Abstract:
A method of manufacturing a jaw member of a surgical forceps includes forming a jaw frame having a distal jaw support. The method also includes forming an electrically-conductive defining an aperture having a first diameter, forming a stop member including a body having a second diameter smaller than the first diameter and a shoulder having a third diameter greater than the first diameter. The method also includes inserting the stop member into the aperture such that the body extends through the aperture and the shoulder abuts a portion of the electrically-conductive plate surrounding the aperture, and overmolding an outer housing about at least a portion of the jaw frame, electrically-conductive plate, and stop member to secure the jaw frame, electrically-conductive plate, and stop member to one another.

Description:
BACKGROUND 
       [0001]    Technical Field 
         [0002]    The present disclosure relates to surgical instruments and methods and, more particularly, to surgical forceps and methods for manufacturing jaw members of surgical forceps. 
         [0003]    Background of Related Art 
         [0004]    Open or endoscopic electrosurgical forceps utilize both mechanical clamping action and electrical energy to effect hemostasis. The electrode of each opposing jaw member is charged to a different electric potential such that when the jaw members grasp tissue, electrical energy can be selectively transferred through the tissue. A surgeon can treat tissue by either cauterizing, coagulating/desiccating, sealing, and/or simply reducing or slowing bleeding, by controlling the intensity, frequency and duration of the electrosurgical energy applied between the electrodes and through the tissue. 
         [0005]    In order to promote accurate, consistent and effective, sealing and other tissue treatment effects, one or more insulative stop members may be positioned along one or both opposed surfaces of the jaw members to maintain a specific gap distance between the jaw members when the jaw members are in a clamping position with tissue grasped therebetween. 
         [0006]    The stop members may be secured to the opposed surfaces of the jaw members via one or more suitable securement methods. The current techniques of forming and securing the stop members to the opposed surfaces of the jaw members may require specialty equipment, precise tolerances, and/or introduce process variability which increases the manufacturing cost of the jaw members. 
       SUMMARY 
       [0007]    As used herein, the term “distal” refers to the portion that is being described which is closest to a patient, while the term “proximal” refers to the portion that is being described which is farthest from a patient. Further, to the extent consistent, any of the aspects described herein may be used in conjunction with any or all of the other aspects described herein. 
         [0008]    A method of manufacturing a jaw member of a surgical forceps in accordance with the present disclosure includes forming a jaw frame including a distal jaw support. The method also includes forming an electrically-conductive plate defining an aperture having a first diameter, forming a stop member including a body having a second diameter smaller than the first diameter and a shoulder having a third diameter greater than the first diameter. The method also includes inserting the stop member into the aperture such that the body extends through the aperture and the shoulder abuts a portion of the electrically-conductive plate surrounding the aperture, and overmolding an outer housing about at least a portion of the jaw frame, electrically-conductive plate, and stop member to secure the jaw frame, electrically-conductive plate, and stop member to one another. 
         [0009]    In one aspect of the present disclosure, the method further includes positioning an insulative spacer on the distal jaw support. 
         [0010]    In another aspect the present disclosure, the electrically-conductive plate is formed via stamping. 
         [0011]    In another aspect of the present disclosure, forming the stop member includes forming a body portion of the stop member having a height such that the body portion of the stop member extends from a tissue-contacting surface of the electrically-conductive plate a distance of between about 0.001 inches and about 0.006 inches. 
         [0012]    In still another aspect of the present disclosure, positioning the insulative spacer on the distal jaw support includes overmolding the insulative spacer on the distal jaw support. 
         [0013]    In yet another aspect of the present disclosure, the method further includes positioning the electrically-conductive plate and the stop member located therein on the insulative spacer and the jaw frame. 
         [0014]    In another aspect of the present disclosure, the method further includes forming an outer housing about a portion of the jaw frame, the insulative spacer, and the electrically-conductive plate such that the jaw frame, the insulative spacer, the electrically-conductive plate, and the stop member located therein are secured in an assembled condition. 
         [0015]    In still yet another aspect of the present disclosure, forming the electrically-conductive plate includes deforming the electrically-conductive plate to form a fill-aperture configured to locate a portion of the outer housing. 
         [0016]    In another aspect of the present disclosure, forming the electrically-conductive plate includes deforming the electrically-conductive plate such that the electrically-conductive plate includes a thickness, wherein the difference between the height of the body portion of the stop member and the thickness of the electrically-conductive plate is between about 0.001 inches and about 0.006 inches. 
         [0017]    In yet another aspect of the present disclosure, forming the stop member includes forming the stop member from a heat-resistant ceramic, wherein the stop member is machined from a ceramic rod or slug. 
         [0018]    In still another aspect of the present disclosure, forming the stop member includes forming the stop member from a heat-resistant ceramic, wherein the stop member is injection molded. 
         [0019]    According to aspects of the present disclosure, a method of manufacturing a jaw member of a surgical forceps includes stamping a blank to form an electrically-conductive plate including an aperture defining a first diameter and at least one leg defining a fill-aperture. The method also includes machining a stop member including a body having a second diameter smaller than the first diameter and a shoulder having a third diameter greater than the first diameter of the aperture. The method also includes inserting the stop member into the aperture such that the body extends through the aperture and the shoulder abuts a portion of the electrically-conductive plate surrounding the aperture, and overmolding an outer housing about a portion of the electrically-conductive plate and the stop member such that the electrically-conductive plate and the stop member are secured to one another in an assembled condition. 
         [0020]    In an aspect of the present disclosure, the method further includes inserting the stop member into the aperture of the electrically-conductive plate such that the stop member extends from a tissue-contacting surface of the electrically-conductive plate a distance of between about 0.001 inches and about 0.006 inches. 
         [0021]    In another aspect of the present disclosure, machining the stop member includes deforming a ceramic rod or slug. 
         [0022]    In still another aspect of the present disclosure, the method further includes forming a jaw frame having a distal jaw support and overmolding an insulative spacer onto the distal jaw support such that the jaw frame is electrically-isolated from the electrically-conductive plate. 
         [0023]    In yet another aspect of the present disclosure, overmolding the outer housing includes filling the fill-aperture of the electrically-conductive plate with a portion of the outer housing. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0024]    Various aspects and features of the present disclosure described herein with reference to the drawings wherein: 
           [0025]      FIG. 1  is a perspective view of a surgical instrument provided in accordance with the present disclosure with jaw members of the end effector assembly of the surgical instrument disposed in a spaced-apart position; 
           [0026]      FIG. 2  is a longitudinal, cross-sectional view taken along section line “ 2 - 2 ” of  FIG. 1 ; 
           [0027]      FIG. 3  is a perspective view of the end effector assembly of the surgical instrument of  FIG. 1  including the jaw members disposed in the spaced-apart position; 
           [0028]      FIG. 4  is a perspective view of the end effector assembly of the surgical instrument of  FIG. 1  including the jaw members disposed in the approximated position; 
           [0029]      FIG. 5  is a side, perspective view of the distal end of the surgical instrument of  FIG. 1  with the jaw members disposed in the spaced-apart position; 
           [0030]      FIG. 6  is a side, perspective view of one of the jaw members of the surgical instrument of  FIG. 1  with a portion thereof removed; 
           [0031]      FIG. 7A  is a longitudinal, cross-sectional view taken along section line “ 7 A- 7 A” of  FIG. 6  including a jaw frame and an insulative spacer disposed thereon; 
           [0032]      FIG. 7B  is a schematic view of a blank for forming an electrically-conductive plate of the jaw member of  FIG. 6 ; 
           [0033]      FIG. 7C  is a schematic view of forming the electrically-conductive plate having an aperture and a stop member of the jaw member of  FIG. 6 ; 
           [0034]      FIG. 7D  is a schematic view of the electrically-conductive plate having the aperture and the stop member of the jaw member of  FIG. 6  disposed therein; and 
           [0035]      FIG. 7E  is a schematic view of the electrically-conductive plate, the stop member, and the insulative spacer of the jaw member of  FIG. 6  in an assembled condition. 
       
    
    
     DETAILED DESCRIPTION 
       [0036]    Referring generally to  FIGS. 1 and 2 , a surgical instrument provided in accordance with the present disclosure is shown generally identified by reference numeral  10 . Instrument  10 , as described below, is configured for grasping, treating, and/or dissecting tissue and may find particular applicability for use in performing tonsillectomy and/or adenoidectomy procedures, although use of instrument  10  in various other surgical procedures is also contemplated and within the scope of the present disclosure. 
         [0037]    With reference to  FIGS. 1-4 , instrument  10  generally includes a housing  20 , a handle assembly  30 , a trigger assembly  70 , a shaft  80 , an end effector assembly  100 , a drive assembly  140 , a knife assembly  170 , and an energy activation assembly  190 . Shaft  80  extends distally from housing  20  and supports end effector assembly  100  at distal end  82  thereof. Drive assembly  140  operably couples handle assembly  30  with end effector assembly  100  to enable selective manipulation of jaw members  110 ,  120  of end effector assembly  100 . Knife assembly  170  is operably coupled with trigger assembly  70  to enable selective translation of a knife blade  174  of knife assembly  170  relative to end effector assembly  100 . Energy activation assembly  190  enables energy to be selectively delivered to end effector assembly  100 . 
         [0038]    Instrument  10  may also include an electrosurgical cable (not shown) that connects instrument  10  to a generator (not shown) or other suitable power source, although instrument  10  may alternatively be configured as a battery-powered instrument. The electrosurgical cable includes lead wires, e.g., lead wires  107  (see  FIG. 4 ), extending therethrough that have sufficient length to extend through housing  20  and shaft  80  in order to operably couple the generator, energy activation assembly  190 , and end effector assembly  100  with one another to enable the selective supply of energy to electrically-conductive plates  112 ,  122  of jaw members  110 ,  120  of end effector assembly  100 , e.g., upon activation of activation switch  194  of energy activation assembly  190 . 
         [0039]    For a detailed description of instrument  10 , reference may be made to U.S. patent application Ser. No. 14/719,422, filed May 22, 2015, entitled “SURGICAL INSTRUMENTS AND METHODS FOR PERFORMING TONSILLECTOMY, ADENOIDECTOMY, AND OTHER SURGICAL PROCEDURES,” the entire contents of which are incorporated by reference herein. However, the aspects and features of the present disclosure are equally applicable for use with other suitable surgical instruments. 
         [0040]    With additional reference to  FIGS. 5 and 6 , as mentioned above, end effector assembly  100  is operably supported at distal end  82  of shaft  80  and includes opposing jaw members  110 ,  120  pivotably coupled to one another and movable relative to one another and shaft  80  between a spaced-apart position (see  FIG. 3 ) and an approximated position (see  FIG. 4 ) for grasping tissue therebetween. Each jaw member  110 ,  120  includes an electrically-conductive plate  112 ,  122 , a jaw frame  113 ,  123 , an insulative spacer  115  (only insulative spacer  115  of jaw member  120  is shown, see  FIGS. 7A and 7E ), and an outer housing  118 ,  128 , each of which is detailed below. 
         [0041]    Although only the features of jaw member  110  or jaw member  120  are described below and/or illustrated in the figures, it is noted that jaw members  110 ,  120  defines mirror-image configurations of one another (unless specifically contradicted herein) and, thus, any description and/or illustration of one jaw member  110 ,  120  applies similarly to the other jaw member  110 ,  120 . 
         [0042]    Jaw frames  113 ,  123  of jaw members  110 ,  120  each include a pair of spaced-apart proximal flanges  113   a ,  123   a  and a distal jaw support  113   b ,  123   b . Proximal flanges  113   a  of jaw member  110  are spaced-apart further than proximal flanges  123   a  of jaw member  120  so as to allow proximal flanges  123   a  of jaw member  120  to be positioned between proximal flanges  113   a  of jaw member  110  during assembly. Further, the proximal flanges  113   a ,  123   a  of each pair define aligned pivot apertures  114   a ,  124   a  and aligned cam slots  114   b ,  124   b.    
         [0043]    With brief reference to  FIGS. 2 and 3 , jaw members  110 ,  120  are pivotably coupled to one another and to shaft  80  via a pivot pin  103  such that jaw members  110 ,  120  are laterally movable, e.g., along the larger width dimension of shaft  80 , between the spaced-apart and approximated positions. The cam slots  114   b  of proximal flanges  113   a  of jaw member  110  are oppositely angled relative to the cam slots  124   b  of proximal flanges  123   a  of jaw member  120 . A camming pin  105  of end effector assembly  100  is configured for insertion through each cam slot  114   b ,  124   b  as well as a cam-pin aperture (not shown) of the drive bar (not shown) of drive assembly  140  to operably couple drive assembly  140  with jaw members  110 ,  120  such that translation of the drive bar of drive assembly  140  relative to jaw members  110 ,  120  pivots jaw members  110 ,  120  about pivot pin  103  and relative to one another and shaft  80  between the spaced-apart and approximated positions. 
         [0044]    Distal jaw support  123   b  of jaw frame  123  of jaw member  120  extends distally from proximal flange  123   a  and defines a generally “L-shaped” configuration. Distal jaw support  123   b  is configured to support electrically-conductive plate  122 , insulative spacer  115  (see  FIG. 7A ), and outer housing  128  of jaw member  120  thereon. However, distal jaw support  123   b  does not extend distally the entire length of jaw member  120 . Rather, distal jaw support  123   b  defines a length of about 50% to about 75% of the lengths of electrically-conductive plate  122 , insulative spacer  115 , and outer housing  128  such that about 25% to about 50% of the lengths of these components extend distally beyond distal jaw support  123   b.    
         [0045]    The electrically-conductive plate  112 ,  122  of each jaw member  110 ,  120  defines a generally planar tissue-contacting surface  112   a ,  122   a , an elongated slot  112   b ,  122   b  extending through the respective tissue-contacting surface  112   a ,  122   a , and a pair of legs  122   c  (only legs  122   c  of jaw member  120  are shown) extending downwardly from each side of the respective tissue-contacting surface  112   a ,  122   b.    
         [0046]    Tissue-contacting surface  112   a  of electrically-conductive plate  112  of jaw member  110  and/or tissue-contacting surface  122   a  of electrically-conductive plate  122  of jaw member  120  may further include a stop member  126  operably associated therewith. For illustrative purposes, only one stop member  126  is shown in connection with jaw member  120 . However, it is contemplated that jaw member  110  and/or jaw member  120  may include a plurality of stop members  126  at various different positions. Stop members  126  are configured to maintain a minimum clearance or gap distance “G” (see  FIG. 4 ) between jaw members  110 ,  120  within a specified range, typically about 0.001″ to about 0.006″, although other ranges, depending upon a particular purpose, are also contemplated. 
         [0047]    Outer housings  118 ,  128  partially enclose respective jaw members  110 ,  120  with the exception of a portion of the distal jaw support  113   b ,  123   b  thereof and the tissue-contacting surface  112   a ,  122   a  thereof, which remain exposed. As will be detailed below, outer housings  118 ,  128  are configured to secure the components of each jaw member  110 ,  120  in an assembled condition. Outer housings  118 ,  128  define lengths extending along the sides of respective jaw members  110 ,  120  and thicknesses that decrease in the proximal-to-distal direction along the lengths thereof. 
         [0048]    With additional reference to  FIGS. 7A-7E , the configuration and manufacture jaw members  110 ,  120  is detailed in accordance with the present disclosure. However, since jaw members  110 ,  120  define mirror-image configurations of one another, and thus include substantially similar methods of manufacture, only the configuration and manufacture of jaw member  120  is described to avoid repetition. 
         [0049]    As noted above, jaw member  120  includes a jaw frame  123  configured to support insulative spacer  115  and electrically-conductive plate  122 . Referring now to  FIG. 7A , jaw frame  123  is formed via stamping and made from stainless steel, although other manufacturing processes and/or materials for forming jaw frame  123  are also contemplated. Insulative spacer  115  of jaw member  120  is formed from an electrically-insulative material and is positioned on distal jaw support  123   b  to electrically-isolate electrically-conductive plate  122  and distal jaw support  123   b  from one another. Insulative spacer  115  is overmolded onto distal jaw support  123   b , although outer manufacturing processes are also contemplated. 
         [0050]    Referring now to  FIGS. 7B and 7C , electrically-conductive plate  122  of jaw member  120  is formed via stamping a blank “B” made from any suitable temperature-resistant, electrically conductive material, such as, for example, stainless steel, although other manufacturing processes and/or materials for forming electrically-conductive plate  122  are also contemplated. Blank “B” is provided and stamped to form electrically-conductive plate  122  having generally planar tissue-contacting surface  122   a , elongated slot  122   b  (see  FIG. 6 ), and a legs  122   c , as noted above. Once formed, electrically-conductive plate  122  defines a thickness “T” between tissue-contacting surface  122   a  and a bottom surface  122   e  thereof. 
         [0051]    During the stamping process, prior thereto, or after stamping, electrically-conductive plate  122  is punched such that an aperture  122   d  extends entirely through tissue-contacting surface  122   a , thickness “T,” and bottom surface  122   e  of electrically-conductive plate  122 . Additionally, one or more fill-apertures  122   f  (see also  FIG. 6 ) are formed on legs  122   c  of electrically-conductive plate  122 . 
         [0052]    Aperture  122   d  of electrically-conductive plate  122  is configured to locate stop member  126  therein, and as such, defines a shape corresponding to a shape of at least a portion of stop member  126 . For example, in some embodiments, stop member  126  has a generally cylindrical configuration and, thus, aperture  122   d  has a corresponding circular shape. However, other configurations, such as, for example, square, rectangular, oval, and the like, are also contemplated. 
         [0053]    Referring now to  FIGS. 7C and 7D , stop member  126  is constructed separately from electrically-conductive plate  122 . As noted above, stop member  126  is configured to create a minimum clearance or gap distance “G” between jaw members  110 ,  120 , typically within a specified range of about 0.001″ to about 0.006″. Given these tight tolerances, it is contemplated that constructing stop member  126  separately from electrically-conductive plate  122 , prior to inserting stop member  126  into aperture  122 d of electrically-conductive plate  122 , will reduce the variability in the manufacturing process, eliminate the need for precision equipment for forming stop member  126  on or with electrically-conductive plate  122 , and ensure that the extension of stop member  126  through aperture  122   d  of electrically-conductive plate  122  will fall within the specified range of about 0.001″ to about 0.006″. 
         [0054]    Stop member  126  is constructed from heat-resistant ceramic and is formed via machining ceramic rods or slugs or through an injection molding process. Alternatively, it is contemplated that stop member  126  may be constructed from other non-conductive materials, such as, for example, a high-strength thermosetting polymeric material and may be formed via other suitable manufacturing processes. 
         [0055]    Stop member  126  is formed to include a body portion  126   a  and a shoulder portion  126   b . Body portion  126   a  of stop member  126  has a diameter “D1” that is smaller than a diameter “D2” of aperture  122   d  of electrically-conductive plate  122  such that body portion  126   a  of stop member  126  may be inserted therethrough. However, in order to prevent stop member  126  from passing entirely through aperture  122   d  , shoulder portion  126   b  of stop member  126  has a diameter “D3” that is larger than diameter “D2” of aperture  122   d , such that shoulder portion  126   b  abuts the portion of bottom surface  122   e  of electrically-conductive plate  122  that surrounds aperture  122   d . Further, stop member  126  is formed such that body portion  126   a  of stop member  126  has a height “H,” wherein the difference between height “H” of body portion  126   a  and thickness “T” of electrically-conductive plate  122  is between about 0.001″ to about 0.006″ so as to define a minimum gap distance “G” ( FIG. 4 ) in that range. Alternatively, where jaw member  110  ( FIGS. 3-4 ) includes an opposing stop member  126 , the difference in height “H” of body portion  126   a  and thickness “T” of electrically-conductive plate  122  may be half of that noted above, such that the opposing stop members  126  cooperate to define a minimum gap distance “G” ( FIG. 4 ) in the above-noted range. Other suitable ranges are also contemplated. 
         [0056]    After stop member  126  is inserted into aperture  122   d  of electrically-conductive plate  122 , the combination is positioned on insulative spacer  115 , as shown in  FIG. 7E . Outer housing  128  is then formed about jaw member  120  via an overmolding process, such that outer housing  128  partially encloses jaw frame  123  ( FIG. 7A ), electrically-conductive plate  122 , and insulative spacer  115  of jaw member  120  and secures these components in position relative to one another. During the overmolding process, the plurality of fill-apertures  122   f  (see also  FIGS. 6 ) on legs  122   c  of electrically-conductive plate  122  of jaw member  120  are filled with the overmolded material forming outer housing  128  to enhance the securement of the components of jaw member  120  in an assembled condition. 
         [0057]    The various embodiments disclosed herein may also be configured to work with robotic surgical systems and what is commonly referred to as “Telesurgery.” Such systems employ various robotic elements to assist the surgeon and allow remote operation (or partial remote operation) of surgical instrumentation. Various robotic arms, gears, cams, pulleys, electric and mechanical motors, etc. may be employed for this purpose and may be designed with a robotic surgical system to assist the surgeon during the course of an operation or treatment. Such robotic systems may include remotely steerable systems, automatically flexible surgical systems, remotely flexible surgical systems, remotely articulating surgical systems, wireless surgical systems, modular or selectively configurable remotely operated surgical systems, etc. 
         [0058]    The robotic surgical systems may be employed with one or more consoles that are next to the operating theater or located in a remote location. In this instance, one team of surgeons or nurses may prep the patient for surgery and configure the robotic surgical system with one or more of the instruments disclosed herein while another surgeon (or group of surgeons) remotely control the instruments via the robotic surgical system. As can be appreciated, a highly skilled surgeon may perform multiple operations in multiple locations without leaving his/her remote console which can be both economically advantageous and a benefit to the patient or a series of patients. 
         [0059]    The robotic arms of the surgical system are typically coupled to a pair of master handles by a controller. The handles can be moved by the surgeon to produce a corresponding movement of the working ends of any type of surgical instrument (e.g., end effectors, graspers, knifes, scissors, etc.) which may complement the use of one or more of the embodiments described herein. The movement of the master handles may be scaled so that the working ends have a corresponding movement that is different, smaller or larger, than the movement performed by the operating hands of the surgeon. The scale factor or gearing ratio may be adjustable so that the operator can control the resolution of the working ends of the surgical instrument(s). 
         [0060]    The master handles may include various sensors to provide feedback to the surgeon relating to various tissue parameters or conditions, e.g., tissue resistance due to manipulation, cutting or otherwise treating, pressure by the instrument onto the tissue, tissue temperature, tissue impedance, etc. As can be appreciated, such sensors provide the surgeon with enhanced tactile feedback simulating actual operating conditions. The master handles may also include a variety of different actuators for delicate tissue manipulation or treatment further enhancing the surgeon&#39;s ability to mimic actual operating conditions. 
         [0061]    From the foregoing and with reference to the various figure drawings, those skilled in the art will appreciate that certain modifications can also be made to the present disclosure without departing from the scope of the same. While several embodiments of the disclosure have been shown in the drawings, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.