Abstract: A method of manufacturing a two-part sealing plate of a jaw member of an end effector assembly includes: fabricating a series of grooves through an upper plate of a two-part sealing plate of a jaw member; securing a lower plate to a non-tissue engaging side of the upper plate such that an upper surface of the lower plate defines a corresponding bottom surface of at least one of the series of grooves; and securing the seal plate to a support base of the jaw member.

Abstract: An end effector assembly of a surgical instrument includes opposing first and second jaw members. A first sealing plate is positioned on the first jaw member. The first sealing plate defines a first surface facing the second jaw member. A second sealing plate is positioned on the second jaw member. The second sealing plate defines a second surface facing the first jaw member. A mesa is formed in the first sealing plate. The mesa protrudes from the first surface toward the second surface in the second position of the first and second jaw members. A material is disposed on the mesa. The mesa and the material define a stop member. The stop member maintains a gap distance between the first and second surfaces when the first and second jaw members are in the second position.

Abstract: A jaw member of an electrosurgical instrument includes a U-shaped structural frame defining a cavity therein and extending therealong configured to receive at least a portion of an insulative spacer therein such that the insulative spacer extends distally therefrom. The insulative spacer includes a tapered fin at a distal end thereof. A tissue treating plate is disposed on the face of the insulative spacer, the tissue treating plate is adapted to connect to a source of energy to treat tissue therewith. The tapered fin is configured to extend to and support a distal end of the tissue treating plate.

Abstract: An electrosurgical system includes an electrosurgical instrument having an electrode with a polymeric dielectric coating; and an electrosurgical generator, which includes a power converter configured to generate RF energy; a sensor coupled to the power converter and configured to sense a parameter of the RF energy; and a controller coupled to the sensor and the power converter. The controller is configured to control the power converter to output an RF waveform to achieve conductor breakthrough through the polymeric dielectric coating. The controller is further configured to determine whether the conductor breakthrough occurred based on the parameter; and execute a treatment algorithm based on a determination of the conductor breakthrough.

Abstract: An electrosurgical system includes an electrosurgical instrument having an electrode with a polymeric dielectric coating; and an electrosurgical generator, which includes a power converter configured to generate RF energy; a sensor coupled to the power converter and configured to sense a parameter of the RF energy; and a controller coupled to the sensor and the power converter. The controller is configured to control the power converter to output an RF waveform to achieve conductor breakthrough through the polymeric dielectric coating. The controller is further configured to determine whether the conductor breakthrough occurred based on the parameter; and execute a treatment algorithm based on a determination of the conductor breakthrough.

Abstract: A method of manufacturing a two-part sealing plate of a jaw member of an end effector assembly includes: fabricating a series of grooves through an upper plate of a two-part sealing plate of a jaw member; securing a lower plate to a non-tissue engaging side of the upper plate such that an upper surface of the lower plate defines a corresponding bottom surface of at least one of the series of grooves; and securing the seal plate to a support base of the jaw member.

Abstract: An end effector assembly includes a pair of opposing jaw members, one or both of the jaw members having a support base and an electrical jaw lead adapted to operably connect to an electrosurgical generator. A sealing plate is operably coupled to the support base and includes: an upper plate having an outer peripheral edge that extends therefrom and that defines a cavity configured to receive a lower plate; and a series of grooves defined within the upper plate and projecting therethrough to expose the lower plate. One or both of the upper plate or the lower plate is operably coupled to the electrical lead.

Abstract: An electrosurgical system includes an electrosurgical instrument having an electrode with a polymeric dielectric coating; and an electrosurgical generator, which includes a power converter configured to generate RF energy; a sensor coupled to the power converter and configured to sense a parameter of the RF energy; and a controller coupled to the sensor and the power converter. The controller is configured to control the power converter to output an RF waveform to achieve conductor breakthrough through the polymeric dielectric coating. The controller is further configured to determine whether the conductor breakthrough occurred based on the parameter; and execute a treatment algorithm based on a determination of the conductor breakthrough.

Abstract: A jaw member for a surgical instrument includes an outer housing having a sealing plate operably coupled thereon including an upper knife channel defined therethrough and extending therealong. A pair of opposing jaw flanges is configured to operably couple to a corresponding pair of jaw flanges of an opposing jaw member. An insulative insert is disposed within the outer housing and includes opposing sidewalls and a connector portion which define an engagement channel and a lower knife channel in vertical registration with the upper knife channel, the upper and lower knife channels configured to receive a knife of a knife assembly, the engagement channel configured to receive a tube of the knife assembly. A top plate is engaged between the jaw flanges, a portion of the top plate is configured to extend across the engagement channel and retain the tube within the engagement channel during translation of the knife assembly.

Abstract: A jaw member of an electrosurgical forceps includes a jaw body, an electrically conductive tissue sealing surface extending along a length of the jaw body, and an insulative housing coupled to the jaw body and the sealing surface. The insulative housing has a proximal end defining an oblique surface.

Abstract: A surgical instrument is provided. The surgical instrument includes a housing. A movable handle is coupled to the housing and is configured to approximate a pair of jaw members toward and away from one another. A latch mechanism operably couples to the movable handle and includes one or more mechanical interfaces configured to selectively engage a corresponding mechanical interface disposed within the housing to lock and unlock the jaw members in an approximated configuration. When the movable handle is in a jammed position, the mechanical interface(s) of the latch mechanism is/are configured to deform and separate from the corresponding mechanical interface disposed within the housing when the movable handle is moved from the jammed position.

Abstract: A method of manufacturing a jaw member of an end-effector assembly includes forming one or more stress-relief cavities within a sealing plate. Each one of the one or more stress-relief cavities defines a pad portion of an electrically-conductive surface of the sealing plate. The method also includes forming a stop member on each pad portion of the electrically-conductive surface of the sealing plate, performing an overmolding operation wherein the one or more stress-relief cavities is configured to prevent force applied to a bottom surface of the sealing plate during the overmolding operation from stressing each pad portion to avoid compromising adhesion between the stop member and the electrically-conductive surface of the sealing plate.

Abstract: An electrosurgical instrument includes a housing including an elongated shaft. A stationary actuation member is axially disposed within the elongated shaft and includes a cam pin. An actuating mechanism is operably coupled to the elongated shaft and is moveable relative to the housing to selectively cause movement of the elongated shaft. An end effector includes a pair of opposing first and second jaw members operably coupled about a common pivot. One or both of the jaw members includes a camming slot configured to engage the cam pin. Each jaw member includes an electrically conductive tissue sealing surface adapted to connect to a source of electrosurgical energy. A knife blade is supported in the elongated shaft and moveable in a longitudinal direction to cut tissue disposed between the jaw members. A wire retention unit is supported within the housing and includes a plurality of wire clasps and a plurality of guide ribs configured to define at least one wire path.

Abstract: An assembly tool for facilitating assembly of a surgical instrument includes a handle, a neck extending from the handle, and a portion of or an entire pivot pin engaged with the neck via a frangible connection. The pivot pin is engagable with the surgical instrument. The frangible connection is configured to break upon application of stress thereto above a threshold, thereby separating the pivot pin (or portion thereof) from the neck. A method of assembling using such an assembly tool includes positioning a component of a surgical instrument for receipt of a pivot pin, manipulating the assembly tool to operably engage the pivot pin with the component, and manipulating the assembly tool to apply stress to the frangible connection to break-off the pivot pin (or portion thereof) from the assembly tool along the frangible connection.

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: An assembly tool for facilitating assembly of a surgical instrument includes a handle, a neck extending from the handle, and a portion of or an entire pivot pin engaged with the neck via a frangible connection. The pivot pin is engagable with the surgical instrument. The frangible connection is configured to break upon application of stress thereto above a threshold, thereby separating the pivot pin (or portion thereof) from the neck. A method of assembling using such an assembly tool includes positioning a component of a surgical instrument for receipt of a pivot pin, manipulating the assembly tool to operably engage the pivot pin with the component, and manipulating the assembly tool to apply stress to the frangible connection to break-off the pivot pin (or portion thereof) from the assembly tool along the frangible connection.

Abstract: A method of manufacturing a jaw member of an end-effector assembly includes forming one or more stress-relief cavities within a sealing plate. Each one of the one or more stress-relief cavities defines a pad portion of an electrically-conductive surface of the sealing plate. The method also includes forming a stop member on each pad portion of the electrically-conductive surface of the sealing plate, performing an overmolding operation wherein the one or more stress-relief cavities is configured to prevent force applied to a bottom surface of the sealing plate during the overmolding operation from stressing each pad portion to avoid compromising adhesion between the stop member and the electrically-conductive surface of the sealing plate.

Abstract: A forceps includes an end effector assembly having first and second jaw members. Each jaw member includes an elongated proximal segment and a distal segment. The distal segments are configured to grasp tissue therebetween. The jaw members are biased towards a spaced-apart position relative to one another. A sliding unit is disposed about the first and second jaw members and is slidable relative to the jaw members between a first position, wherein the sliding unit is disposed about the elongated proximal segments of the jaw members, and a second position, wherein the sliding unit is disposed about the distal segments of the jaw members. The sliding unit is configured to transition the jaw members against the bias from the spaced-apart position to an approximated position for grasping tissue therebetween upon sliding of the sliding unit from the first position to the second position.

Abstract: An electrosurgical instrument includes a housing including an elongated shaft. A stationary actuation member is axially disposed within the elongated shaft and includes a cam pin. An actuating mechanism is operably coupled to the elongated shaft and is moveable relative to the housing to selectively cause movement of the elongated shaft. An end effector includes a pair of opposing first and second jaw members operably coupled about a common pivot. One or both of the jaw members includes a camming slot configured to engage the cam pin. Each jaw member includes an electrically conductive tissue sealing surface adapted to connect to a source of electrosurgical energy. A knife blade is supported in the elongated shaft and moveable in a longitudinal direction to cut tissue disposed between the jaw members. A wire retention unit is supported within the housing and includes a plurality of wire clasps and a plurality of guide ribs configured to define at least one wire path.

Abstract: A surgical instrument is provided. The surgical instrument includes a housing. A movable handle is coupled to the housing and is configured to approximate a pair of jaw members toward and away from one another. A latch mechanism operably couples to the movable handle and includes one or more mechanical interfaces configured to selectively engage a corresponding mechanical interface disposed within the housing to lock and unlock the jaw members in an approximated configuration. When the movable handle is in a jammed position, the mechanical interface(s) of the latch mechanism is/are configured to deform and separate from the corresponding mechanical interface disposed within the housing when the movable handle is moved from the jammed position.