152的表面上。在高温下，金属合金焊料7154中的活性元素与陶瓷7152反应，以在陶瓷7152与金属合金焊料7154之间的界面7156处形成化学粘结(例如，Al(Ti)-Ag相或Cu-Sn相)。在随后的结合步骤中，化学粘结和金属合金焊料7154层提供了更高水平的结合部强度并且产生高性能陶瓷金属结合部，其优于通过多步MoMn和电镀过程制造的大多数钎焊蓝宝石和陶瓷-金属结合部。
图11是根据本公开的一个方面的陶瓷7164(例如，PZT)和金属合金焊料7162化学粘结7160的微结构图示。在陶瓷7164与金属合金焊料7162的界面7168处形成反应区7166。S-Bond金属合金焊料提供高结合部剪切强度。例如，使用高温S-Bond金属合金焊料金属化过程，界面7168处的化学粘结7160的剪切强度可以超过7,000psi并且耐50-150℃的热循环。S-Bond金属合金焊料适合于结合陶瓷和金属表面而无需焊剂或电镀，并且由于S-Bond金属合金焊料的高表面张力，该过程更加容忍结合部变化。S-Bond金属合金焊料结合过程不使用必须被清洁或可能蚀刻金属部件从而留下外观缺陷的化学焊剂。
在一个方面，本公开提供了一种将陶瓷压电元件(例如，PZT)声学联接到金属(例如，钛/钛合金)超声波导以用于D31配置的过程。该过程还包括以D31声学系配置与两个压电元件的两侧进行电连接。通常，该方法包括在对压电元件进行极化之前将陶瓷压电元件焊接到金属超声波导，以及然后对组件进行极化。以上结合图8-11描述了用于将陶瓷粘结到金属的技术。在一个方面，该方法包括经由焊膏将陶瓷压电元件(例如PZT)固定到金属(例如钛/钛合金)超声波导，使焊膏回流以将压电元件粘结到超声波导，以及将压电元件作为超声波导/压电元件组件的一部分进行极化。以下结合图12A-12C描述该过程的一个方面。
图12A-12C示出了超声外科器械7200，其包括通过粘结材料附接到超声换能器7212的超声波导7202，其中超声外科器械7100被构造成能够以D31模式操作。超声换能器7212包括通过粘结材料附接到超声波导7202的相对侧的第一未极化压电元件7204a和第二未极化压电元件7204b。图12A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7200。超声外科器械7200包括金属超声波导7202(例如，钛/钛合金)。粘结材料(诸如焊膏7206)被施加到第一未极化压电元件7204a和第二未极化压电元件7204b的一个表面上。焊膏7206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7204a、7204b。焊膏7206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7204a、7204b。在粘贴之后，压电元件7204a、7204b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7204a、7204b固定到超声波导7202。
图12B示出了根据本公开的一个方面的在极化之前的图12A的超声外科器械7200以及以D31配置固定到超声波导7202的第一未极化压电元件7204a和第二未极化压电元件7204b。在粘贴之后，使用自动或手动过程将压电元件7204a、7204b固定到超声波导7202。在将固定的压电元件7204a、7204b和超声波导7202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7204a和第二未极化压电元件7204b。一旦进入焊炉，使焊膏7206回流以将第一未极化压电元件7204a和第二未极化压电元件7204b粘结到超声波导7202。
图12C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7202的第一未极化压电元件7204a和第二未极化压电元件7204b进行极化之前的图12的超声器械7200。一旦将固定的压电元件7204a、7204b和超声波导7202组件传送到回流焊炉，焊膏7206就回流以在第一未极化压电元件7204a和第二未极化压电元件7204b与超声波导7202之间建立粘结。可以使用标准表面安装技术使焊膏7206回流。存在许多用于使焊料7206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未极化压电元件7204a和第二未极化压电元件7204b附接到超声波导7202之后，整个超声器械7200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7204a、7204b的极化轴线(P)分别由方向箭头7208a、7208b指示。响应于压电元件7204a、7204b的激励的超声波导7202的运动轴线由超声波导7202的远侧端部处的运动箭头7210示出，该远侧端部通常称为超声波导7202的超声刀部分。运动轴线7210与极化轴线(P)7208a、7208b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。压电性可以表现为极化强度、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。
下面结合图13A-13C描述了用于将陶瓷压电元件(例如，PZT)声学联接到金属超声波导(例如，钛/钛合金)以按照D31配置使用的另一种技术。图13A示出了超声外科器械7300，其包括通过粘结材料附接到超声波导7302的超声换能器7318，其中超声外科器械7300被构造成能够以D31模式操作。如图13A所示，根据本公开的一个方面，超声外科器械7300包括被构造成能够保持压电元件7304a、7304b的超声波导7302。超声波导7302包括用于保持压电元件7304a、7304b的几何特征部。超声波导7302包括基部部分7320和从基部部分7320的一侧基本垂直于纵向轴线LA延伸的第一组壁7314a、7316a。第二组壁7314b、7316b从基部部分7320的相对侧基本垂直于纵向轴线LA延伸。凸缘7306a、7308a沿纵向轴线LA从对应的壁7314a、7316a突出。凸缘7306b、7308b沿纵向轴线LA从对应的壁7314b、7316b突出。凸缘7306a、7306b、7308a、7308b延伸到超声波导7302的基部部分7320上方并且基本平行于基部部分7320。在一个方面，第一组凸缘7306a、7306b和基部部分7320的一侧限定空间7310a、7310b以接纳压电元件7304a、7304b的一个端部。第二组凸缘7308a、7308b和基部部分7320的相对侧限定空间7312a、7312b以接纳压电元件7304a、7304b的另一端部。
超声换能器7318包括通过粘结材料7322a、7322b(诸如导电的环氧树脂、焊料或金属焊料合金)附接到超声波导7302的基部部分7320的相对侧的第一压电元件7304a和第二压电元件7304b。第一压电元件7304a可滑动地接纳在第一组空间7310a、7312a中。第二压电元件7304b可滑动地接纳在第二组空间7310b、7312b中。
一旦压电元件7304a、7304b可滑动地接纳在空间7310a、7310b、7312a、7312b中，压电元件7304a、7304b就可以使用上面结合图8-11或图12A-12C描述的各种粘结技术和粘结材料来附接到超声波导7302的基部部分7320。
图13B示出了类似于图13A所示的超声外科器械7300的超声外科器械7330，其中超声波导7302的凸缘7306a、7306b、7308a、7308b被朝向超声波导7302的基部7320偏压或略微弯曲以施加将压电元件7304a、7304b抵靠超声波导7302的基部部分7320的保持力。凸缘7306a、7306b、7308a、7308b可以在压电元件7304a、7304b可滑动地插入空间7310a、7310b、7312a、7312b之前或之后弯曲。
图13C示出了根据本公开的一个方面的类似于图13A和图13B所示的超声外科器械7300、7330的超声外科器械7340。如图13C所示，压电元件7304a、7304b可以通过以下的组合来附接到超声波导7302：结合图13A所述的那样施加粘结材料，以及如结合图13B所述的那样凸缘7306a、7306b、7308a、7308b被朝向超声波导7302的基部部分7320偏压，以向压电元件7304a、7304b施加偏压力。
在常规的D33超声换能器结构中，超声换能器的压电元件(例如，PZT板)以预压缩状态组装以便确保压电元件不以拉伸模式操作。然而，在D31架构配置中，可能希望在每个压电元件与超声波导之间进行一些预压缩。图14和图15示出了在压电元件与超声波导的粘结阶段期间预压缩压电元件的技术，如下所述。
图14示出了根据本公开的一个方面的超声外科器械7400，其包括通过粘结材料附接到超声波导7402的超声换能器7412，其中超声器械被构造成能够以D31模式操作。超声换能器7412包括第一压电元件7404a和第二压电元件7404b。图15示出了根据本发明的一个方面的在粘结阶段期间将电压V施加到压电元件7404a、7404b的图14所示的超声外科器械7400。如图14所示，使用粘结材料(诸如环氧树脂粘合剂7406)将压电元件7404a、7404b附接到超声波导7402，以将压电元件7404a、7404b粘结到超声波导7402。在一个方面，压电元件7404a、7404b的预压缩可以通过在环氧树脂7406固化的同时向压电元件7404a、7404b施加电压来实现。
因此，现在参考图14和图15，在D31架构配置中，通过在环氧树脂7406的固化过程期间向每个压电元件7404a、7404b施加电压V，可以在每个压电元件7404a、7404b与超声波导7402之间获得预压缩。例如，正电位可以施加到在每个压电元件7404a、7404b的自由端上形成的电连接7408a、7408b，并且可以将接地电位施加与超声波导7402的电连接7410。如图15所示，施加电压V以使压电元件7404a、7404b例如在如结合图2B所述的振动的纵向轴线LA的方向上收缩。超声波导7402与压电元件7404a、7404b的固定端之间的电连接可以由导电的环氧树脂7406提供。压电元件7404a、7404b可以使用各种粘结材料(诸如结合图8-11或图12A-12C描述的粘结材料)来附接到超声波导7402。
在其他方面，在D31超声换能器架构配置中，本公开提供了用于将能量源电连接到每个压电元件(例如，PZT板)两侧上的D31电接触件的方法。如果存在从压电元件到超声波导的电接触，则可以将接地连接施加到超声波导。在一个方面，该方法在低温下进行以防止或最小化压电元件发生的损坏(<150℃)。电连接可以用作散热器。以下结合图16描述这些技术。
图16示出了根据本公开的一个方面的超声外科器械7500，其包括通过粘结材料附接到超声波导7502的超声换能器7510，其中超声外科器械7500被构造成能够以D31模式操作。超声换能器7510包括通过粘结材料附接在超声波导7502的相对侧上的压电元件7506a、7104b。在一个方面，粘结材料是导电粘合剂7508。根据本公开的一个方面，导电板7504a、7504b分别通过粘结材料(诸如导电粘合剂7508)来附接到压电元件7506a、7506b。方法包括在一侧将压电元件7506a、7506b直接焊接到导电板7504a、7504b(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7502。导电的环氧树脂7508施加在导电板7504a、7504b与压电元件7506a、7506b的自由端之间。导电的环氧树脂7508也施加在压电元件7506a、7506b的固定端与超声波导7502之间。导电元件(诸如导线)可以连接到导电板7504a、7504b和超声波导7502。在一个方面，超声波导7502可以通过冲压形成，并且可以将电连接特征部添加到超声波导7502。导电板7504a、7504b可以由铜片形成并且组装到缆线上的阴电连接器。压接连接可以冲压或形成在超声波导7502和导电板7504a、7504b(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，电连接过程可以包括以上的任何组合。
图17和图18示出了超声外科器械7600，其包括通过粘结材料附接到超声波导7602的超声换能器7624，其中超声外科器械7600被构造成能够以D31模式操作。如图17和图18所示，根据本公开的一个方面，超声外科器械7600包括声学联接到超声波导7602的单个中平面超声换能器7624，该超声波导包括音叉状框架7606。如贯穿本公开所述，超声波导7602和音叉状框架7606由诸如钛或钛合金的金属制成。音叉状框架7606包括上叉臂7622a和下叉臂7622b，在该上叉臂和下叉臂之间限定了U形孔7608以在其中接纳超声换能器7624。在一个方面，音叉状框架7606配置约束了超声换能器7624的顶侧和底侧以将更多振动能量联接到超声波导7602中。单个中平面超声换能器7624包括单个压电元件7612(例如，PZT)和导电板7618a、7618b，该导电板例如通过导电粘结材料(诸如导电的环氧树脂、焊料、或金属焊料合金)来附接到压电元件7612的顶侧和底侧。音叉状框架7606的上叉臂7622a限定孔7604，以便为与顶部导电板7618a的电连接提供通路。超声换能器7624沿箭头7622的方向可滑动地插入U形孔7608中并且然后如图18所示的那样固定在其中。
图18是根据本发明的一个方面的超声换能器7624插入由超声波导7602的音叉状框架7606限定的U形孔7608的图17所示的超声外科器械7600的剖视图。在将超声换能器7624插入U形孔7608之前，将诸如电绝缘粘合剂7614(例如，电绝缘导电的环氧树脂)的第一粘结材料施加到音叉状框架7606的上叉臂7622a的内表面7610a或上导电板7618a或者两者。电绝缘粘合剂7614将音叉状框架7606和超声波导7602与上导电元件7618a电隔离。而且，在将超声换能器7624插入U形孔7608之前，将诸如导电粘合剂7616(例如，导电的环氧树脂)的第二粘结材料施加到音叉状框架7606的下叉臂7622b的内表面7610b、或下导电板7618b或两者。导电粘合剂7616将下导电板7618b电联接到音叉状框架7606和超声波导7602。
一旦超声换能器7624插入U形孔7608中，电绝缘粘合剂7614和导电粘合剂7616就固化以将超声换能器7624粘结到超声波导7602的音叉状框架7606。能量源的一个极(例如，正极)通过孔7604电连接到上导电板7618a。能量源的另一极(例如，负极或接地)通过导电粘合剂7616电连接到超声波导7602和音叉状框架7606并电连接到下导电板7618b。通常，能量源的正极连接到上导电板7618a，并且能量源的负极或接地连接到超声波导7602或音叉状框架7606。然而，本发明考虑了能量源的负极或接地极连接到上导电板7618a，并且能量源的正极连接到超声波导7602或音叉状框架7606的配置。
在一个方面，本发明提供了其中金属部件通过型锻过程来结合的D33超声换能器配置。D33压电元件位于音叉状金属框架中并受到插入框架近侧端部的金属塞的压缩。金属塞通过型锻过程结合到金属框架。型锻是其中使用模具来改变物品尺寸的锻造过程，物品被强制进入该模具中。型锻通常是冷加工过程，但也可能是热加工的。组件夹具在型锻过程中施加压缩力以在堆叠中留下压缩应力。可以通过测量压电叠堆电压来测量压缩力。另一种配置包括U形框架，其中在U形框架的远侧端部上设置有开口。通过将超声波变幅杆/波导(例如，钛或钛合金)插入开口中以及在压电堆叠处于压缩状态的同时对部件进行磨锻或螺纹连接来实现压电堆叠压缩。框架可以由与超声波变幅杆/波导不同的材料制成，例如铝。以下结合图19-21描述这些方面。
图19A和图19B示出了根据本公开的一个方面的D33超声换能器配置7700。在图19A中，提供了音叉状金属框架7708，其在金属框架7708的近侧端部中限定U形孔7702。音叉状金属框架7708由诸如钛或钛合金的金属制成，如本文所述。如图19B所示，将多个压电元件7706a、7706b、7706c、7706d插入U形孔7702中以形成压电Langevin堆叠。金属塞7704插入音叉状金属框架7708的近侧端部中，直到塞7704接触压电堆叠。组件夹具从远侧端部施加压缩力FA1并且从近侧端部施加压缩力FA2以压缩外壳7708中的压电元件7706a-7706d的堆叠。将型锻力FS施加到金属塞7704以将金属塞7704与音叉状金属框架7708结合，以便保持压电元件7706a-7706d的堆叠处于压缩下。
图20示出了根据本公开的一个方面的D33超声换能器配置7800。超声换能器7800包括限定U形孔的U形金属外壳7802，其中多个压电元件7804a、7804b、7804c、7804d被定位成形成Langevin堆叠。超声变幅杆/波导7806插入U形金属外壳7802的远侧端部中，直到塞7806接触压电元件7804a-7804d的堆叠。组件夹具从远侧端部施加压缩力FA1并且从近侧端部施加压缩力FA2以在外壳7802(例如，铝)中压缩压电元件7804a-7804d。将型锻力FS施加到超声波变幅杆/波导7806以将超声波变幅杆/波导7806结合到金属外壳7802，以便保持压电元件7804a-7804d的堆叠处于压缩下。
图21示出了根据本公开的一个方面的D33超声换能器配置7900。超声换能器7900包括U形金属外壳7902，其限定U形孔以接纳Langevin堆叠形式的多个压电元件7904a、7904b、7904c、7904d。U形金属外壳7902的远侧端部包括阴螺纹7906，并且超声变幅杆/波导7910包括阳螺纹7908。超声波变幅杆/波导7910通过螺纹接合到U形金属外壳7902。组件夹具从远侧端部施加压缩力FA1并且从近侧端部施加压缩力FA2以压缩外壳7902中的压电元件7904a-7904d的堆叠。将螺纹FT施加到超声波变幅杆/波导7910以将超声波变幅杆/波导7910螺纹结合到外壳7902，同时压电元件7904a-7904d的堆叠处于压缩下。
图22A-D示出了根据本公开的一个方面的D33超声换能器配置10000。超声换能器10000包括U形金属外壳10008，该U形金属外壳在其近侧端部处限定被构造成能够接纳以Langevin堆叠形式的多个压电元件10006a-d的孔10002。塞10004插入U形金属外壳10008的近侧端部中，直到其接触压电元件10006a-d的堆叠。塞10004可以具有如图22A所示的T形配置、如图22B所示的倒圆边缘、如图22B-C所示的I形配置、如图22D所示的矩形配置、或任何其他此类合适的配置。组件夹具从远侧端部施加压缩力FA1并且从近侧端部施加FA2以压缩外壳10008中的压电元件10006a-d的堆叠。一旦实现所需的压缩力(通过例如压电元件10006a-d的堆叠的电压来测量)，则在压电元件10006a-d的堆叠处于压缩状态的同时，在塞10004与外壳10008之间的相互作用点处施加粘结10010。组件夹具可以保持压缩力FA1、FA2，直到粘结10010足够强以便在压电元件10006a-d的堆叠上独立地保持期望压缩力。粘结10010可包括例如粘合剂树脂或互补螺纹，诸如以上关于图21所述的。粘结10010也可以通过制造过程(包括例如焊接或钎焊)来实现。如果用于建立或制造粘结10010的过程需要足够高的温度以便在压电元件10006a-d中产生去极化，则超声换能器10000可以在组装之后被极化或重新极化。
图23示出了根据本公开的一个方面的D33超声换能器配置10100。超声换能器10100包括U形金属外壳10108，该U形金属外壳在其远侧端部处限定被构造成能够接纳以Langevin堆叠形式的多个压电元件10106a-d的孔。超声波导10102的近侧端部10103(其限定塞)插入U形金属外壳10108的远侧端部中，直到其接触压电元件10106a-d的堆叠。组件夹具从远侧端部施加压缩力FA1并且从近侧端部施加FA2以压缩外壳10108中的压电元件10106a-d的堆叠。一旦实现所需的压缩力(通过例如压电元件10106a-d的堆叠的电压来测量)，则在压电元件10006a-d的堆叠处于压缩状态的同时，在超声波导10102与外壳10108之间的相互作用点处施加粘结10104。组件夹具可以保持压缩力FA1、FA2，直到粘结10104足够强以便在压电元件10106a-d的堆叠上独立地保持期望压缩力。粘结10104可包括例如粘合剂树脂或互补螺纹，诸如以上关于图21所述的。粘结10104也可以通过制造过程(包括例如焊接或钎焊)来实现。如果用于建立或制造粘结10104的过程需要足够高的温度以便在压电元件10106a-d中产生去极化，则超声换能器10100可以在组装之后被极化或重新极化。超声波导10102可以由与外壳10108相同的金属材料或不同的金属材料(例如铝)构成。
图24A-C示出了根据本公开的一个方面的D31超声换能器10200配置。超声换能器10200包括：由形状记忆合金构成的外壳10202、设置在外壳10202的内部的换能器基板10208(例如，换能器安装部分)、以及延伸穿过外壳10202的近侧孔10210的超声波导10206。换能器基板10208包括用于接纳压电元件的在相对侧上的平面。构成外壳10202的形状记忆合金可以包括例如CuAlTi和NiTi合金。在各个方面，外壳10202的形状记忆合金具有默认形状10212(即，外壳10202在加热时返回的形状)，该默认形状小于外壳10202的工作形状(即，利用外壳10202来开始组装超声换能器10200时的形状)，如图24C所描绘的。在一个方面，外壳10202的默认形状10212在轴向和径向上都小于外壳10202的工作形状。在另选方面，与外壳10202的工作形状相比，默认形状10212可以在任何数量的尺寸上更小。计算默认形状10212的尺寸以对应于超声换能器10200的最终期望尺寸，其中超声换能器10200的所有部件可操作地联接。外壳10202可以具有各种形状，例如圆柱形。
外壳10202包括，被构造成能够接纳穿过其中的压电元件的多个槽10204a、10204b。在所描绘的方面，槽10204a、10204b纵向地布置在外壳10202上并且每个槽10204a、10204b沿着换能器基板10208的一侧在外壳10202内延伸。可以通过每个槽10204a、10204b插入压电元件，使得每个压电元件以D31配置定位在换能器基板的相对侧上。在另选方面，槽的数量和定向可以变化，使得压电元件可能以替代配置(诸如D33配置)放置在外壳10202内。一旦压电元件位于槽10204a、10204b内，超声换能器10200就被加热到致使外壳10202的形状记忆合金返回到默认形状10212的温度，如图24C中描绘的。当外壳10202返回其默认形状10212时，它在其中的部件上施加轴向压缩力FA和径向压缩力FR。压缩力FA、FR的一个影响是使压电元件与换能器基板10208牢固地接触并以D31配置保持就位。如上所述，此后可以电激励压电元件以引发超声振动。第二个效果是压缩力FA、FR将超声波导10206结合到换能器基板10208并将这些部件牢固地保持在适当位置，使得超声振动可以通过换能器基板10208传输到超声波导10206。一旦被组装，D31超声换能器10200的这个方面可以与例如外科器械结合使用。如果用于加热外壳10202的形状记忆合金的过程需要足够高的温度以便在压电元件中产生去极化，则超声换能器10200可以在组装之后被极化或重新极化。
图25A-C示出了根据本公开的一个方面的D33超声换能器10300配置。超声换能器10300包括U形金属外壳10308，该U形金属外壳在其近侧端部处限定被构造成能够接纳以Langevin堆叠形式的多个压电元件10306a-d的孔10302。10302插入U形金属外壳10308的近侧端部中，直到其接触压电元件10306a-d的堆叠。当塞10304a插入外壳10308中时，设置在塞10304a上的螺纹10312接合设置在外壳10308的内表面上的互补螺纹10310，从而允许塞10304a牢固地抵靠压电元件10306a-d的堆叠拧紧以对其施加压缩力。一旦实现所需的压缩力(通过例如压电元件10306a-d的堆叠的电压来测量)，就可以停止塞10304a的拧紧。一旦被拧紧，接合的螺纹10310、10312将使塞10304a保持就位。压电元件10306a-d可以在组装超声换能器10300之前被极化，或者超声换能器10300可以在组装之后被极化或重新极化。
图25D示出了根据本公开的一个方面的D33超声换能器10300配置。在这方面，塞10304b包括螺纹10316，其与螺母10314的互补螺纹10318接合。当螺母10314与塞10304b通过螺纹接合时，拧紧螺母10304b致使塞10304b被驱动到外壳10308的内部中并接触压电元件10306a-d的堆叠，从而如上所述的那样对其施加压缩力。在所描绘的方面，塞10304b没有与外壳10308的内螺纹接合的螺纹。在另选方面，超声换能器10300可以包括与塞10304b通过螺纹接合的螺母10314以及与外壳10308的内螺纹13310接合的塞螺纹10312的组合，如上面相对于图25A-C所描述的。
图25E示出了根据本公开的一个方面的D33超声换能器配置。在这方面，超声换能器10300包括一个或多个紧固件10322a、10322b，其被构造成能够延伸穿过外壳10308并接合塞10304c以便将塞10304c保持就位。紧固件10322a、10322b可以包括例如被构造成与塞10304c螺纹接合的螺钉。紧固件10322a、10322b可以被构造成例如从外壳10308的远侧端部纵向延伸穿过到达近侧端部以接合塞10304c。当紧固件10322a、10322b与塞10304c接合时，拧紧紧固件10322a、10322b致使塞10304c接触压电元件10306a-d的堆叠并在其上施加压缩力，如上所述。在所描绘的方面，塞10304c没有与外壳10308的内螺纹接合的螺纹。在一个另选方面，超声换能器10300可以包括与塞10304c接合的紧固件10322a、10322b以及与外壳10308的内螺纹13310接合的塞螺纹10312的组合，如上面相对于25A-C所述的。
图26A-D示出了根据本公开的一个方面的D33超声换能器配置及其组装过程。超声换能器10400包括U形金属外壳10408，该U形金属外壳在其近侧端部处限定被构造成能够接纳以Langevin堆叠形式的多个压电元件10406a-d的孔10402。外壳10408还包括沿着限定孔10402的每个相对表面纵向延伸的通道10410。塞10404包括一对凸片10412a、10412b，其被构造成能够可滑动地接合沿着外壳10408的相对内侧延伸的通道10410。如图26A所描绘的，塞10404沿着通道10410插入U形金属外壳10408的近侧端部中，直到其接触压电元件10406a-d的堆叠。如图26C所描绘的，组件夹具然后将压缩力F1施加到塞10404以压缩外壳10008中的压电元件10406a-d的堆叠。一旦实现了期望的压缩力(通过例如压电元件10406a-d的堆叠的电压来测量)，则在压电元件10406a-d堆叠处于压缩下的同时，将第二压缩力F2施加到外壳10408，如图26D中描述的。压缩力F2使通道10410(以及位于其中的突片10412a、10412b)变形，从而将塞10404锁定就位。可以通过例如冲床来施加压缩力F2。压电元件10406a-d可以在组装超声换能器10400之前被极化，或者超声换能器10400可以在组装之后被极化或重新极化。
图27示出了根据本公开的一个方面的D31超声换能器配置10500。超声换能器10500包括U形金属外壳10508，该U形金属外壳在其近侧端部处限定被构造成能够接纳换能器基板10504(例如，换能器安装部分)的孔10502，该换能器基板包括用于接纳压电元件10506a-b的在相对侧上的平面。压电元件10506a-b可以经由例如环氧树脂层10518a-b固定在换能器基板10504上。换能器基板10504具有大致T形配置，包括终止于远侧端部10514的纵向或轴向部分10512和附接到轴向部分10512的近侧端部的横向部分10510。在一个方面，压电元件10506a-b和轴向部分10512的尺寸被设置成使得当换能器基板10504插入孔10502中时，它们与限定孔10502的内表面10524形成压力或过盈配合。过盈配合在轴向和/或径向方向上压缩压电元件10506a-b。压电元件10506a-b的这种预压缩改善了超声换能器10500的性能。外壳10508还包括被构造成能够接纳换能器基板10504的远侧端部10514的槽10516。在一个方面，远侧端部10514和槽10516被构造成能够以压力配合或过盈配合进行接合。在另一方面，远侧端部10514通过粘合树脂、紧固件、焊接、钎焊、物理变形结合部或另一种这样的固定方法来粘结到槽10516。当换能器基板10504以所述方式固定到外壳10508时，由压电元件10506a-b产生的超声振动通过换能器基板10504传输到超声波导。换能器基板10504的横向部分10510被构造成密封或塞住孔10502。在一个方面，横向部分10510的一个或多个表面10520a-b通过粘合树脂、紧固件、焊接、钎焊、物理变形结合部或另一种这样的固定方法来固定到外壳10508的相对表面10522a-b上。压电元件10506a-b可以在组装超声换能器10500之前被极化，或者超声换能器10500可以在组装之后被极化或重新极化。
图28示出了根据本公开的一个方面的D31超声换能器配置10600。超声换能器10600包括金属外壳10608，该金属外壳限定各自被构造成能够在其中接纳压电元件10606a-b的一个或多个凹槽10602。凹槽10602的尺寸等于对压电元件10606a-b的尺寸的紧容差，使得当压电元件10606a-b插入其中时，凹槽10602将压电元件10606a-b保持固定在适当位置。在所描绘的方面，金属外壳10608包括第一凹槽10602和设置在与第一凹槽10602相对的一侧上的第二凹槽(未示出)。每个凹槽10602包括沿其侧面设置的多个空腔10610。每个空腔10610的尺寸和形状设计成牢固地接纳沿着压电元件10606a-b的边缘设置的对应凸片10604。具有凹槽10602的外壳10608可以经由例如金属注射成型来制造。
由于凹槽10602的尺寸基本上等于压电元件10606a-b的尺寸，并且突片10604延伸超出压电元件10606a-b的周边，因此压电元件10606a-b在标准状况下不能插入凹槽10602中。在组装超声换能器10600的一个方面，外壳10608被加热到致使构造外壳10608的材料膨胀和/或呈现为可延展的温度。在将外壳10608加热到适当的温度之后，然后将压电元件10606a-b插入凹槽10602中，使得凸片10604各自接合对应的空腔10610。然后冷却组装的超声换能器10600。在一些方面，超声换能器10600在其冷却时被附加地压缩。当超声换能器10600冷却(并且可选地经受外部压缩)时，凹槽10602围绕在其中的压电元件10606a-b进行压缩，从而致使突片10604变为固定在空腔10610内并由此将压电元件10606a-b固定在适当位置。在其中利用金属注射成型来制造外壳10608的方面，压电元件10606a-b可以在外壳10608被烧结之前插入凹槽10602中，因为外壳10608在烧结过程期间收缩。另选地，压缩元件10606a-b可以在外壳10608已经被烧结之后，但在金属注射成型过程中的热等静压步骤之前插入凹槽10602中，因为外壳10608在热等静压步骤期间也会收缩。在另选方面，压电元件10606a-b而不是外壳10608被加热到致使压电元件10606a-b能够插入凹槽10602中的温度。一旦加热的压电元件10606a-b放置在凹槽10602内，则超声换能器10600然后在有或没有外部压缩的情况下如上所述的那样冷却。如果用于加热超声换能器10600的过程需要足够高的温度以便在压电元件10606a-b中产生去极化，则超声换能器10600可以在组装之后被极化或重新极化。
图29A-B示出了根据本公开的一个方面的D31超声换能器10700配置。超声换能器10700包括金属外壳10708，该金属外壳限定延伸穿过其的一个或多个孔10702。在一个方面，孔10702是横跨外壳10708延伸的挤出通孔。孔10702被构造成能够在其中接纳压电元件10706。在所描绘的方面，超声换能器10700包括单个孔10702；然而，超声换能器10700可以包括任何数量的孔10702和对应的压电元件10706。孔10702的尺寸等于对压电元件10706的尺寸的紧容差，使得当压电元件10706插入其中时，孔10702将压电元件10706保持固定在适当位置。具有孔10702的外壳10708可以经由例如金属注射成型来制造。
在组装超声换能器10700的一个方面，外壳10708被加热到致使构造外壳10708的材料膨胀和/或呈现为可延展的温度。在将外壳10708加热到适当的温度之后，然后将压电元件10706插入孔10702中。然后冷却组装的超声换能器10700。在一些方面，超声换能器10700在其冷却时被附加地压缩。当超声换能器10700冷却(并且任选地经受外部压缩)时，凹槽10702围绕在其中的压电元件10706进行压缩，从而由于压电元件10706的表面与孔1702的表面之间的摩擦接合而将压电元件10706固定在适当位置。在其中利用金属注射成型来制造外壳10708的方面，压电元件10706可以在外壳10708被烧结之前插入孔10702中，因为外壳10708在烧结过程期间收缩。另选地，压缩元件10706可以在外壳10708已经被烧结之后，但在金属注射成型过程中的热等静压步骤之前插入孔10702中，因为外壳10708在热等静压步骤期间也会收缩。在另选方面，压电元件10706而不是外壳10708被加热到致使压电元件10706能够插入孔10702中的温度。一旦加热的压电元件10706放置在孔10702内，组装超声换能器10700的过程与前述方面相同。如果用于加热超声换能器10700的过程需要足够高的温度以便在压电元件10706中产生去极化，则超声换能器10700可以在组装之后被极化或重新极化。
图30A-D示出了根据本公开的一个方面的D31超声换能器10800配置。超声换能器10800包括：换能器基板10802、以D31配置粘结到换能器基板10802的相对表面(例如，换能器安装部分)的多个压电元件1806a-b、以及粘接到每个压电元件1806a-b的外表面上的压缩板10808a-b。超声换能器10800的各种部件可以通过例如导电的环氧树脂粘合剂来彼此粘结。在图30A-B中描绘的方面，换能器基板10802、压电元件1806a-b和压缩板10808a-b包括一系列孔，这些孔被构造成能够彼此对准使得当组件固定在一起时可以通过其接纳紧固件10804。紧固件10804包括例如具有互补螺母10810的螺钉。在图30C-D中描绘的另选方面，仅压缩板10808a-b包括一系列孔，这些孔被构造成能够彼此对准使得当部件固定在一起时可以通过其接纳紧固件10804a-b。这些紧固件10804a-b同样可以包括例如具有互补螺母10810a-b的螺钉。拧紧紧固件10804将附加的压缩力施加到超声换能器10800，这可以改善超声换能器10800的性能。在一些方面，压缩板10808a-b由金属材料构成，这可有助于超声换能器10800的散热。
图31示出了根据本公开的一个方面的D33超声换能器配置10900。超声换能器10900包括金属外壳10908，该金属外壳限定被构造成能够接纳Langevin堆叠形式的多个压电元件10906a-d的开放内部10902。超声换能器10900还包括螺纹塞或螺纹杆10904，其延伸穿过设置在外壳10908的近侧端部处的螺纹孔10912到达外壳内部10902中。当螺纹杆10904被拧紧时，其远侧端部10910接触压电元件10906a-d的堆叠并施加压缩力以压缩外壳10908中的压电元件10906a-d的堆叠。一旦获得期望的压缩力，螺纹杆10904将由于其与螺纹孔10912的接合而保持在特定的拧紧位置。由螺纹杆10904施加的压缩力的程度可以通过松开或拧紧螺纹杆10904来调整，以便调节压电元件10906a-d堆叠的频率，而不需要拆卸超声换能器10900。在一些方面，超声换能器10900可以根据在压电元件10906a-d的堆叠上施加的压缩力的程度在操作频率之间进行切换。当超声换能器10900与外科器械结合使用时，能够现场在操作频率之间进行切换可以允许超声换能器10900调整以适应外科器械所遇到的组织效应或不同的端部执行器类型。
图32A-B示出了根据本公开的一个方面的具有多对压电元件的D31超声换能器11000配置。超声换能器11000包括设置在换能器基板11008的第一面上的第一换能器阵列11002a(例如，换能器安装部分)和设置在换能器基板11008的与第一面相对的第二面上的第二换能器阵列11002b。在图32A所描绘的方面，换能器阵列11002a-b以D31配置进行布置。每个换能器阵列11002a-b包括彼此相邻布置的第一压电元件11006a和第二压电元件11006b。在所描绘的方面，压电元件11006a-b相对于换能器基板11008的纵向轴线纵向布置。在其他方面，压电元件11006a-b相对于换能器基板10008以其他定向(诸如正交)进行布置。在一些方面，相对的换能器阵列11002a-b的压电元件11006a-b以匹配对进行布置。换句话说，第一换能器阵列10002a的每个压电元件11006a-b与第二换能器阵列11002b的对应压电元件对齐。在所描绘的方面，压电元件11006a-b的形状为矩形，并且换能器阵列11002a的形状为方形。
在图32B所描绘的方面，换能器阵列11002c包括彼此相邻布置的第一压电元件11006c、第二压电元件11006d、第三压电元件11006e和第四压电元件11006f。在一个方面，压电元件11006c-f沿平面换能器阵列11002c的x轴和y轴对称布置。在所描绘的方面，压电元件11006c-f的形状是方形的，并且换能器阵列11002c的形状同样是方形的。
在各个方面，图32A-B中描绘的换能器阵列11002a-c可以与彼此或其他压电元件阵列相结合地使用或代替其使用。分段换能器阵列11002a-c中的压电元件11006a-f可以各自被单独驱动，由此允许换能器阵列11002a-c产生不平衡的振动。在其中换能器基板11008的相对面上的压电元件相对于彼此平衡的先前讨论的方面，波导和/或端部执行器的非纵向运动是不期望的。然而，可能以不对称或非平衡方式选择性地激活的分段换能器阵列11002a-c可以产生两种期望的效果。首先，如果外科系统中存在不希望的振动或弯曲，则可以选择性地激活分段换能器阵列11002a-c以便抵消不期望的横向振动并使系统返回产生稳定的纵向运动。其次，在一些情况下，期望端部执行器的横向或扭转运动。因此，在这些情况下，可以按不对称的方式选择性地激活分段换能器阵列11002a-c以便在端部执行器处引发期望的非纵向移动。可以例如通过控制施加到各个压电元件11006a-f的电流量来控制换能器阵列11002a-c中的压电元件11006a-f的激活。
图33A-C示出了根据本公开的一个方面的具有可不对称激励的压电换能器组件11102、11202、11302的D31超声换能器11100、11200、11300配置。如上面相对于图32A-B所讨论的那样，以下是有利的：使超声换能器能够在某些情况下产生不平衡或不对称的振动，诸如用于抵消外科系统内不期望的非纵向振动，或故意在端部执行器处引发非纵向移动。在一些方面，可以通过使压电元件相对于超声波导的纵向轴线不对称地布置来实现不对称。在其他方面，可以通过使压电元件相对于超声波导的纵向轴线对称地布置，但能够以不对称方式选择性地激活来实现不对称。在其中超声换能器能够取决于由换能器阵列组成的压电元件的选择性激活而产生对称或非对称振动的方面，合并超声换能器的外科系统可以被构造成通过可逆地激活(即，电激励)或停用各个压电元件而在对称和非对称激活模式之间可互换地切换。
图33A示出了D31超声换能器11100配置，其包括换能器基板11108(例如，换能器安装部分)，该换能器基板包括用于在其上接纳压电元件11106a-c的在相对侧上的平面。压电元件11106a-c的尺寸、形状和布置被设置成关于波导11104的纵向轴线不对称。第一压电元件11106a和第三压电元件11106c的形状大致为三角形的，并且第二压电元件11106b的形状为不规则的。在该方面，第一压电元件11106a和第二压电元件11106b被构造成能够产生关于波导11104的纵向轴线的对称振动。同样地，第一压电元件11106a和第三压电元件11106c被构造成能够产生关于波导11104的纵向轴线的对称振动。然而，所有三个压电元件11106a-c的激活或第二压电元件11106b和第三压电元件11106c的激活被构造成能够由于压电元件11106a-c的尺寸、形状和布置而产生不对称振动。
图33B示出了D31超声换能器11200配置，其包括换能器基板11208(例如，换能器安装部分)，该换能器基板包括用于在其上接纳压电元件11206a-c的在相对侧上的平面。压电元件11206a-c的尺寸、形状和布置被设置成关于波导11204的纵向轴线对称，但其可以被选择性地激活以产生不对称的振动。具体地，所有三个压电元件11206a-c的激活或第一压电元件11206a和第三压电元件11206c的激活被构造成能够产生对称振动。相反，第二压电元件11206b以及第一压电元件11206a或第三压电元件11206c中的一个的激活被构造成能够产生不对称振动。
图33B示出了D31超声换能器11300配置，其包括换能器基板11308(例如，换能器安装部分)，该换能器基板包括用于在其上接纳压电元件11306a-c的在相对侧上的平面。压电元件11306a-c的尺寸和形状被彼此等效地设置，但其围绕波导11304的纵向轴线不对称地布置。第一压电元件11306a和第二压电元件11306b的激活被构造成能够产生对称振动；然而，压电元件11306a-c的任何其他组合的激活被构造成能够产生不对称振动。
应当指出的是，图32A-33C仅是示例性的，并且可设想被构造成能够产生对称振动、不对称振动、或对称振动或不对称振动的组合的分段超声换能器阵列的各种其他配置。此外，合并2、3和4个压电元件的超声换能器阵列的各个方面的描述仅是示例性的。本文的教导同样适用于合并多于4个压电元件的超声换能器阵列。更进一步地，在各个方面，超声换能器阵列的压电元件可以同步、异步地或者通过可在频率、相位或幅度上不同的各种超声激活信号来激活。
图34A-B示出了根据本公开的一个方面的D31超声换能器11400配置，其中压电元件11406a–b相对于彼此偏移。超声换能器11400包括换能器基板11408(例如，换能器安装部分)、设置在换能器基板11408的第一面上的第一压电元件11406a、以及设置在与第一面相对的第二面上的第二压电元件11406b。第一压电元件11406a和第二压电元件11406b彼此纵向偏移。在一个方面，每个压电元件11406a-b定位在换能器基板11408上的声学组件的节点处。节点是振动运动驻波中的最小值或过零点(即，其中运动通常是最小的)。因此，压电元件11406a-b彼此偏移的距离等于声学组件的半波长(λ/2)。
在合并在换能器基板11408上以对齐方式(即，彼此不偏移)布置的压电元件的超声换能器的方面，超声换能器产生半波。相反，将压电元件11406a-b布置成使得它们偏移声学组件的半波长(λ/2)致使超声换能器11400产生全波。可以利用全波振动运动将非纵向运动引入由声学组件驱动的端部执行器。超声换能器11400可以附加地包括一个或多个平衡特征部，其被构造成能够平衡或补偿由偏移压电元件11406a-b产生的全波所引发的弯曲运动或弯曲模式。如果利用附加的平衡特征部来补偿偏移的压电元件11406a-b，则超声换能器11400在端部执行器处引发纵向运动，如图34C中描绘的。如果不利用平衡特征部来补偿压电元件11406a-b，则超声换能器11400在端部执行器处引发非纵向或弯曲运动，如图34D中描绘的。在一些方面，平衡特征部可以被选择性地激活，从而允许合并超声换能器11400的外科器械在端部执行器的纵向模式和非纵向模式之间切换。
应当指出的是，被描述为特定换能器架构(例如D31换能器架构或D33换能器架构)的超声换能器组件的任何方面的教导同样适用于利用其他配置的超声换能器，除非另有说明或此类教导与特定换能器结构的结构相冲突。例如，被描绘为D31换能器结构的超声换能器组件(诸如在图19A–23、图25A–26D和图31中)的一个方面的教导同样适用于D33换能器组件(诸如在图4A-C、图27-30D和图32A-34B中)(除非它们与特定换能器架构的结构相冲突)。
图35A-E示出了根据本公开的一个方面的外科工具11500的各种视图及其制造过程，该外科工具包括具有复杂特征部的外科器械的波导11508。外科工具11500包括近侧换能器基板11506(例如，换能器安装部分)、远侧端部执行器11502、以及在其间延伸的纵向部分或波导11508。在各个方面，波导11508还包括沿其长度设置的多个齿11504。此外，在各个方面，波导11508被扭曲，使得齿11504以各种不同的角度从波导11508的纵向轴线延伸，如图35E中描绘的。
为了制造外科器械11500，第一步骤是制造包括多个齿11504的平板外科工具11500，如图35B和图35D中描绘的。外科工具11500可以经由各种制造过程(例如包括金属注射成型)来制造。齿11504可以经由金属注射成型过程或经由例如成形、机械加工、切割、锻造、研磨、抛光、去毛刺、翻滚或任何其他此类制造过程来在外科器械11500上形成。接下来，波导11508逐渐被扭曲，如图35C中描绘的。波导11508可以经由各种制造过程(例如包括使波导11508通过一系列级进模)来扭曲。扭曲还可以用于调整波导11508的各种特征部，诸如曲率、偏移、弯曲部分以及薄或锥形的组织夹紧部分。波导11508可以沿其长度在任何点处扭曲。在一个方面，波导被扭曲，使得齿11504彼此对称地偏移(即，相邻齿11504以固定量成角度地分开)。在这方面，角度对称的齿11504在端部执行器11502处产生纵向运动和扭转(即，非纵向)运动。
图36A-D示出了根据本公开的一个方面的被构造成能够产生非纵向运动的D31超声换能器11600配置及其部件的各种视图。超声换能器11600包括金属外壳11608，该金属外壳包括被构造成能够在其中接纳圆柱形压电元件11604的凹槽11602。超声换能器11600还包括被构造成能够在其上支撑圆柱形元件11604的圆柱形换能器支撑件11610以及围绕压电元件11604布置的多个电极11612a-c。在一个方面，电极11612a-c以固定量彼此成角度地偏移(即，电极11612a-c是角度对称的)。压电元件11604可以通过例如导电的环氧树脂来固定到换能器支撑件11610。换能器支撑件11610可以固定到凹槽11602的内侧壁，由此将压电元件11604和电极11612a-c支撑在凹槽内。在各个方面，每个电极11612a-c至少在轴线(即，x、y或z)上是不对称的或不平衡的，由此致使每个电极11612a-c具有净质量偏移。当使用超声换能器11600时，被不对称加权的角度偏移电极11612a-c致使超声换能器11600在外科器械的端部执行器处引发纵向运动和扭转(即，非纵向)运动。
图37示出了根据本公开的一个方面的用于外科器械的超声信号发生器的电连接器11700的透视图。各种外科器械(诸如在名称为“TISSUE LOADING OF A SURGICALINSTRUMENT”的美国专利申请代理人案卷号END7917USNP5/160045-5中公开的外科器械，所述专利申请的全部内容以引用方式结合在此)包括可连接到超声信号发生器以驱动压电元件的电连接器11700。电连接器11700包括：设置在内侧11704上的第一导线11706a和第二导线11706b，其被构造成能够封闭在外科器械的外壳内；以及设置在外侧11704上的第一销11708a和第二销11708b，其被构造成能够连接到超声信号发生器。第一导线11706a和第二导线11706b电连接到超声换能器的压电元件，并且将由超声信号发生器产生的信号传输到其。
电连接器11700的内侧11704旨在与周围环境密封隔离，以避免可能损害外科器械的功能或者另外对操作者和/或患者来说是安全隐患的水分、微生物和其他污染物进入。如果污染物进入外科器械的外壳，则可能期望使外科器械产生警告或警报、停止运行、或执行一些其他动作以向器械的操作者通知已经发生错误。在这方面，电连接器11700包括分别从第一导线11706a和第二导线11706b沿电连接器11700的内侧11704延伸的第一导电通路11712a和第二导电通路11712b。导电通路11712a-b可以包括例如焊接通道。导电通路11712a-b朝向彼此延伸，但终止使得它们被间隙分开，该间隙是足够大的以防止其间的电弧放电，但又是足够小的以使得相对少量的水可以桥接间隙。在一个方面，导电通路11712a-b之间的间隙填充有亲水涂层11714，如图37中描绘的。在另一个方面，电连接器11700的几何形状被构造成能够将流体引导到导电通路11712a-b之间的间隙(例如，内侧11704被构造为具有位于间隙处的局部或全局最小值的弯曲表面)。在任一方面，如果流体进入外科器械的外壳，则其被流漏到或吸引到导电通路11712a-b之间的间隙。当流体到达间隙时，它会导致电气系统短路。在一个方面，短路致使外科器械停止运转。因此，如果外科器械的内部外壳被湿气污染，则防止使用外科器械。在另一个方面，短路致使外科器械的电路产生错误信号，该错误信号继而可以被检测并致使产生警告或警报。
图38-41示出了根据本公开的一个方面的D33超声换能器11800配置的各种视图。超声换能器11800包括金属外壳11808，该金属外壳限定被构造成能够接纳Langevin堆叠形式的多个压电元件11806a-f的开放内部11802。外壳11816包括被构造成能够接纳超声波导的连接器11816。超声换能器11800还包括螺纹塞或螺纹杆11804，其延伸穿过设置在外壳11808的近侧端部处的螺纹孔11814到达外壳内部11802中。超声换能器11800还包括位于压电元件11806a-f的堆叠与螺杆11804的远侧端部11810之间的板11812。当螺纹杆11804被拧紧时，其远侧端部11810接触板11812并施加压缩力以压缩外壳11808中的压电元件11806a-f的堆叠。在各个方面，板11812由导电材料构成。
一旦获得期望的压缩力，螺纹杆11804将由于其与螺纹孔11814的接合而保持在特定的拧紧位置。由螺纹杆11804施加的压缩力的程度可以通过松开或拧紧螺纹杆11804来调整，以便调节压电元件11806a-f堆叠的频率，而不需要拆卸超声换能器11800。在一些方面，超声换能器11800可以根据在压电元件11806a-d的堆叠上施加的压缩力的程度在操作频率之间进行切换。当超声换能器11800与外科器械结合使用时，能够现场在操作频率之间进行切换可以允许超声换能器11800调整以适应外科器械所遇到的组织效应或不同的端部执行器类型。
超声换能器11800还包括电联接到压电元件11806a-f的堆叠的第一导线11818和第二导线11820。第一导线11818可以用于递送第一电势并且第二导线11820可以用于递送第二电势。在一个方面，第一电势是正的并且第二电势是接地或负的。在一个方面，第一导线11818的连接点11822a-c和第二导线11820的连接点11824a-d附接在板11812与可例如通过导电粘合剂来连接的每个压电元件11806a-f之间的接合部(junctions)处。第一导线11818的连接点11822a-c和第二导线11820的连接点11824a-d可以被布置成使得它们彼此交替。在一个方面，第二导线11820的连接点11824a-d(表示负连接或接地连接)可以位于压电元件11806a-f的堆叠的外部连接点11824a、11824d处。
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1.一种压缩超声换能器组件，包括：金属外壳，所述金属外壳限定开口；至少两个压电元件，所述至少两个压电元件设置在所述开口内并受到压缩力的压缩，其中所述至少两个压电元件被构造成能够以D33模式工作；以及金属塞，所述金属塞结合到所述金属外壳以封闭所述开口并使所述至少两个压电元件在所述金属外壳内保持在压缩状态。
实施例2.根据实施例1所述的压缩超声换能器组件，还包括用于将所述金属塞结合到所述金属外壳的焊接结合部。
实施例3.根据实施例1或实施例2所述的压缩超声换能器组件，还包括用于将所述金属塞结合到所述金属外壳的环氧树脂结合部。
实施例4.根据实施例1至实施例3中的一项或多项所述的压缩超声换能器组件，其中，所述金属外壳和所述金属塞各自包括螺纹端部，并且所述金属外壳和所述金属塞螺纹联接。
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压缩超声换能器组件，还包括用于将所述金属塞结合到所述金属外壳的型锻结合部。
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压缩超声换能器组件，其中，所述金属外壳具有叉状金属框架。
实施例7.一种超声外科器械，包括：超声波导；超声换能器，所述超声换能器安装到超声波导并被构造成能够以D31模式操作，超声换能器包括：第一陶瓷压电元件，所述第一陶瓷压电元件的第一侧通过第一粘结材料附接到超声波导的第一侧；以及第二陶瓷压电元件，所述第二陶瓷压电元件的第一侧通过第一粘结材料附接到超声波导的第二侧，其中超声波导的第一侧与超声波导的第二侧相对。
实施例8.根据实施例7所述的超声外科器械，还包括：第一导电板，其通过第二粘结材料附接到所述第一陶瓷压电元件的第二侧；以及第二导电板，其通过所述第二粘结材料附接到所述第二陶瓷压电元件的第二侧。
实施例9.根据实施例7或实施例8所述的超声外科器械，其中，所述第一粘结材料与所述第二粘结材料相同。
实施例10.根据实施例8至实施例9中的一项或多项所述的超声外科器械，其中，所述第一粘结材料是焊料粘结材料，并且所述第二粘结材料是导电的环氧树脂粘结材料。
实施例11.根据实施例8至实施例10中的一项或多项所述的超声外科器械，其中，所述焊料是金属焊料合金粘结材料。
实施例12.根据实施例7至实施例11中的一项或多项所述的超声外科器械，其中，所述第一粘结材料是焊料粘结材料。
实施例13.根据实施例12所述的超声外科器械，其中，所述焊料材料是金属焊料合金粘结材料。
实施例14.根据实施例7至实施例13中的一项或多项所述的超声外科器械，其中，所述第一陶瓷压电元件在从所述第一陶瓷压电元件的第一侧到第二侧的方向上具有极化轴线，并且所述第二陶瓷压电元件在从所述第二陶瓷压电元件的第一侧到第二侧的方向上具有极化轴线，以便以D31模式操作。
实施例15.根据实施例14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陶瓷压电元件和第二陶瓷压电元件的极化轴线正交。
实施例16.根据实施例14至实施例15中的一项或多项所述的超声外科器械，其中，所述第一压电元件和第二压电元件在粘结到所述超声波导的相应的所述第一侧和所述第二侧之前是非极化的，并且在所述第一压电元件和第二压电元件粘结到所述超声波导的相应的所述第一侧和所述第二侧之后被极化。
实施例17.一种超声外科器械，包括：超声波导，所述超声波导包括：基部部分；从所述基部部分的一侧延伸的第一壁和第二壁；以及从对应的所述第一壁和第二壁突出的第一凸缘和第二凸缘，其中第一空间限定在所述第一凸缘与所述基部部分之间，并且其中第二空间限定在所述第二凸缘与所述基部部分之间；以及附接到超声波导的超声换能器，其中超声换能器包括可滑动地设置在所述第一空间与所述第二空间之间并固定在其中的至少一个压电元件。
实施例18.根据实施例17所述的超声外科器械，其中，所述至少一个压电元件通过粘结材料附接到所述超声波导的所述基部部分。
实施例19.根据实施例17或实施例18所述的超声外科器械，其中，所述第一凸缘和所述第二凸缘被朝向所述超声波导的所述基部部分偏压，以将所述至少一个压电元件附接到所述超声波导的所述基部部分。
实施例20.根据实施例17至实施例19中的一项或多项所述的超声外科器械，其中，所述至少一个压电元件通过粘结材料附接到所述超声波导的所述基部部分，并且其中所述第一凸缘和所述第二凸缘被朝向所述超声波导的所述基部部分偏压，以与所述粘结材料相结合地将所述至少一个压电元件附接到所述超声波导的所述基部部分。
实施例21.根据实施例17至实施例20中的一项或多项所述的超声外科器械，其中，所述超声波导还包括从所述基部部分的相对侧延伸的第三壁和第四壁；从对应的所述第三壁和第四壁突出的第三凸缘和第四凸缘，其中第三空间限定在所述第三凸缘与所述基部部分之间，并且其中第四空间限定在所述第四凸缘与所述基部部分之间。
实施例22.根据实施例21所述的超声外科器械，其中，所述超声换能器还包括可滑动地设置在所述第三空间与所述第四空间之间并固定在其中的第二压电元件。
实施例23.根据实施例22所述的超声外科器械，其中，所述第二压电元件通过粘结材料附接到所述超声波导的所述基部部分。
实施例24.根据实施例22至实施例23中的一项或多项所述的超声外科器械，其中，所述第三凸缘和所述第四凸缘被朝向所述超声波导的所述基部部分偏压，以将所述第二压电元件附接到所述超声波导的所述基部部分。
实施例25.根据实施例22至实施例24中的一项或多项所述的超声外科器械，其中，所述第二压电元件通过粘结材料附接到所述超声波导的所述基部部分，并且其中所述第三凸缘和所述第四凸缘被朝向所述超声波导的所述基部部分偏压，以与所述粘结材料相结合地将所述第二压电元件附接到所述超声波导的所述基部部分。
实施例26.一种超声外科器械，包括：超声波导；以及附接到所述超声波导的超声换能器；其中所述超声波导包括音叉状框架，所述音叉状框架包括：上叉臂；和下叉臂，在所述上叉臂和下叉臂之间限定U形孔，所述U形孔被构造成能够在其中接纳所述超声换能器。
实施例27.根据实施例26所述的超声器械，其中，所述音叉状框架的上叉臂限定孔，以便为与所述超声换能器的电连接提供通路。
实施例28.根据实施例26或实施例27所述的超声器械，其中，所述超声换能器包括：压电元件；第一导电板，所述第一导电板通过导电粘结材料附接到所述压电元件的顶侧；以及第二导电板，所述第二导电板通过导电粘结材料附接到所述压电元件的底侧。
实施例29.根据实施例28所述的超声器械，还包括：电绝缘粘结材料，所述电绝缘粘结材料设置在所述第一导电板与所述上叉臂的内表面之间；以及导电粘结材料，所述导电粘结材料设置在所述第二导电板与所述下叉臂的内表面之间。

Claims (29)

1.一种压缩超声换能器组件，包括：
金属外壳，所述金属外壳限定开口；
至少两个压电元件，所述至少两个压电元件设置在所述开口内并受到压缩力的压缩，其中所述至少两个压电元件被构造成能够以D33模式工作；和
金属塞，所述金属塞结合到所述金属外壳以封闭所述开口并使所述至少两个压电元件在所述金属外壳内保持在压缩状态。
2.根据权利要求1所述的压缩超声换能器组件，还包括用于将所述金属塞结合到所述金属外壳的焊接结合部。
3.根据权利要求1所述的压缩超声换能器组件，还包括用于将所述金属塞结合到所述金属外壳的环氧树脂结合部。
4.根据权利要求1所述的压缩超声换能器组件，其中，所述金属外壳和所述金属塞各自包括螺纹端部，并且所述金属外壳和所述金属塞通过螺纹联接。
5.根据权利要求1所述的压缩超声换能器组件，还包括用于将所述金属塞结合到所述金属外壳的型锻结合部。
6.根据权利要求1所述的压缩超声换能器组件，其中，所述金属外壳具有叉状金属框架。
7.一种超声外科器械，包括：
超声波导；
超声换能器，所述超声换能器安装到所述超声波导并被构造成能够以D31模式操作，超声换能器包括：
第一陶瓷压电元件，所述第一陶瓷压电元件的第一侧通过第一粘结材料附接到所述超声波导的第一侧；和
第二陶瓷压电元件，所述第二陶瓷压电元件的第一侧通过所述第一粘结材料附接到所述超声波导的第二侧，其中所述超声波导的所述第一侧与所述超声波导的所述第二侧相对。
8.根据权利要求7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陶瓷压电元件的第二侧；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陶瓷压电元件的第二侧。
9.根据权利要求8所述的超声外科器械，其中，所述第一粘结材料与所述第二粘结材料相同。
10.根据权利要求8所述的超声外科器械，其中，所述第一粘结材料是焊料粘结材料，并且所述第二粘结材料是导电的环氧树脂粘结材料。
11.根据权利要求8所述的超声外科器械，其中所述焊料是金属焊料合金粘结材料。
12.根据权利要求7所述的超声外科器械，其中，所述第一粘结材料是焊料粘结材料。
13.根据权利要求12所述的超声外科器械，其中，所述焊料材料是金属焊料合金粘结材料。
14.根据权利要求7所述的超声外科器械，其中，所述第一陶瓷压电元件在从所述第一陶瓷压电元件的所述第一侧到所述第二侧的方向上具有极化轴线，并且所述第二陶瓷压电元件在从所述第二陶瓷压电元件的所述第一侧到所述第二侧的方向上具有极化轴线，以便以D31模式操作。
15.根据权利要求14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陶瓷压电元件和第二陶瓷压电元件的所述极化轴线正交。
16.根据权利要求14所述的超声外科器械，其中，所述第一压电元件和第二压电元件在粘结到所述超声波导的相应的所述第一侧和所述第二侧之前是非极化的，并且在所述第一压电元件和第二压电元件粘结到所述超声波导的相应的所述第一侧和所述第二侧之后被极化。
17.一种超声外科器械，包括：
超声波导，所述超声波导包括：
基部部分；
从所述基部部分的一侧延伸的第一壁和第二壁；和
从对应的所述第一壁和第二壁突出的第一凸缘和第二凸缘，其中第一空间限定在所述第一凸缘与所述基部部分之间，并且其中第二空间限定在所述第二凸缘与所述基部部分之间；和
附接到所述超声波导的超声换能器，其中所述超声换能器包括可滑动地设置在所述第一空间与所述第二空间之间并固定在其中的至少一个压电元件。
18.根据权利要求17所述的超声外科器械，其中，所述至少一个压电元件通过粘结材料附接到所述超声波导的所述基部部分。
19.根据权利要求17所述的超声外科器械，其中，所述第一凸缘和所述第二凸缘被朝向所述超声波导的所述基部部分偏压，以将所述至少一个压电元件附接到所述超声波导的所述基部部分。
20.根据权利要求17所述的超声外科器械，其中，所述至少一个压电元件通过粘结材料附接到所述超声波导的所述基部部分，并且其中所述第一凸缘和所述第二凸缘被朝向所述超声波导的所述基部部分偏压，以与所述粘结材料相结合地将所述至少一个压电元件附接到所述超声波导的所述基部部分。
21.根据权利要求17所述的超声外科器械，其中，所述超声波导还包括：
从所述基部部分的相对侧延伸的第三壁和第四壁；和
从对应的所述第三壁和第四壁突出的第三凸缘和第四凸缘，其中第三空间限定在所述第三凸缘与所述基部部分之间，并且其中第四空间限定在所述第四凸缘与所述基部部分之间。
22.根据权利要求21所述的超声外科器械，其中，所述超声换能器还包括可滑动地设置在所述第三空间与所述第四空间之间并固定在其中的第二压电元件。
23.根据权利要求22所述的超声外科器械，其中，所述第二压电元件通过粘结材料附接到所述超声波导的所述基部部分。
24.根据权利要求22所述的超声外科器械，其中，所述第三凸缘和所述第四凸缘被朝向所述超声波导的所述基部部分偏压，以将所述第二压电元件附接到所述超声波导的所述基部部分。
25.根据权利要求22所述的超声外科器械，其中，所述第二压电元件通过粘结材料附接到所述超声波导的所述基部部分，并且其中所述第三凸缘和所述第四凸缘被朝向所述超声波导的所述基部部分偏压，以与所述粘结材料相结合地将所述第二压电元件附接到所述超声波导的所述基部部分。
26.一种超声外科器械，包括：
超声波导；和
附接到所述超声波导的超声换能器；
其中所述超声波导包括音叉状框架，所述音叉状框架包括：
上叉臂；和
下叉臂，在所述上叉臂和下叉臂之间限定U形孔，所述U形孔被构造成能够在其中接纳所述超声换能器。
27.根据权利要求26所述的超声器械，其中，所述音叉状框架的所述上叉臂限定孔，以便为与所述超声换能器的电连接提供通路。
28.根据权利要求26所述的超声器械，其中，所述超声换能器包括：
压电元件；
第一导电板，所述第一导电板通过导电粘结材料附接到所述压电元件的顶侧；和
第二导电板，所述第二导电板通过导电粘结材料附接到所述压电元件的底侧。
29.根据权利要求28所述的超声器械，还包括：
电绝缘粘结材料，所述电绝缘粘结材料设置在所述第一导电板与所述上叉臂的内表面之间；和
导电粘结材料，所述导电粘结材料设置在所述第二导电板与所述下叉臂的内表面之间。
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