Abstract: An electrosurgical vessel sealing instrument having a first and a second opposing jaw member at a distal end thereof, wherein each jaw member includes a jaw housing, a seal plate having a tissue contacting surface and a side wall, and an insulating region disposed on the side wall of the seal plate. The instrument includes the ability to move the jaw members relative to one another from a first position wherein the jaw members are disposed in spaced relation relative to one another to a second position wherein the jaw members cooperate to grasp tissue. The insulating region enables precision overmolding of the jaw housing to the seal plate, while advantageously reducing thermal spread and edge cutting during vessel sealing procedures.

Abstract: A forceps is provided and includes a housing having a shaft. An end effector assembly operatively connects to a distal end of the shaft and includes a pair of first and second jaw members. One or both of the first and second jaw members is movable relative to the other jaw member from a clamping position to an open position. A resilient member operably couples to at least one of the first and second jaw members. The resilient member is configured to bias the first and second jaw members in the clamping position and provide a closure force on tissue disposed therebetween.

Abstract: An end effector assembly for use with an electrosurgical instrument is provided. The end effector assembly has a pair of opposing jaw members. One or more of the jaw members includes a support base, an electrical jaw lead, and a sealing plate coupled to the electrical jaw lead. The sealing plate has a stainless steel layer and one or more piezoelectric sensors. The jaw member also includes an insulative plate disposed between the support base and the sealing plate.

Abstract: An end effector assembly adapted to couple to an electrosurgical instrument, the end effector assembly including a pair of opposing jaw members pivotably attached about a pivot member and moveable from a first spaced position to a second grasping position. Each jaw member includes a jaw housing and a seal plate formed on an inner surface of the jaw member including at least two seal plate segments extending along a substantial portion of the length of the jaw members. An insulating member is positioned between adjacent seal plate segments and configured to provide electrical isolation between adjacent seal plate segments. Each sealing plate segment is adapted to selectively connect to an electrosurgical energy source and form part of an electrosurgical energy delivery circuit.

Abstract: A method of manufacturing a shaft of a surgical instrument including forming a proximal segment of the shaft to include one or more features for operably engaging the shaft to a first component of the surgical instrument, forming a distal segment of the shaft to include one or more features for operably engaging the shaft to a second component of the surgical instrument and forming an intermediate segment of the shaft. The proximal segment is welded to a proximal end of the intermediate segment; and the distal segment is welded to a distal end of the intermediate segment. The proximal and distal segments are welded to the intermediate segment such that the one or more features thereof are aligned in a pre-determined orientation relative to one another.

Abstract: A surgical instrument includes an end effector assembly having first and second jaw members moveable relative to one another between a spaced-apart position and an approximated position for grasping tissue therebetween. In the approximated position, the jaw members cooperate to define a cavity that is configured to house tissue grasped between the jaw members. An injectable material configured for injection into the cavity defined by the jaw members is also provided. The injectable material is configured to substantially surround tissue housed within the cavity. The injectable material is transitionable from a first state, facilitating injection of the injectable material into the cavity, to a second state, wherein the injectable material forms about tissue housed within the cavity to occlude tissue.

Abstract: An electrosurgical forceps is provided with a shaft that extends from a housing of the electrosurgical forceps. An end effector assembly includes a pair of first and second jaw members pivotably coupled to one another via a pivot pin. One or both of the first and second jaw members may be movable from an open position for positioning tissue therebetween to a clamping position for grasping tissue. A detent is operably disposed proximal the pivot pin and extends radially outward from a proximal flange of one of the jaw members. The detent is configured to releasably engage a corresponding slot disposed on a proximal flange of the other jaw member. The detent and slot are configured to control a gap distance between the first and second jaw members when the first and second jaw members are in the clamping position.

Abstract: An end effector assembly includes a pair of opposing jaw members, each jaw member having a jaw housing and a seal plate. The seal plate is associated with the jaw housing and includes an interior surface and an exterior surface. A portion of the exterior surface defines a tissue contacting surface and at least a portion of the interior surface includes a conductive element that is disposed thereon. The conductive element facilitates soldering a wire lead thereto for electrical communication with the seal plate.

Abstract: A method of manufacture for an end effector assembly is provided. The method includes providing a pair of jaw members. A step of the method includes forming one or more seal plates positionable on one of the pair of jaw members. Etching a dam along a side of the one or more seal plates is a step of the method, wherein the etched dam inhibits the flow of a plastic on the one or more seal plate such that a height of the plastic with respect to the at least one seal plate during an overmolding process may be controlled. The method includes positioning the one or more seal plates on the one of the pair of jaw members; and overmolding the seal plate to one or more of the pair of jaw members.

Abstract: A system for the manufacture of an end effector assembly which is configured for use with an electrosurgical instrument configured for performing an electrosurgical procedure is provided. The system includes a photolithography module that is configured to etch one or more pockets on a seal surface of the seal plate. A vacuum module is configured to raise, transfer and lower a spacer from a location remote from the pocket(s) on the seal plate to the pocket on the seal plate(s). An adhesive dispensing module is configured to dispense an adhesive into the pocket on the seal plate. An optical module is configured to monitor a volume of the adhesive dispensed within the pocket and monitor placement of the spacer within the pocket.

Abstract: A method of manufacture for an end effector assembly is provided. The method includes providing a pair of jaw members. A step of the method includes forming one or more seal plates positionable on one of the pair of jaw members. Etching a dam along a side of the one or more seal plates is a step of the method, wherein the etched dam inhibits the flow of a plastic on the one or more seal plate such that a height of the plastic with respect to the at least one seal plate during an overmolding process may be controlled. The method includes positioning the one or more seal plates on the one of the pair of jaw members; and overmolding the seal plate to one or more of the pair of jaw members.

Abstract: An end effector assembly for use with an electrosurgical instrument is provided. The end effector assembly has a pair of opposing jaw members. Each of the jaw members has a support base, an electrical jaw lead, and a sealing plate coupled to the electrical jaw lead. The sealing plate has a stainless steel layer and an electrically insulative layer.

Abstract: An end effector assembly includes a pair of opposing jaw members. One or more of the jaw members includes a support base, an electrical jaw lead, a sealing plate, and a ceramic layer. The sealing plate is coupled to the electrical jaw lead and mounted to the support base. The sealing plate includes a tissue engaging surface, an opposing surface, and a series of depressions formed within the opposing surface and projecting from the tissue engaging surface. The ceramic layer is deposited atop each of the series of depressions. The combination of the depressions that project from the tissue engaging surface and their ceramic layers form a corresponding series of nonconductive stop members for controlling the separation distance between opposing jaw members when closed about tissue.

Abstract: An end effector assembly for use with an electrosurgical instrument is provided. The end effector assembly has a pair of opposing jaw members. One or more of the jaw members includes a support base, an electrical jaw lead, and a sealing plate coupled to the electrical jaw lead. The sealing plate has a stainless steel layer and one or more piezoelectric sensors. The jaw member also includes an insulative plate disposed between the support base and the sealing plate.

Abstract: An end effector assembly for use with an electrosurgical instrument is provided. The end effector assembly has a pair of opposing jaw members. At least one of the jaw members has a support base and a sealing plate coupled to the electrical jaw lead. The sealing plate has a stainless steel layer and a copper layer formed on the underside of the stainless steel layer.

Abstract: A method of manufacture for an end effector assembly is provided. The method includes providing a pair of jaw members. A step of the method includes forming one or more seal plates positionable on one of the pair of jaw members. Etching a dam along a side of the one or more seal plates is a step of the method, wherein the etched dam inhibits the flow of a plastic on the one or more seal plate such that a height of the plastic with respect to the at least one seal plate during an overmolding process may be controlled. The method includes positioning the one or more seal plates on the one of the pair of jaw members; and overmolding the seal plate to one or more of the pair of jaw members.

Abstract: A method of manufacture for an end effector assembly is provided. The method includes providing a pair of jaw members. A step of the method includes forming one or more seal plates positionable on one of the pair of jaw members. Etching a dam along a side of the one or more seal plates is a step of the method, wherein the etched dam inhibits the flow of a plastic on the one or more seal plate such that a height of the plastic with respect to the at least one seal plate during an overmolding process may be controlled. The method includes positioning the one or more seal plates on the one of the pair of jaw members; and overmolding the seal plate to one or more of the pair of jaw members.

Abstract: A forceps includes a housing including a shaft. The shaft includes an end effector assembly having a pair of curved jaw members. The jaw members include an electrically conductive surface and a curved blade channel having opposing sidewalls. A cutting blade is configured for translation within the blade channel. Proximal portions of a first sidewall include incident angles of less than five degrees that engage the cutting blade and direct the blade towards a specific point of contact on the opposing sidewall of the curved blade channel.