Method for manufacturing vessel sealing instrument with reduced thermal spread
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, an inner tissue engaging surface, and an insulating layer disposed therebetween. 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 jaws include a tissue-contacting seal plate having obverse and reverse surfaces. A series of ribs extend from the reverse surface of the seal plate into an insulating layer, which, in turn, is affixed to a jaw housing. The ribbed structure of the seal plate reduces thermal spread and edge cutting during vessel sealing procedures, leading to improved surgical outcomes.
1. A method of manufacturing a jaw member, comprising the steps of:
providing a blank seal plate;
applying a resist mask to a reverse surface of the seal plate defining a plurality of valley regions;
etching the masked reverse surface of the seal plate to form a plurality of valleys therein defining at least one rib on the reverse surface of the seal plate;
removing the resist mask from the seal plate;
affixing an insulating layer to the reverse surface of the seal plate; and
affixing a reverse surface of the insulating layer to a jaw housing.
2. The method of manufacturing a jaw member in accordance with claim 1 , further comprising the step of electromechanically coupling a conductor to the seal plate.
3. The method of manufacturing a jaw member in accordance with claim 1 , wherein the insulating layer is formed from polyimide affixed to the seal plate by overmolding.
4. The method of manufacturing a jaw member in accordance with claim 1 , wherein the jaw housing is formed from material affixed to the seal plate by overmolding.
5. The method of manufacturing a jaw member in accordance with claim 4 , wherein the material forming the jaw housing is selected from the group consisting of high-strength ceramic material and a high-strength thermosetting polymeric material.
6. The method of manufacturing a jaw member in accordance with claim 1 , wherein the jaw housing is formed by powder molding.
7. The method of manufacturing a jaw member in accordance with claim 6 , wherein the jaw housing is fixed to the seal plate by adhesive bonding.
8. The method of manufacturing a jaw member in accordance with claim 1 further comprising the step of joining a conductor to the seal plate.