Method of manufacturing tissue sealing electrodes
An electrode assembly for use with an electrosurgical instrument includes a pair of opposing jaw members and an electrode positioned on each jaw member. One or both of the electrodes includes a tissue contacting surface that has an outer periphery and defines a side surface depending therefrom. The tissue contacting surface and the side surface include a conjoining edge formed at a first predetermined angle that defines a first linear transition zone dimensioned to reduce arcing between the opposing jaw members during activation of the electrosurgical instrument.
1. An electrode for use in an electrosurgical instrument, the electrode comprising:
a tissue-contacting surface;
a pair of opposing lateral side surfaces; and
an easement interconnecting the tissue-contacting surface and a first lateral side surface of the pair of opposing lateral side surfaces, the easement including:
a conductive first easement portion having a radius of curvature and extending laterally from the tissue-contacting surface toward the first lateral side surface; and
a conductive second easement portion extending between the first easement portion and the first lateral side surface, wherein the second easement portion has a radius of curvature that is different than the radius of curvature of the first easement portion.
2. The electrode of claim 1 , wherein the first easement portion is disposed between the tissue-contacting surface and the second easement portion.
3. The electrode of claim 1 , wherein the first lateral side surface extends linearly along a vertical axis from the second easement portion.
4. The electrode of claim 1 , wherein each of the first and second easement portions is convex.
5. The electrode of claim 1 , wherein the first easement portion has a first end extending from the tissue-contacting surface and a second end, the second easement portion having a first end extending from the second end of the first easement portion and a second end connected to the first lateral side surface.
6. The electrode of claim 1 , wherein the first easement portion has a longer circumference than the second easement portion.
7. A method for manufacturing an electrode for use in an electrosurgical instrument, the method comprising:
forming an easement between a first lateral side surface of an electrode and a tissue-contacting surface of the electrode, the easement having a curved configuration;
machining the easement to form a conductive first easement portion having a radius of curvature, the first easement portion extending laterally from the tissue-contacting surface toward the first lateral side surface; and
machining the easement to form a conductive second easement portion having a radius of curvature that is different than the radius of curvature of the first easement portion, wherein the easement is continuously convex from the first lateral side surface to the tissue-contacting surface.
8. The method of claim 7 , wherein each of the first and second easement portions is convex.
9. The method of claim 7 , wherein the radius of curvature of at least one of the first easement portion or the second easement portion is calculated from a parabolic equation.
10. The method of claim 7 , wherein the radius of curvature of at least one of the first easement portion or the second easement portion is calculated from a clothoid equation.
11. The method of claim 7 , further comprising machining at least one edge of the electrode to form the easement.
12. The method of claim 7 , wherein the first lateral side surface extends linearly along a vertical axis from the second easement portion.