Patent Publication Number: US-2023137803-A1

Title: Jaw member, surgical instrument including at least one jaw member, and method of manufacturing a jaw member

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of, and priority to, U.S. Provisional Patent Application No. 63/274,886, filed on Nov. 2, 2021, the entire contents of which are hereby incorporated herein by reference. 
    
    
     FIELD 
     The present disclosure relates to surgical instruments and, more particularly, to jaw members, surgical instruments including at least one jaw member, and methods of manufacturing jaw members of surgical instruments. 
     BACKGROUND 
     Ultrasonic surgical instruments and systems utilize ultrasonic energy, i.e., ultrasonic vibrations, to treat tissue. More specifically, ultrasonic surgical instruments and systems utilize mechanical vibration energy transmitted at ultrasonic frequencies to treat tissue. An ultrasonic surgical device may include, for example, an ultrasonic blade and a clamp mechanism to enable clamping of tissue against the blade. Ultrasonic energy transmitted to the blade causes the blade to vibrate at very high frequencies, which allows for heating tissue to treat tissue clamped against or otherwise in contact with the blade. 
     Electrosurgical instruments and systems conduct Radio Frequency (RF) energy through tissue to treat tissue. An electrosurgical instrument or system may be configured to conduct bipolar RF energy between oppositely charged electrodes and through tissue, e.g., tissue clamped between the electrodes or otherwise in contact therewith, to treat tissue. Alternatively or additionally, an electrosurgical instrument or system may be configured to deliver monopolar RF energy from an active electrode to tissue in contact with the electrode, with the energy returning via a remote return electrode device to complete the circuit. 
     SUMMARY 
     As used herein, the term “distal” refers to the portion that is described which is further from an operator (whether a human surgeon or a surgical robot), while the term “proximal” refers to the portion that is being described which is closer to the operator. Terms including “generally,” “about,” “substantially,” and the like, as utilized herein, are meant to encompass variations, e.g., manufacturing tolerances, material tolerances, use and environmental tolerances, measurement variations, and/or other variations, up to and including plus or minus 10 percent. Further, any or all of the aspects described herein, to the extent consistent, may be used in conjunction with any or all of the other aspects described herein. 
     Provided in accordance with aspects of the present disclosure is a jaw member of a surgical instrument including a structural body and a jaw liner. The structural body includes a tissue-facing surface having an elongated opening defined therethrough and defines an internal cavity in communication with the elongated opening. The jaw liner material is not conducive to molding and is more malleable and plastically deformable through heat and/or pressure, while still maintaining its structural integrity, such that, under heat and/or pressure, the jaw liner can be formed into a desired shape. The jaw liner includes an internal portion substantially filling the internal cavity and extending to the elongated opening. 
     In an aspect of the present disclosure, the material is PTFE. 
     In another aspect of the present disclosure, the jaw liner includes an external portion that extends from the elongated opening and protrudes from the tissue-facing surface and/or extends outwardly over the tissue-facing surface. 
     In yet another aspect of the present disclosure, the external portion of the jaw liner defines at least one feature therein or thereon. 
     In still another aspect of the present disclosure, the internal cavity defines first and second portions having different widths. The first portion is disposed in direct communication with the elongated opening and the second portion communicates with the elongated opening through the first portion. 
     In still yet another aspect of the present disclosure, the structural body includes at least one retention feature extending into the internal cavity and configured to facilitate retention of the jaw liner. 
     In another aspect of the present disclosure, the structural body includes a raised mesa extending from the tissue-facing surface. The elongated opening is defined through the raised mesa. In such aspects, the jaw liner may include an external portion that extends from the elongated opening outwardly over at least a portion of the raised mesa. 
     In another aspect of the present disclosure, except for the elongated opening, the structural body substantially encloses the internal cavity. 
     A method of manufacturing a jaw member of a surgical instrument provided in accordance with the present disclosure includes preparing a material, forging the material into an internal cavity defined within a structural body of a jaw member, and setting the material once the material substantially fills the internal cavity and is retained therein thereby forming a jaw liner of the jaw member. 
     In an aspect of the present disclosure, prior to forging the material, the method includes positioning the structural body within a fixture. 
     In another aspect of the present disclosure, the forging includes impression die forging. 
     In another aspect of the present disclosure, preparing the material includes heating the material. 
     In still another aspect of the present disclosure, the material is PTFE or another material that cannot be molded (e.g., that does not flow in a manner conducive to plastic molding when heated above a melting point thereof). 
     In yet another aspect of the present disclosure, forging the prepared material includes urging the material through an elongated opening defined within a tissue-facing surface of the structural body and into the internal cavity. 
     In still yet another aspect of the present disclosure, setting the material includes actively cooling the material or allowing the material to cool. 
     In another aspect of the present disclosure, forging the material into the internal cavity defined within the structural body further includes forging a portion of the material externally of the structural body. Forging the portion of the material externally of the structural body may include protruding the portion of material from or extending the portion of material along the tissue-facing surface of the structural body. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other aspects and features of the present disclosure will become more apparent in light of the following detailed description when taken in conjunction with the accompanying drawings wherein like reference numerals identify similar or identical elements. 
         FIG.  1    is a side view of a surgical system provided in accordance with the present disclosure including a surgical instrument, a surgical generator, and a return electrode device; 
         FIG.  2    is perspective view of another surgical system provided in accordance with the present disclosure including a surgical instrument incorporating an ultrasonic generator, electrosurgical generator, and power source therein; 
         FIG.  3    is a schematic illustration of a robotic surgical system provided in accordance with the present disclosure; 
         FIG.  4    is a longitudinal, cross-sectional view of a distal end portion of the surgical instrument of  FIG.  1   ; 
         FIG.  5    is a transverse, cross-sectional view of the end effector assembly of the surgical instrument of  FIG.  1   ; 
         FIG.  6    is a transverse, cross-sectional view of another configuration of the end effector assembly of the surgical instrument of  FIG.  1   ; 
         FIGS.  7 A and  7 B  are perspective and sectioned perspective views, respectively, of a portion of a jaw member provided in accordance with the present disclosure and configured for use with the surgical instrument of  FIG.  1   , the surgical instrument of  FIG.  2   , or any other suitable surgical instrument; 
         FIG.  8    is a perspective view of the portion of the jaw member of  FIGS.  7 A and  7 B  without the jaw liner; 
         FIG.  9    is a perspective view of the portion of the jaw member of  FIGS.  7 A and  7 B  without the structural body; 
         FIGS.  10 A and  10 B  are transverse, cross-sectional views of another jaw member provided in accordance with the present disclosure and configured for use with the surgical instrument of  FIG.  1   , the surgical instrument of  FIG.  2   , or any other suitable surgical instrument, without and with the jaw liner, respectively; 
         FIG.  11    is a sectioned perspective view of another jaw member provided in accordance with the present disclosure and configured for use with the surgical instrument of  FIG.  1   , the surgical instrument of  FIG.  2   , or any other suitable surgical instrument, without the jaw liner; 
         FIG.  12    is a flow diagram illustrating a method of manufacturing a jaw member in accordance with the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIG.  1   , a surgical system provided in accordance with aspects of the present disclosure is shown generally identified by reference numeral  10  including a surgical instrument  100 , a surgical generator  200 , and, in some aspects, a return electrode device  500 , e.g., including a return pad  510 . Surgical instrument  100  includes a handle assembly  110 , an elongated assembly  150  extending distally from handle assembly  110 , an end effector assembly  160  disposed at a distal end of elongated assembly  150 , and a cable assembly  190  operably coupled with handle assembly  110  and extending therefrom for connection to surgical generator  200 . 
     Surgical generator  200  includes a display  210 , a plurality user interface features  220 , e.g., buttons, touch screens, switches, etc., an ultrasonic plug port  230 , a bipolar electrosurgical plug port  240 , and active and return monopolar electrosurgical plug ports  250 ,  260 , respectively. As an alternative to plural dedicated ports  230 - 260 , one or more common ports (not shown) may be configured to act as any two or more of ports  230 - 260 . 
     Surgical instrument  100  may be configured to operate in one or more electrosurgical modes supplying Radio Frequency (RF) energy to tissue to treat tissue, e.g., a monopolar configuration and/or a bipolar configuration, and/or in an ultrasonic mode supplying ultrasonic energy to tissue to treat tissue. Other additional or alternative energy modalities are also contemplated such as, for example, microwave energy, thermal energy, light energy, etc. Surgical generator  200  is configured to produce ultrasonic drive signals for output through ultrasonic plug port  230  to surgical instrument  100  to activate surgical instrument  100  in the ultrasonic mode (where so provided) and/or to provide electrosurgical energy, e.g., RF bipolar energy for output through bipolar electrosurgical plug port  240  and/or RF monopolar energy for output through active monopolar electrosurgical port  250  to surgical instrument  100  to activate surgical instrument  100  in the one or more electrosurgical modes (where so provided). Plug  520  of return electrode device  500  is configured to connect to return monopolar electrosurgical plug port  260  to return monopolar electrosurgical energy from surgical instrument  100  in the monopolar electrosurgical mode. 
     Continuing with reference to  FIG.  1   , handle assembly  110  includes a housing  112 , an activation button  120 , and a clamp trigger  130 . Housing  112  is configured to support an ultrasonic transducer  140 . Ultrasonic transducer  140  may be permanently engaged within housing  112  or removable therefrom. Ultrasonic transducer  140  includes a piezoelectric stack other suitable ultrasonic transducer components electrically coupled to surgical generator  200 , e.g., via one or more of first electrical lead wires  197 , to enable communication of ultrasonic drive signals to ultrasonic transducer  140  to drive ultrasonic transducer  140  to produce ultrasonic vibration energy that is transmitted along a waveguide  154  of elongated assembly  150  to blade  162  of end effector assembly  160  of elongated assembly  150 , as detailed below. Feedback and/or control signals may likewise be communicated between ultrasonic transducer  140  and surgical generator  200 . Ultrasonic transducer  140 , more specifically, may include a stack of piezoelectric elements secured, under pre-compression between proximal and distal end masses or a proximal end mass and an ultrasonic horn with first and second electrodes electrically coupled between piezoelectric elements of the stack of piezoelectric elements to enable energization thereof to produce ultrasonic energy. However, other suitable ultrasonic transducer configurations, including plural transducers and/or non-longitudinal, e.g., torsional, transducers are also contemplated. 
     An activation button  120  is disposed on housing  112  and coupled to or between ultrasonic transducer  140  and/or surgical generator  200 , e.g., via one or more of first electrical lead wires  197 , to enable activation of ultrasonic transducer  140  in response to depression of activation button  120 . In some configurations, activation button  120  may include an ON/OFF switch. In other configurations, activation button  120  may include multiple actuation switches to enable activation from an OFF position to different actuated positions corresponding to different activation settings, e.g., a first actuated position corresponding to a first activation setting (such as a LOW power or tissue sealing setting) and a second actuated position corresponding to a second activation setting (such as a HIGH power or tissue transection setting). In still other configurations, separate activation buttons may be provided, e.g., a first actuation button for activating a first activation setting and a second activation button for activating a second activation setting. Additional activation buttons, sliders, wheels, etc. are also contemplated to enable control of various different activation settings from housing  112 . 
     Elongated assembly  150  of surgical instrument  100  includes an outer drive sleeve  152 , an inner support sleeve  153  ( FIG.  4   ) disposed within outer drive sleeve  152 , a waveguide  154  extending through inner support sleeve  153  ( FIG.  4   ), a drive assembly (not shown), a rotation knob  156 , and an end effector assembly  160  including a blade  162  and a jaw member  164 . In aspects where only electrosurgical energy is provided and/or other configurations, waveguide  154  and blade  162  may be replaced with a second jaw member (not shown) configured to oppose jaw member  164 . Rotation knob  156  is rotatable in either direction to rotate elongated assembly  150  in either direction relative to handle assembly  110 . The drive assembly operably couples a proximal portion of outer drive sleeve  152  to clamp trigger  130  of handle assembly  110 . A distal portion of outer drive sleeve  152  is operably coupled to jaw member  164  and a distal end of inner support sleeve  153  ( FIG.  4   ) pivotably supports jaw member  164 . As such, clamp trigger  130  is selectively actuatable to thereby move outer drive sleeve  152  about inner support sleeve  153  ( FIG.  4   ) to pivot jaw member  164  relative to blade  162  of end effector assembly  160  from a spaced apart position to an approximated position for clamping tissue between jaw member  164  and blade  162 . The configuration of outer and inner sleeves  152 ,  153  ( FIG.  4   ) may be reversed, e.g., wherein outer sleeve  152  is the support sleeve and inner sleeve  153  ( FIG.  4   ) is the drive sleeve. Other suitable drive structures as opposed to a sleeve are also contemplated such as, for example, drive rods, drive cables, drive screws, etc. 
     Referring still to  FIG.  1   , the drive assembly may be tuned to provide a jaw clamping force, or jaw clamping force within a jaw clamping force range, to tissue clamped between jaw member  164  and blade  162  or may include a force limiting feature whereby the clamping force applied to tissue clamped between jaw member  164  and blade  162  is limited to a particular jaw clamping force or a jaw clamping force within a jaw clamping force range. 
     Waveguide  154 , as noted above, extends from handle assembly  110  through inner sleeve  153  ( FIG.  4   ). Waveguide  154  includes blade  162  disposed at a distal end thereof. Blade  162  may be integrally formed with waveguide  154 , separately formed and subsequently attached (permanently or removably) to waveguide  154 , or otherwise operably coupled with waveguide  154 . Waveguide  154  and/or blade  162  may be formed from titanium, a titanium alloy, or other suitable electrically conductive material(s), although non-conductive materials are also contemplated. Waveguide  154  includes a proximal connector (not shown), e.g., a threaded male connector, configured for engagement, e.g., threaded engagement within a threaded female receiver, of ultrasonic transducer  140  such that ultrasonic motion produced by ultrasonic transducer  140  is transmitted along waveguide  154  to blade  162  for treating tissue clamped between blade  162  and jaw member  164  or positioned adjacent to blade  162 . 
     Cable assembly  190  of surgical instrument  100  includes a cable  192 , an ultrasonic plug  194 , and an electrosurgical plug  196 . Ultrasonic plug  194  is configured for connection with ultrasonic plug port  230  of surgical generator  200  while electrosurgical plug  196  is configured for connection with bipolar electrosurgical plug port  240  of surgical generator  200  and/or active monopolar electrosurgical plug port  250  of surgical generator  200 . In configurations where generator  200  includes a common port, cable assembly  190  may include a common plug (not shown) configured to act as both the ultrasonic plug  194  and the electrosurgical plug  196 . In configurations where surgical instrument  100  is only configured for ultrasonic operation, electrosurgical plug  196  and associated components are omitted. 
     Plural first electrical lead wires  197  electrically coupled to ultrasonic plug  194  extend through cable  192  and into handle assembly  110  for electrical connection to ultrasonic transducer  140  and/or activation button  120  to enable the selective supply of ultrasonic drive signals from surgical generator  200  to ultrasonic transducer  140  upon activation of activation button  120  in an ultrasonic mode. In addition, plural second electrical lead wires  199  are electrically coupled to electrosurgical plug  196  and extend through cable  192  into handle assembly  110 . In bipolar configurations, separate second electrical lead wires  199  are electrically coupled to waveguide  154  and jaw member  164  (and/or different portions of jaw member  164 ) such that bipolar electrosurgical energy may be conducted between blade  162  and jaw member  164  (and/or between different portions of jaw member  164 ). In monopolar configurations, a second electrical lead wire  199  is electrically coupled to waveguide  154  such that monopolar electrosurgical energy may be supplied to tissue from blade  162 . Alternatively or additionally, a second electrical lead wire  199  may electrically couple to jaw member  164  in the monopolar configuration to enable monopolar electrosurgical energy to be supplied to tissue from jaw member  164 . In configurations where both bipolar and monopolar functionality are enabled, one or more of the second electrical lead wires  199  may be used for both the delivery of bipolar energy and monopolar energy; alternatively, bipolar and monopolar energy delivery may be provided by separate second electrical lead wires  199 . One or more other second electrical lead wires  199  is electrically coupled to activation button  120  to enable the selective supply of electrosurgical energy from surgical generator  200  to waveguide  154  and/or jaw member  164  upon activation of activation button  120  in an electrosurgical mode(s). 
     As an alternative to a remote generator  200 , surgical system  10  may be at least partially cordless in that it incorporates an ultrasonic generator, an electrosurgical generator, and/or a power source, e.g., a battery, thereon or therein. In this manner, the connections from surgical instrument  100  to external devices, e.g., generator(s) and/or power source(s), is reduced or eliminated. More specifically, with reference to  FIG.  2   , another surgical system in accordance with the present disclosure is shown illustrated as a surgical instrument  20  supporting an ultrasonic generator  310 , a power source (e.g., battery assembly  400 ), and an electrosurgical generator  600  thereon or therein. Surgical instrument  20  is similar to surgical instrument  100  ( FIG.  1   ) and may include any of the features thereof except as explicitly contradicted below. Accordingly, only differences between surgical instrument  20  and surgical instrument  100  ( FIG.  1   ) are described in detail below while similarities are omitted or summarily described. 
     Housing  112  of surgical instrument  20  includes a body portion  113  and a fixed handle portion  114  depending from body portion  113 . Body portion  113  of housing  112  is configured to support an ultrasonic transducer and generator assembly (“TAG”)  300  including ultrasonic generator  310  and ultrasonic transducer  140 . TAG  300  may be permanently engaged with body portion  113  of housing  112  or removable therefrom. 
     Fixed handle portion  114  of housing  112  defines a compartment  116  configured to receive battery assembly  400  and electrosurgical generator  600  and a door  118  configured to enclose compartment  116 . An electrical connection assembly (not shown) is disposed within housing  112  and serves to electrically couple activation button  120 , ultrasonic generator  310  of TAG  300 , and battery assembly  400  with one another when TAG  300  is supported on or in body portion  113  of housing  112  and battery assembly  400  is disposed within compartment  116  of fixed handle portion  114  of housing  112 , thus enabling activation of surgical instrument  20  in an ultrasonic mode in response to appropriate actuation of activation button  120 . Further, the electrical connection assembly or a different electrical connection assembly disposed within housing  112  serves to electrically couple activation button  120 , electrosurgical generator  600 , battery assembly  400 , and end effector assembly  160  (e.g., blade  162  and jaw member  164  and/or different portions of jaw member  164 ) with one another when electrosurgical generator  600  and battery assembly  400  are disposed within compartment  116  of fixed handle portion  114  of housing  112 , thus enabling activation of surgical instrument  20  in an electrosurgical mode, e.g., bipolar RF, in response to appropriate actuation of activation button  120 . For a monopolar electrosurgical mode, return electrode device  500  ( FIG.  1   ) may be configured to connect to surgical instrument  20  (electrosurgical generator  600  thereof, more specifically), to complete a monopolar circuit through tissue and between surgical instrument  20  (e.g., blade  162  and/or jaw member  164 ) and return electrode device  500  ( FIG.  1   ). 
     Turning to  FIG.  3   , a robotic surgical system in accordance with the aspects and features of the present disclosure is shown generally identified by reference numeral  1000 . For the purposes herein, robotic surgical system  1000  is generally described. Aspects and features of robotic surgical system  1000  not germane to the understanding of the present disclosure are omitted to avoid obscuring the aspects and features of the present disclosure in unnecessary detail. 
     Robotic surgical system  1000  generally includes a plurality of robot arms  1002 ,  1003 ; a control device  1004 ; and an operating console  1005  coupled with control device  1004 . Operating console  1005  may include a display device  1006 , which may be set up in particular to display three dimensional images; and manual input devices  1007 ,  1008 , by means of which a person (not shown), for example a surgeon, may be able to telemanipulate robot arms  1002 ,  1003  in a first operating mode. Robotic surgical system  1000  may be configured for use on a patient  1013  lying on a patient table  1012  to be treated in a minimally invasive manner. Robotic surgical system  1000  may further include a database  1014 , in particular coupled to control device  1004 , in which are stored, for example, pre-operative data from patient  1013  and/or anatomical atlases. 
     Each of the robot arms  1002 ,  1003  may include a plurality of members, which are connected through joints, and an attaching device  1009 ,  1011 , to which may be attached, for example, a surgical tool “ST” supporting an end effector  1050 ,  1060 . One of the surgical tools “ST” may be surgical instrument  100  ( FIG.  1   ), surgical instrument  20  ( FIG.  2   ), or any other suitable surgical instrument  20  configured for use in both an ultrasonic mode and one or more electrosurgical (bipolar and/or monopolar) modes, wherein manual actuation features, e.g., actuation button  120  ( FIG.  1   ), clamp lever  130  ( FIG.  1   ), etc., are replaced with robotic inputs. In such configurations, robotic surgical system  1000  may include or be configured to connect to an ultrasonic generator, an electrosurgical generator, and/or a power source. The other surgical tool “ST” may include any other suitable surgical instrument, e.g., an endoscopic camera, other surgical tool, etc. Robot arms  1002 ,  1003  may be driven by electric drives, e.g., motors, that are connected to control device  1004 . Control device  1004  (e.g., a computer) may be configured to activate the motors, in particular by means of a computer program, in such a way that robot arms  1002 ,  1003 , their attaching devices  1009 ,  1011 , and, thus, the surgical tools “ST” execute a desired movement and/or function according to a corresponding input from manual input devices  1007 ,  1008 , respectively. Control device  1004  may also be configured in such a way that it regulates the movement of robot arms  1002 ,  1003  and/or of the motors. 
     Referring to  FIGS.  4 - 6   , end effector assembly  160  of surgical instrument  100  of surgical system  10  ( FIG.  1   ) is detailed, although the aspects and features of end effector assembly  160  may similarly apply, to the extent consistent, to surgical instrument  20  ( FIG.  2   ) and/or any other suitable surgical instrument or system. End effector assembly  160 , as noted above, includes blade  162  and jaw member  164 . Blade  162  may define a linear configuration, may define a curved configuration, or may define any other suitable configuration, e.g., straight and/or curved surfaces, portions, and/or sections; one or more convex and/or concave surfaces, portions, and/or sections; etc. With respect to curved configurations, blade  162 , more specifically, may be curved in any direction relative to jaw member  164 , for example, such that the distal tip of blade  162  is curved towards jaw member  164 , away from jaw member  164 , or laterally (in either direction) relative to jaw member  164 . Further, blade  162  may be formed to include multiple curves in similar directions, multiple curves in different directions within a single plane, and/or multiple curves in different directions in different planes. In addition, blade  162  may additionally or alternatively be formed to include any suitable features, e.g., a tapered configuration, various different cross-sectional configurations along its length, cut outs, indents, edges, protrusions, straight surfaces, curved surfaces, angled surfaces, wide edges, narrow edges, and/or other features. 
     Blade  162  may define a polygonal, rounded polygonal, or any other suitable cross-sectional configuration(s). Waveguide  154  or at least the portion of waveguide  154  proximally adjacent blade  162 , may define a cylindrical shaped configuration. Plural tapered surfaces (not shown) may interconnect the cylindrically shaped waveguide  154  with the polygonal (rounded edge polygonal, or other suitable shape) configuration of blade  162  to define smooth transitions between the body of waveguide  154  and blade  162 . 
     Blade  162  may be wholly or selectively coated with a suitable material, e.g., a non-stick material, an electrically insulative material, an electrically conductive material, combinations thereof, etc. Suitable coatings and/or methods of applying coatings include but are not limited to Teflon®, polyphenylene oxide (PPO), deposited liquid ceramic insulative coatings; thermally sprayed coatings, e.g., thermally sprayed ceramic; Plasma Electrolytic Oxidation (PEO) coatings; anodization coatings; sputtered coatings, e.g., silica; ElectroBond® coating available from Surface Solutions Group of Chicago, Ill., USA; or other suitable coatings and/or methods of applying coatings. 
     Continuing with reference to  FIGS.  4 - 6   , blade  162 , as noted above, in addition to receiving ultrasonic energy transmitted along waveguide  154  from ultrasonic transducer  140  ( FIG.  1   ), may be adapted to connect to generator  200  ( FIG.  1   ) to enable the supply of RF energy to blade  162  for conduction to tissue in contact therewith. In bipolar configurations, RF energy is conducted between blade  162  and jaw member  164  (or between portions of jaw member  164  and/or blade  162 ) and through tissue disposed therebetween to treat tissue. In monopolar configurations, RF energy is conducted from blade  162 , serving as the active electrode, to tissue in contact therewith and is ultimately returned to generator  200  ( FIG.  1   ) via return electrode device  500  ( FIG.  1   ), serving as the passive or return electrode. 
     Jaw member  164  of end effector assembly  160  includes more rigid structural body  182  and more compliant jaw liner  184 . Structural body  182  may be formed from an electrically conductive material, e.g., stainless steel, and/or may include electrically conductive portions. Structural body  182  includes a pair of proximal flanges  183   a  that are pivotably coupled to the inner support sleeve  153  via receipt of pivot bosses (not shown) of proximal flanges  183   a  within corresponding openings (not shown) defined within the inner support sleeve  153  and operably coupled with outer drive sleeve  152  via a drive pin  155  secured relative to outer drive sleeve  152  and pivotably received within apertures  183   b  defined within proximal flanges  183   a . As such, sliding of outer drive sleeve  152  about inner support sleeve  153  pivots jaw member  164  relative to blade  162  from a spaced apart position to an approximated position to clamp tissue between jaw liner  184  of jaw member  164  and blade  162 . 
     With reference to  FIG.  5   , structural body  182  may be adapted to connect to a source of electrosurgical energy, e.g., generator  200  ( FIG.  1   ), and, in a bipolar electrosurgical mode, is charged to a different potential as compared to blade  162  to enable the conduction of bipolar electrosurgical (e.g., RF) energy through tissue clamped therebetween, to treat the tissue. In a monopolar electrosurgical mode, structural body  182  may be un-energized, may be charged to the same potential as compared to blade  162  (thus both defining the active electrode), or may be energized while blade  162  is not energized (wherein structural body  182  defines the active electrode). In either monopolar configuration, energy is returned to generator  200  ( FIG.  1   ) via return electrode device  500  ( FIG.  1   ), which serves as the passive or return electrode. 
     Referring to  FIG.  6   , as an alternative to the entirety of structural body  182  of jaw member  164  being connected to generator  200  ( FIG.  1   ), the structural body may be formed from or embedded at least partially in an insulative material, e.g., an overmolded plastic, or a conductive material coated or otherwise treated to be non-conductive, e.g., PEO-coated titanium, ceramic-coating steel, etc. In such configurations, electrically conductive surfaces  188 , e.g., in the form of plates, may be disposed on (e.g., bonded to, deposited onto, mechanically engaged with, etc.) or captured by the insulative material (e.g., overmolded plastic) to define electrodes on either side of jaw liner  184  on the blade facing side of jaw member  164 . The electrically conductive surfaces  188 , in such aspects, are connected to generator  200  ( FIG.  1   ) and may be energized for use in bipolar and/or monopolar configurations, e.g., energized to the same potential as one another and/or blade  162  and/or different potentials as one another and/or blade  162 . In aspects, electrically conductive surfaces  188  are disposed at additional or alternative locations on jaw member  164 , along either or both sides thereof, along a back surface thereof, etc. 
     Again referring to  FIGS.  4 - 6   , jaw liner  184  is retained within a cavity  185  defined within structural body  182 . Jaw liner  184  is fabricated from an electrically insulative, compliant material such as, for example, polytetrafluoroethylene (PTFE), although other suitable materials, including conductive materials, partially conductive and partially non-conductive materials, Positive Temperature Coefficient (PTC) materials, Negative Temperature Coefficient (NTC) materials, combinations of the above and/or other materials, etc. are also contemplated. The compliance of jaw liner  184  enables blade  162  to vibrate while in contact with jaw liner  184  without damaging components of ultrasonic surgical instrument  100  ( FIG.  1   ) and without compromising the hold on tissue clamped between jaw member  164  and blade  162 . As an alternative to jaw member  164  and, more specifically, jaw liner  184  thereof opposing blade  162  in the approximated position of jaw member  164 , jaw member  164  (including jaw liner  184 ) may be utilized in an end effector assembly having an opposing jaw member (not shown), e.g., for transmission of energy (electrosurgical, thermal, microwave, light, ultrasonic, etc.) to tissue to seal and/or cut tissue grasped therebetween. In such configurations, the opposing jaw member (not shown) may include a thermal cutting element configured to thermally cut tissue and positioned to oppose jaw liner  184  (wherein jaw liner  184  functions as the insulative member of the jaw member), for example, as described in Patent Application Pub. US 2021/0186587, the entire contents of which are hereby incorporated herein by reference. 
     Jaw liner  184 , in aspects, extends from structural body  182  towards blade  162  to inhibit contact between structural body  182  and blade  162  in the approximated position of jaw member  164 . The insulation of jaw liner  184  maintains electrical isolation between blade  162  and structural body  182  of jaw member  164 , thereby inhibiting shorting. 
     Turning to  FIGS.  7 A- 9   , a portion of a jaw member  700  provided in accordance with the present disclosure is shown. Jaw member  700  may be similar to and include any of the features (or combination of features) of the various configurations of jaw member  164  ( FIG.  4   ) detailed hereinabove. Alternatively, jaw member  700  may be configured similar to any other suitable jaw member having a structural body and a jaw liner (also referred to in the art, instead of a liner, as a pad, insulator, insert, spacer, or other like structure associated with a structural body of a jaw member). Thus, jaw member  700  may be utilized with surgical instrument  100  ( FIG.  1   ), surgical instrument  20  ( FIG.  2   ), or any other suitable surgical instrument. Jaw member  700  includes a structural body  710  and a jaw liner  750 . 
     Structural body  710  of jaw member  700  may be formed from any suitable material, e.g., stainless steel, and may be machined or formed in any other suitable manner. Structural body  710  and/or one or more components disposed thereon may be connected to a source of electrical energy (electrical, thermal, microwave, light) to deliver energy to tissue or may only be used to facilitate grasping and manipulating tissue. Structural body  710  includes a base  712  defining a tissue-facing surface  714 , a back surface  716 , a pair of side walls  718 , a distal end  720 , and a proximal end (not shown, including, in aspects, one or more proximal flanges  183   a  ( FIG.  4   ) or other suitable connecting structures for pivotably, otherwise movably, or fixedly coupling structural body  710  of jaw member  700  to a support and/or actuator). Structural body  710  further includes an internal cavity  722  defined therein and communicating with an elongated opening  724  defined through tissue-facing surface  714 . Base  712  of structural body  710  may otherwise enclose internal cavity  722 , e.g., such that internal cavity is not accessible via back surface  716 , side walls  718 , distal end  720 , or the proximal end, although other configurations are also contemplated. 
     Internal cavity  722  of structural body  710  defines a non-uniform shape such as, for example, including a first portion  726  defining a first width and a second portion  728  defining a second width different from the first width. The first and second widths may be consistent or may vary (similarly or differently) along the lengths of first and second portions  726 ,  728 . The widths and/or lengths of first and second portions  726 ,  728  may be similar or different. In aspects, the first width of first portion  726  is smaller than the second width of second portion  728  along at least portions of lengths thereof and first portion  726  is disposed in direct communication with elongated opening  724  while the second portion  728  is disposed in communication with elongated opening  724  via first portion  726 . That is, internal cavity  722  may define an upside down T-shaped configuration (as viewed from the orientation shown in  FIG.  7 B ) along at least a portion of a length thereof. The first and second portions  726 ,  728  may define similar or different heights that may be consistent or vary along the length of internal cavity  722 . Other polygonal (including vertical or angled walls), curved, or combinations of polygonal and curved configurations of first and second portions  726 ,  728  are also contemplated, as are greater or fewer than two portions defining internal cavity  722 . Regardless of the particular shape of internal cavity  722  (or the portions thereof), internal cavity  722  is configured to retain a portion of jaw liner  750  therein such that, once jaw liner  750  is formed at least partially within internal cavity  722 , the portion of jaw liner  750  is retained therein in substantially fixed relation relative to structural body  710 . This may be accomplished via providing the first width of first portion  726  smaller than the second width of second portion  728  along at least portions of lengths thereof as detailed above, or in any other suitable manner. 
     Elongated opening  724  and/or internal cavity  722  may be laterally centered relative to tissue-facing surface  714  of base  712  of structural body  710  or may be laterally offset relative thereto. Further, elongated opening  724  and/or internal cavity  722  may extend from the proximal end of tissue-facing surface  714  to a position proximally-spaced from the distal end thereof, may extend from a position proximally-spaced from the proximal end of tissue-facing surface  714  to the distal end of tissue-facing surface  714 , or may be spaced-apart from both the proximal and distal ends of tissue-facing surface  714 . Elongated opening  714  may additionally or alternatively define a curvature and one or more angled segments, similarly as a curvature or angle of base  712  of structural body  710  or differently therefrom. Further still, internal cavity  722  may be symmetric or asymmetric with respect to elongated opening  724 . 
     In aspects, structural body  710  includes one or more apertures  730  and/or other features (e.g., protrusions, slots, etc.) defined therein, e.g., through either or both sidewalls  718  thereof, to facilitate retention of structural body  710  in a fixture (not shown), e.g., to facilitate formation of jaw liner  750  at least partially within internal cavity  722  of base  712  of structural body  710 . 
     Continuing with reference to  FIGS.  7 A- 9   , jaw liner  750  is configured for receipt at least partially within internal cavity  722  of base  712  of structural body  710  and extends to or through elongated opening  724  thereof. Jaw liner  750  may be formed from an insulative material, conductive material, or partially conductive and partially non-conductive material. Further, jaw line  750 , in aspects, may be formed form a compliant material. As examples, jaw liner  750  may be formed from polytetrafluoroethylene (PTFE), Positive Temperature Coefficient (PTC) materials, Negative Temperature Coefficient (NTC) materials, combinations of the above and/or other materials, etc. While materials that flow when heated above their melting point in a manner that enables injection molding and/or overmolding are contemplated, materials that do not flow in this manner or are otherwise not conducive to injection molding and/or overmolding, such as PTFE, are particularly suitable for use in forming jaw liner  750  in accordance with the aspects and features of the present disclosure. 
     Jaw liner  750  is not pre-formed and inserted into structural body  710  without or with minimal manipulation thereof but, rather, is formed to its final configuration and secured within structural body  710  via forging. Thus, jaw liner  750  as shown in  FIG.  9    is provided for illustration purposes only as jaw liner  750  would not assume this configuration in the absence of and until it is forged into structural body  710 . Forging is advantageous at least in that it may be used on materials that do not retain desired material properties after being heated above their melting points, materials where heating the material above its melting point is not desired (e.g., where certain gasses may be released), and/or materials that are otherwise not conducive to injection molding or overmolding, although it can also be used on moldable materials. In aspects, jaw liner  750  is formed to its final configuration and secured within structural body  710  via die forging (e.g., via open die forging or closed die forging (also referred to as impression die forging)). In this manner, the material  752  of jaw liner  750  is forged through elongated opening  724  and into internal cavity  722  in a more-malleable state (as a result of the heat and/or pressure applied thereto) that enables the material to enter and substantially conform to the configuration of internal cavity  722  and, once set (i.e., allowed to cool or otherwise return to the less-malleable, final form thereof), is fixedly secured therein. For example, as shown in  FIG.  7 B , the material  752  of jaw liner  750  that is forged through elongated opening  724  and into internal cavity  722  may define an upside down T-shaped configuration along at least a portion of a length thereof, complementary to the shape of internal cavity  722 . 
     The material  754 , if any, of jaw liner  750  that remains external of internal cavity  722  may be forged to define any suitable configuration extending from elongated opening  724  and/or tissue-facing surface  714  of base  712  of structural body  710 . For example, the material  754  of jaw liner  750  that remains external of internal cavity  722  may extend outwardly from elongated opening  724  onto portions of tissue-facing surface  714  on either side of elongated opening  724  (and onto a portion of tissue-facing surface  714  disposed distally of elongated opening  724 ) so as to define an apron surrounding elongated opening  724 . Additionally, or alternatively, the material  754  may protrude from tissue-facing surface  714  elongated opening  724  and define a semi-circular transverse cross-sectional configuration (as shown) or any other suitable transverse cross-sectional configuration. One or more features  756  may be formed on or within the material  754  such as, for example, one or more longitudinal channels (as shown), one or more longitudinal protrusions, one or more transverse channels and/or protrusions, grasping teeth, grasping recesses, etc. The one or more features  756  may additionally or alternatively include surface features such as, for example, saw-tooth, sine-wave, stepped, and/or other suitable surface features formed on the material  754 . The particular configuration of the material  754  and/or features  756  thereof may be established by use of appropriate forging tools (e.g., wherein the forging die(s) are configured to achieve a desired configuration and/or feature(s) of the material  754 ). 
     Referring to  FIGS.  10 A and  10 B , another portion of a jaw member  800  provided in accordance with the present disclosure is shown. Jaw member  800  may be similar to and include any of the features of jaw member  700  ( FIGS.  7 A- 9   ) and, thus, only differences therebetween are described in detail hereinbelow. Jaw member  800  includes a structural body  810  and a jaw liner  850 . 
     Structural body  810  of jaw member  800  includes a raised mesa  815  extending from tissue-facing surface  814 . Structural body  810  further includes an internal cavity  822  defined therein and communicating with an elongated opening  824  defined through raised mesa  815 . Elongated opening  824  and/or raised mesa  815  may be laterally centered on tissue-facing surface  814  or offset relative thereto. Internal cavity  822  of structural body  810  includes a first portion  826  (corresponding to the portion defined through raised mesa  815 ) in direct communication with elongated opening  824  and defining a first width and height, and a second portion  828  (corresponding to the portion defined through base  812 ) in indirect communication with elongated opening  824  and defining a second width and height. The second width and height are greater than the first width and height, respectively, although other configurations are also contemplated. In aspects, as an alternative or in addition to a raised mesa  815 , structural body  810  may include one or more other features defined on or within tissue-facing surface  814  such as, for example, continuous and/or discrete protrusions and/or steps that are rounded, angled, etc. 
     Jaw liner  850  is formed to its final configuration and secured within structural body  810  via forging. The material  852  of jaw liner  850  that is forged through elongated opening  824  and into internal cavity  822  defines a configuration complementary to the shape of internal cavity  822 . The material  854  of jaw liner  850  that remains external of internal cavity  822  is forged to extend outwardly on either side of elongated opening  824  to cover at least a portion of the substantially flat tissue-facing surface of raised mesa  815  and defines a substantially planar raised surface with rounded edges extending along the length thereof (and a rounded distal end, in aspects). Further, a feature  856 , e.g., an elongated channel, is defined within the substantially planar raised surface of the material  854 . The channel may be configured to receive an apex of an opposing structure, e.g., of an ultrasonic blade or of a thermal cutting element of an opposing jaw member, when jaw member  800  is disposed in the approximated position for grasping tissue in conjunction with the opposing structure. 
     With reference to  FIG.  11   , another structural body  910  configured for use with any of the jaw members (or jaw liners) detailed herein or any other suitable jaw member (or jaw liner) is provided in accordance with the present disclosure is shown. Structural body  910  may be similar to and include any of the features of structural bodies  710 ,  810  ( FIGS.  7 A- 8    and  FIGS.  10 A- 10 B , respectively) and, thus, only differences therebetween are described in detail hereinbelow. 
     Structural body  910  of jaw member  900  includes an internal cavity  922  defined therein and communicating with an elongated opening  924  defined through tissue-facing surface  914  thereof. Internal cavity  922  of structural body  910  defines a substantially rectangular transverse cross-sectional configuration. Structural body  910  includes a pair of retention features  919  that protrude inwardly into internal cavity  922  from opposing sidewalls thereof. Retention features  919  may be elongated ribs defining triangular transverse cross-sectional configurations, or may be any other suitable retention features, e.g., elongated or discrete protruding structures on either or both sides of internal cavity  922  along the length thereof, plural retention features along the height of internal cavity  922 , shelves, angled surfaces, etc. Regardless of the particular configuration, retention features  919  facilitate retention of a jaw liner within structural body  910  when the jaw liner is forged and set within internal cavity  922 . 
     Turning to  FIG.  12   , a method of manufacturing a jaw member in accordance with the present disclosure is illustrated and identified as method  1200 . At steps  1210  and  1220 , a structural body of a jaw member and an amount of jaw liner material, respectively, are obtained. The structural body of the jaw member is positioned in a fixture at step  1230  such as, for example, within a die fixture for die forging. At step  1240 , the jaw liner material is prepared such as, for example, heated to a suitable temperature and/or pressurized for forging, or otherwise prepared to achieve a more-malleable state that enables forging. Thereafter, at step  1250 , the jaw liner material is forged into the structural body such that at least a portion of the jaw liner material substantially fills and conforms to the shape of a cavity defined within the structural body and, in aspects, such that a portion of the jaw liner material extends from the structural body to define a suitable configuration and/or features. This may be accomplished by relative movement between one or more dies and the die fixture, or in any other suitable manner. At step  1260  the jaw liner material is set to its final form, thereby securing the jaw liner within the structural body. Setting the jaw liner material may be accomplished by allowing the heated jaw liner material to cool, by actively cooling the heated jaw liner material, by releasing or removing the forge pressure, or setting the jaw liner material in any other suitable manner to retain its final form. Finally, at step  1270 , the structural body, including the jaw liner secured thereto, is removed from the fixture. 
     While several aspects of the disclosure have been detailed above and are 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 and accompanying drawings should not be construed as limiting, but merely as exemplifications of particular aspects. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.