Limits and Opportunities for Miniaturizing Ultrasonic Surgical Devices Based on a Langevin Transducer

Can Mn:PIN-PMN-PT piezocrystal replace hard piezoceramic in power ultrasonic devices?

Mn:PIN-PMN-PT piezocrystal is investigated to determine whether its enhanced energy density makes it a candidate transducer material for power ultrasonics applications. To this end, the electromechanical and vibrational characteristics of a simple configuration of a bolted Langevin transducer (BLT) and then an ultrasonic surgical device, both incorporating Mn:PIN-PMN-PT piezocrystal, are compared with the same transducer configurations incorporating a conventional hard PZT piezoceramic commonly used in high-power ultrasonic transducers. The material properties of Mn:PIN-PMN-PT are determined using a single sample characterisation technique and these are used in finite element analysis (FEA) to design and then fabricate the BLT and ultrasonic surgical device, tuned to the first and second longitudinal modes at 20 kHz respectively. FEA is similarly used for the hard PZT versions. It is found that the superior elastic compliance of Mn:PIN-PMN-PT results in a higher radial piezo-stack deformation than the hard PZT under ultrasonic excitation of the BLT. However, the resulting longitudinal displacement amplitude of the two BLTs and two ultrasonic surgical devices is found to be equal, despite the higher figure of merit (Qkeff2) of those incorporating Mn:PIN-PMN-PT. The electrical impedance is measured at increasing excitation levels to evaluate the quality factor, Q. It is found that damping in the BLT with hard PZT is negligibly affected in the excitation range considered; however, the BLT incorporating Mn:PIN-PMN-PT exhibits a large reduction in Q. These findings indicate that, for measurements in air, the advantages of the high figure of merit of the piezocrystal material are not realised in a high-power transducer due to significantly increased damping at high excitation levels. To compare the vibrational response of the two ultrasonic surgical devices, L-C electrical impedance matching was implemented to maximise the efficiency of energy transfer from the source to the transducer under load. Results suggest that similar responses occurred for the two surgical devices in cutting tests using a low strength bone mimic material. However, the Mn:PIN-PMN-PT device exhibited better performance in cutting through higher strength ex-vivo chicken femur.

A cascaded Nitinol Langevin transducer for resonance stability at elevated temperatures

Across power ultrasonics and sensing, piezoelectric ultrasonic transducers commonly experience degradation in mechanical, electrical, and dynamic performance due to the relatively high sensitivity of piezoelectric materials to changes in temperature. These changes, arising for example through high excitation voltages or environmental conditions, can lead to nonlinear dynamic behaviours which compromise device performance. To overcome this, the excitation signal to the piezoelectric material is often pulsed, mitigating the influence of temperature rises. However, there remain constraints on suitable candidate piezoelectric materials for power ultrasonic devices. As a novel approach to mitigating the influence of temperature on the properties of piezoelectric materials, the phase-transforming shape memory alloy Nitinol is incorporated into the piezoelectric stack of a Langevin power ultrasonic transducer, in a cascade formation. The underlying principle is that the nonlinear hardening response of Nitinol to rising temperature can be used to dynamically compensate for the nonlinear softening of the piezoelectric materials. Thus, the dynamic response of the transducer can be linearised at elevated excitation levels. In this study, two configurations of Langevin transducer are designed and characterised. One transducer incorporates a Nitinol middle mass, and in the second, titanium. A combination of electrical and thermomechanical characterisation is undertaken, where it is demonstrated that the nonlinear softening of the piezoelectric stack can be mitigated through control of the Nitinol microstructure. The vibration amplitudes of the Nitinol-middle cascaded transducer are higher and more stable when the Nitinol is austenite rather than a combination of martensite and austenite at room temperature. It has also been shown that the vibration amplitude and resonance frequency of Nitinol-middle cascaded transducer remain stable as temperature changes from 20 °C to 45 °C, dependent of the excitation voltage. Moreover, the self-heating experiment demonstrates the resonance stability of the Nitinol-middle cascaded transducer for continuous operation.

Multi-mode coupled vibration analysis and radiation sound field investigation of a novel multidirectional piezoelectric ultrasonic transducer

Nowadays, expanding the operating range and realizing multifrequency operation have emerged as focal and imperative objectives in the design of ultrasonic transducers. Due to the limitations of structure and radial sizes, conventional Langevin transducers encounter challenges in meeting the increasingly stringent requirements across diverse ultrasonic applications. Hence, this paper proposes a multidirectional piezoelectric ultrasonic transducer (MPUT) consisting of a large-dimension sandwich piezoelectric transducer (LSPT) and a metal tube in mutli-mode coupled vibration, capable of achieving wide-ranging and multifrequency acoustic radiation. Based on the analytical method, a two-dimensional electromechanical equivalent circuit model (2D-EECM) of the MPUT is established, and its frequency calculation results are validated through the finite element method (FEM) and impedance analysis experiment. The vibration testing results indicate that adjusting the radial size can control the coupled vibration intensity of the MPUT and achieve dual-frequency and multidirectional uniform radiation. The radiation sound field testing results confirm the MPUT's satisfactory three-dimensional radiation capability in water and significant improvement in acoustics operating range.

Review of the design of power ultrasonic generator for piezoelectric transducer

The power ultrasonic generator (PUG) is the core device of power ultrasonic technology (PUT), and its performance determines the application of this technology in biomedicine, semiconductor, aerospace, and other fields. With the high demand for sensitive and accurate dynamic response in power ultrasonic applications, the design of PUG has become a hot topic in academic and industry. However, the previous reviews cannot be used as a universal technical manual for industrial applications. There are many technical difficulties in establishing a mature production system, which hinder the large-scale application of PUG for piezoelectric transducers. To enhance the performance of the dynamic matching and power control of PUG, the studies in various PUT applications have been reviewed in this article. Initially, the demand design covering the piezoelectric transducer application and parameter requirements for ultrasonic and electrical signals is overall summarized, and these parameter requirements have been recommended as the technical indicators of developing the new PUG. Then the factors affecting the power conversion circuit design are analyzed systematically to realize the foundational performance improvement of PUG. Furthermore, advantages and limitations of key control technologies have been summarized to provide some different ideas on how to realize automatic resonance tracking and adaptive power adjustment, and to optimize the power control and dynamic matching control. Finally, several research directions of PUG in the future have been prospected.

Development and evaluation of a titanium-based planar ultrasonic scalpel for precision surgery

This paper introduces a titanium-based planar ultrasonic microscalpel. The concept of silicon-based planar ultrasonic transducers has already been proven, but they are not yet suitable for clinical use due to material failure. The main objective of this work was to develop a smaller, lighter, and more cost-effective ultrasonic scalpel that could be used as an alternative or supplementary device to current surgical instruments. Various prototypes were fabricated and characterized, differing in bonding by three epoxy adhesives and two solder pastes as well as three variations in tip design. The instruments were designed to operate in the frequency range of commercial instruments and to generate a longitudinal displacement amplitude. The electro-mechanical characterization through impedance analysis and vibration measurements was complemented by an in vitro cutting trial and an acute in vivo animal experiment in comparison to commercial ultrasonic and electrosurgical devices. The operating frequency was around 40 kHz and 48 kHz depending on whether matched or unmatched operation was used. Unmatched operation turned out to be more suitable, achieving displacement amplitudes of 25.3 μm and associated velocity amplitudes of up to 7.9 m/s at an electrical power of 10.2 W. The cutting ability was demonstrated in vivo by successful dissection even under anticoagulation. The geometry of the instrument tip was found to have a major influence on cutting performance by affecting the resonance behaviour and tissue penetration.