Patent ID: 8740901

Claim:
A method of manufacturing an electrode assembly, the method comprising the steps of: providing an electrode assembly for use with an instrument for sealing and cutting vessels and tissue, the electrode assembly comprising: a pair of opposing first and second jaw members each having an insulator and a corresponding pair of electrically conductive tissue sealing surfaces extending along a length thereof, each pair of tissue sealing surfaces being adapted to connect to a source of electrosurgical energy such that each of the electrically conductive tissue sealing surfaces is capable of conducting electrosurgical energy through tissue held therebetween to effect a seal, each pair of the electrically conductive tissue sealing surfaces having an exposed surface; a cutting element operably disposed between the pair of electrically conductive tissue sealing surfaces of the first jaw member, the cutting element and at least one electrically conductive tissue sealing surface having a gap defined therebetween; disposing an insulative material upon first and second opposing sidewalls of the cutting element such that the insulative material extends into the gap, the insulative material configured to reduce an exposed surface area of the electrically conductive tissue sealing surfaces and of the cutting element, wherein the insulative material on the electrically conductive tissue sealing surfaces and the cutting element is positioned to optimize power density and location of a cutting zone during electrosurgical cutting.