Method of manufacturing jaw assembly for vessel sealer and divider

1. A method of manufacturing a jaw member of an end effector assembly for use with a forceps, the method comprising the steps of:

providing a forceps having at least one shaft and an end effector assembly attached to a distal end thereof, said end effector assembly including two opposing jaw members each having a jaw housing, an electrically conductive plate and an insulated wire for conducting a first electrical potential;

molding a first plastic onto a surface of the jaw housing such that the plastic forms a datum for receiving the electrically conductive plate and forms an elongated slot therein for receiving the insulated wire therealong;

engaging a lead end of the wire with the electrically conductive plate such that the first electrical potential is conducted to the electrically conductive plate;

aligning the electrically conductive plate atop the jaw housing and within the plastic datum such that the insulated wire aligns within the elongated slot; and

molding a second plastic to secure the electrically conductive plate and the insulated wire atop the jaw housing.

2. A method of manufacturing a jaw member for use with a jaw assembly according to claim 1 wherein the first plastic of the first molding step and the second plastic of the molding step are the same.

3. A method of manufacturing a jaw member for use with a jaw assembly according to claim 1 wherein the insulated wire is crimped onto the electrically conductive plate.

4. A method of manufacturing a jaw member for use with a jaw assembly according to claim 1 wherein at least one of the first and second molding steps includes an overmolding process.

5. A method of manufacturing a jaw member for use with a jaw assembly according to claim 1 wherein at least one of the first and second molding steps includes an injection molding process.

6. A method of manufacturing a jaw assembly of an end effector assembly for use with a forceps, the method comprising the steps of:

providing a forceps having at least one shaft and an end effector assembly attached to a distal end thereof, said end effector assembly including a first jaw member and a second jaw member, the first jaw member including a first jaw housing, a first electrically conductive plate and an insulated wire for conducting a first electrical potential, the second jaw member including a second jaw housing, a second electrically conductive plate and being in electrical communication with a source of electrosurgical energy having a second potential;

molding a first plastic onto a surface of the first jaw housing such that the plastic forms a datum for receiving the first electrically conductive plate and forms an elongated slot therein for receiving the insulated wire therealong;

engaging a lead end of the wire of the first jaw member with the first electrically conductive plate such that the first electrical potential is conducted to the electrically conductive plate;

aligning the first electrically conductive plate atop the first jaw housing within the plastic datum such that the insulated wire aligns within the elongated slot;

molding a second plastic to secure the first electrically conductive plate and the insulated wire atop the first jaw housing;

securing the second electrically conductive plate atop the second jaw housing; and

engaging the first jaw member with the second jaw member such that the first and second electrically conductive plates oppose one another and the first jaw member is pivotable with respect to the second jaw member.