Method of forming a member of an end effector

{
  "publication_number": "US10080606B2",
  "country": "US",
  "kind": "B2",
  "title": "Method of forming a member of an end effector",
  "abstract": "A method of forming a jaw member of an end effector includes providing a metal support base; engaging a plurality of ceramic stops to the metal support base; and coupling an insulative plate and a sealing plate to the metal support base by aligning the plurality of ceramic stops through a plurality of openings defined in the insulative plate and a plurality of openings defined in the sealing plate.",
  "claims": [
    "1. A method of forming a jaw member of an end effector, comprising; providing a metal support base, an insulative plate having a plurality of openings defined therethrough, and a sealing plate having a plurality of openings defined therethrough; directly connecting a first end of each of a plurality of ceramic stops to a tissue oriented surface of the metal support base, the ceramic stops having a predetermined length; and coupling the insulative plate and the sealing plate to the metal support base by aligning the plurality of ceramic stops through the plurality of openings defined in the insulative plate and the plurality of openings defined in the sealing plate such that a second end of each ceramic stop projects a predetermined distance relative to a tissue-engaging surface of the sealing plate.",
    "2. The method according to claim 1, further comprising forming a longitudinal knife slot through each of the insulative plate and the sealing plate and aligning the slots in registration with one another.",
    "3. The method according to claim 2, wherein the plurality of openings of the insulative plate and the plurality of openings of the sealing plate are formed adjacent each respective longitudinal knife slot.",
    "4. The method according to claim 1, further comprising overmolding an insulative housing around the metal support base.",
    "5. The method according to claim 1, wherein the insulative plate is formed by injection molding.",
    "6. The method according to claim 1, wherein each of the plurality of ceramic stops has a cylindrical configuration.",
    "7. The method according to claim 1, wherein each of the plurality of ceramic stops defines a longitudinal axis therealong and tissue-engaging surface of each of the plurality of ceramic stops defines a plane in perpendicular relation to each respective longitudinal axis.",
    "8. The method according to claim 1, wherein the insulative plate is fabricated from plastic.",
    "9. The method according to claim 1, wherein the predetermined distance is about 0.001 inches to about 0.006 inches.",
    "10. The method according to claim 1, further comprising: moving the insulative plate and the sealing plate in a direction toward the plurality of ceramic stops; and moving the insulative plate and the sealing plate along the plurality of stops toward the metal support base."
  ],
  "description_excerpt": "The present disclosure relates to methods of forming components of surgical instruments and, more particularly, to methods of forming jaw members having ceramic rods that act as a guide during assembly of the jaw members, control a gap distance between the jaw members, and provide electrical insulation between the jaw members.\n\nElectrosurgical instruments, e.g., electrosurgical forceps, utilize both mechanical clamping action and electrical energy to effect hemostasis by heating tissue to coagulate and/or cauterize tissue. Certain surgical procedures require more than simply cauterizing tissue and rely on the unique combination of clamping pressure, precise electrosurgical energy control, and gap distance (i.e., distance between opposing jaw members when closed about tissue) to “seal” tissue.\n\nOne method of controlling the gap distance uses one or more ceramic dots or stop members on one or both jaw members. The stop members are typically deposited atop components of one or more jaw members, e.g., vapor deposited onto sealing plates. The stop members project from the tissue engaging surface of one or both jaw members and control the separation distance between opposing jaw members when closed about tissue. Since the stop members are typically made from ceramic, the stop members are stable at elevated temperatures and usually exhibit low thermal and electrical conductivities. In addition, ceramic materials have high melting points and are resistant to oxidation, corrosion, or other forms of degradation to which metals are usually more prone.",
  "cpc": [
    "A61B 18/1445",
    "A61B 2017/00526",
    "A61B 2017/0088",
    "A61B 2018/00083",
    "A61B 2018/00303",
    "A61B 2018/00607",
    "A61B 2018/00791",
    "A61B 2018/00875",
    "A61B 2018/1455",
    "A61B 34/35"
  ],
  "ipc": [
    "A61B 18/14"
  ],
  "assignees": [
    "Covidien LP"
  ],
  "inventors": [
    "John J. Kappus",
    "David N. Heard",
    "William Scott Darrow"
  ],
  "filing_date": "2015-07-17",
  "publication_date": "2018-09-25",
  "grant_date": "2018-09-25",
  "priority_date": "2014-09-17",
  "application_number": "US-201514802222-A",
  "family_id": "55453633",
  "cited_by_count": 22,
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