Vessel sealing instrument with electrical cutting mechanism

• US 8,333,765 B2
• Filed: 06/04/2012
• Issued: 12/18/2012
• Est. Priority Date: 10/04/2002
• Status: Expired due to Term

• Current Assignee: Covidien AG (Medtronic Plc)
• Original Assignee: Covidien AG (Medtronic Plc)
• Inventors: Johnson, Kristin D., Couture, Gary M., Unger, Jeffrey R., Sharp, Robert M., Garrison, David M., Dycus, Sean T., Hixson, David, Weinberg, Craig
• Primary Examiner(s): PEFFLEY, MICHAEL F
• Application Number:
  US13/488,093
• Publication Number:
  US 20120233844A1
• Time in Patent Office: 197 Days
• Field of Search: 606 45- 52
• US Class Current: 606/51
• CPC Class Codes: A61B 17/07207 the staples being applied sequentially
• CPC Class Codes: A61B 18/1442 Probes having pivoting end effectors, e.g. forceps
• CPC Class Codes: A61B 18/1445 at the distal end of a shaft, e.g. forceps or scissors at the end of a rigid rod
• CPC Class Codes: A61B 18/18 by applying electromagnetic radiation, e.g. microwaves radiation therapy A61N5/00
• CPC Class Codes: A61B 2017/00026 Conductivity or impedance, e.g. of tissue
• CPC Class Codes: A61B 2017/00084 Temperature
• CPC Class Codes: A61B 2017/2945 Curved jaws
• CPC Class Codes: A61B 2018/00404 Blood vessels other than those in or around the heart
• CPC Class Codes: A61B 2018/00601 Cutting
• CPC Class Codes: A61B 2018/0063 Sealing
• CPC Class Codes: A61B 2018/00702 Power or energy
• CPC Class Codes: A61B 2018/00791 Temperature
• CPC Class Codes: A61B 2018/00875 Resistance or impedance
• CPC Class Codes: A61B 2018/1432 curved
• CPC Class Codes: A61B 2090/034 abutting on parts of the device itself
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

An end effector assembly for use with an instrument for sealing vessels and cutting vessels includes a pair of opposing first and second jaw members which are movable relative to one another from a first spaced apart position to a second position for grasping tissue therebetween. Each jaw member includes an electrically conductive tissue contacting surface connected to an electrosurgical energy source. At least one of the jaw members includes an electrically conductive cutting element disposed within an insulator defined in the jaw member. A rigid structural support is included which is configured to support the electrically conductive tissue sealing surface and includes at least one flow channel defined therein.

Claims

1. A method of manufacturing a jaw member for use with an instrument for sealing and/or cutting tissue, the method comprising:

forming a sealing plate having an electrically conductive tissue sealing surface;

forming an electrically conductive cutting element in the electrically conductive tissue sealing surface;

forming the sealing plate into a final shape in a progressive stamping die;

backing the sealing plate with a rigid structural support; and

overmolding the sealing plate and the rigid structural support with an overmold material.

2. The method according to claim 1, wherein the sealing plate is formed by at least one of a photochemical etching process and a stamping process.

3. The method according to claim 1, wherein the electrically conductive cutting element is formed by at least one of a metal deposition process, a photochemical etching process, and a stamping process.

4. The method according to claim 1, wherein the sealing plate is formed into a final shape by stages in the progressive stamping die.

5. The method according to claim 4, wherein when the sealing plate is formed in the progressive stamping die, the electrically conductive cutting element is raised above the electrically conductive issue sealing surface.

6. The method according to claim 1, further including providing at least one support to hold the electrically conductive cutting element in place, the method further including removing the at least one support after the overmolding step.

7. The method according to claim 1, wherein the rigid structural support includes at least one perforation defined therein to allow the overmold material to flow therethrough.

8. The method according to claim 1, wherein the overmold material is an insulative material.

9. The method according to claim 1, wherein at least one of the sealing plate and the electrically conductive cutting element includes a crimping terminal, the method further including electrically coupling an electrical element with the crimping terminal.

10. The method according to claim 9, further including attaching the electrical element to the crimping terminal by at least one of soldering or welding.

11. The method according to claim 1, further including forming an indentation on the electrically conductive cutting element, the indentation configured to hold the electrically conductive cutting element in place in the electrically conductive tissue sealing surface.

12. The method according to claim 11, wherein the indentation is formed by chemical milling.

13. The method according to claim 1, further including providing an insulating layer between the rigid structural support and the sealing plate.

14. The method according to claim 1, wherein the sealing plate includes a bridge located at a distal end thereof.

15. The method according to claim 1, wherein the overmold material is overmolded over the bridge.

16. The method according to claim 1, wherein the final shape is a curved shape.

17. The method according to claim 1, wherein the rigid structural support is formed by at least one of stamping, photo-etching and machining.