Tissue Sealer and End Effector Assembly and Method of Manufacturing Same

• US 20090082767A1
• Filed: 09/19/2008
• Published: 03/26/2009
• Est. Priority Date: 09/20/2007
• Status: Active Grant

• Current Assignee: Covidien LP (Medtronic Plc)
• Original Assignee: Tyco Healthcare Group LP (Medtronic Plc)
• Inventors: James, Jeremy, Garrison, David M., Unger, Jeffrey R., Shields, Chelsea, Chojin, Edward M., Warzecha, Michael R., Kerr, Duane E., Hixson, David W., Sharp, Robert M., Peterson, Darion
• Granted Patent: US 7,877,852 B2
• Time in Patent Office: Days
• US Class Current: 606/51
• 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 18/148 having a short, rigid shaft for accessing the inner body transcutaneously, e.g. for neurosurgery or arthroscopy
• CPC Class Codes: A61B 2018/00083 low, i.e. electrically insulating
• CPC Class Codes: A61B 2018/00345 Vascular system
• CPC Class Codes: A61B 2018/00404 Blood vessels other than those in or around the heart
• CPC Class Codes: A61B 2018/00619 Welding
• CPC Class Codes: A61B 2018/0063 Sealing
• CPC Class Codes: A61B 2018/1412 Blade
• CPC Class Codes: A61B 2018/1455 having a moving blade for cutting tissue grasped by the jaws
• CPC Class Codes: Y10T 29/49002 Electrical device making
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49208 by assembling plural parts

Abstract

A method for manufacturing an end effector assembly for sealing tissue includes the initial step of providing a pair of first and second jaw members each including an inwardly facing electrically conductive sealing surface. The method also includes the steps of: coating the inwardly facing electrically conductive sealing surface of one or both jaw members with an insulative material, the coating having a thickness within the range of about 0.001 inches to about 0.010 inches; allowing the insulative material to cure onto the inwardly facing electrically conductive sealing surface; removing a portion of the insulative material from the inwardly facing electrically conductive sealing surface to form a series of stop members arranged thereacross; and assembling the pair of first and second jaw members about a pivot such that the two inwardly facing electrically conductive sealing surfaces are substantially opposed to each other in pivotal relation relative to one another.

Claims

1. A method for manufacturing an end effector assembly for sealing tissue, comprising the steps of:

providing a pair of first and second jaw members each including an inwardly facing electrically conductive sealing surface;

coating the inwardly facing electrically conductive sealing surface of at least one of the jaw members with an insulative material, the coating having a thickness within the range of about 0.001 inches to about 0.010 inches;

allowing the insulative material to cure onto the inwardly facing electrically conductive sealing surface;

removing a portion of the insulative material from the inwardly facing electrically conductive sealing surface to form a series of stop members arranged thereacross; and

assembling the pair of first and second jaw members about a pivot such that the two inwardly facing electrically conductive sealing surfaces are substantially opposed to each other in pivotal relation relative to one another.

2. A method for manufacturing an end effector assembly for sealing tissue according to claim 1 wherein the removing step includes trimming the insulative material from the inwardly facing electrically conductive sealing surface to form a series of stop members arranged thereacross.

3. A method for manufacturing an end effector assembly for sealing tissue according to claim 1 wherein the removing step includes laser etching.

4. A method for manufacturing an end effector assembly for sealing tissue according to claim 1 wherein the coating step includes plasma deposition.

5. A method for manufacturing an end effector assembly for sealing tissue according to claim 1 wherein the coating step includes pad printing.

6. A method for manufacturing an end effector assembly for sealing tissue according to claim 1 wherein at least one of the inwardly facing electrically conductive sealing surfaces of the providing step includes a knife channel defined along a length thereof.

7. A method for manufacturing an end effector assembly for sealing tissue, comprising the steps of:

providing a pair of first and second jaw members each having an outer insulative housing and an electrically conductive tissue sealing plate, the jaw members being moveable 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 therebetween;

disposing a series of insulative stop members atop the insulative housing of at least one of the first and second jaw members;

forming a corresponding series of apertures within the electrically conductive sealing plate of the at least one of the first and second jaw members in vertical registry with the stop members;

aligning the electrically conductive sealing plate of the at least one of the first and second jaw members atop the insulative housing such that each of the series of stop members are received through a respective aperture within the electrically conductive sealing plate of the at least one of the first and second jaw members;

securing the electrically conductive sealing plate of the at least one of the first and second jaw members atop the insulative housing of the at least one of the first and second jaw members such that the stop members project from the electrically conductive sealing plate of the at least one of the first and second jaw members a distance of about 0.001 inches to about 0.010 inches; and

assembling the pair of first and second jaw members about a pivot such that the respective electrically conductive surfaces are substantially opposed to each other in pivotal relation relative to one another.

8. A method for manufacturing an end effector assembly for sealing tissue, comprising the steps of:

providing a pair of first and second jaw members each having an electrically conductive tissue sealing surface, the jaw members being moveable 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 therebetween;

at least one of the electrically conductive tissue sealing surfaces of one of the first and second jaw members including a series of cavities defined therein;

providing a moldable insulative material from a source;

dispersing an amount of moldable insulative material into at least one of the cavities of the at least one of the electrically conductive tissue sealing surfaces of one of the first and second jaw members;

allowing the stop member to solidify atop the electrically conductive sealing surface to form at least one stop member that projects a distance of about 0.001 inches to about 0.010 inches from the electrically conductive tissue sealing surface; and

assembling the pair of first and second jaw members about a pivot such that the electrically conductive surfaces are substantially opposed to each other in pivotal relation relative to one another.

9. A method for manufacturing an end effector assembly for sealing tissue according to claim 8 wherein the series of cavities are generally key-shaped.