Tissue treatment electrodes for surgical instruments and surgical instruments incorporating them

Abstract

The end effector assembly includes first and second jaw members and an electrode. One or both of the jaw members are movable from a spaced-out position to a close position relative to the other for grasping tissue. The electrode is supported by the second jaw member, extends longitudinally along the second jaw member, and protrudes from the second jaw member. The electrode includes a conductive element and an electrically insulating coating. The conductive element defines a long basal surface, first and second long sides, a proximal end portion, and a distal end portion, all covered by the electrically insulating coating. The conductive element further defines a long tissue treatment surface opposite the long basal surface, which is left exposed, thereby exciting the conductive element with RF energy to concentrate the RF energy on the exposed long tissue treatment surface.

Description

Technical Field

[0001] Cross - reference to Related Applications This application claims the benefit and priority of U.S. Provisional Patent Application No. 63 / 461,992, filed on April 26, 2023, the entire content of which is incorporated herein by reference.

[0002] The present disclosure relates to surgical instruments, and more particularly, to tissue treatment electrodes for surgical instruments and surgical instruments incorporating the same.

Background Art

[0003] Surgical forceps are plier - like instruments that grip, hold, and compress tissue depending on the mechanical action between their jaw members. Electrosurgical forceps use both a mechanical clamping action and energy to heat tissue to treat the tissue, such as coagulate, cauterize, or seal it. Typically, when the tissue is treated, the surgeon needs to accurately sever the treated tissue. Thus, many electrosurgical forceps are designed to incorporate a knife that advances between the jaw members to cut the treated tissue. As an alternative to a mechanical knife, an energy - utilizing tissue cutting element can be provided to cut the treated tissue using energy, such as heat, electrosurgery, ultrasound, light, or other suitable energy.

[0004] Energy - utilizing elements are also used in various other surgical instruments and / or to facilitate the treatment of tissue, such as tissue coagulation, tissue sealing, tissue cutting, etc., using other energy, such as heat, electrosurgery, ultrasound, light, or other suitable energy.

Summary of the Invention

Means for Solving the Problems

[0005] Where used herein, the term “distal” refers to a portion described as being further away from the operator (whether a human surgeon or a surgical robot), and the term “proximal” refers to a portion described as being closer to the operator. Where used herein, terms such as “generally,” “about,” and “substantially” include variations, e.g., manufacturing tolerances, material tolerances, use and environmental tolerances, measurement variations, design variations, and / or other variations, which include up to plus or minus 10 percent. Furthermore, to the extent that it does not conflict, any or all of the embodiments detailed herein may be used in conjunction with any or all of the other embodiments detailed herein.

[0006] According to aspects of this disclosure, an end-effector assembly for a surgical instrument is provided. The end-effector assembly includes first and second jaw members and an electrode. Each of the first and second jaw members defines a tissue treatment surface. At least one of the first and second jaw members is movable from a spaced-out position to a close position relative to the first or second jaw member in order to grasp tissue between the tissue treatment surfaces of the first and second jaw members. The electrode is supported by the second jaw member, extends longitudinally along at least a portion of the length of the second jaw member, and protrudes from the second jaw member toward the first jaw member. The electrode includes a conductive element and an electrically insulating coating. The conductive element defines a long basal surface, a long tissue treatment surface opposite the long basal surface, first and second long sides, a proximal end portion, and a distal end portion. The electrically insulating coating covers the long basal surface, the first and second long sides, the proximal end portion, and the distal end portion, leaving the long tissue treatment surface exposed. The conductive element is adapted to be connected to an RF energy source to excite the conductive element with radio frequency (RF) energy and concentrate the RF energy on the exposed, long tissue treatment surface.

[0007] In some aspects of this disclosure, the electrode defines a width of approximately 0.001 inches to approximately 0.002 inches on a long tissue treatment surface.

[0008] In other aspects of the present disclosure, the thickness of the electrical insulating coating on each of the first and second long sides gradually decreases from the long basal surface towards the long tissue treatment surface.

[0009] In yet another aspect of this disclosure, the maximum thickness of the electrical insulating coating on each of the first and second long sides is approximately 0.002 inches to approximately 0.006 inches.

[0010] In yet another aspect of this disclosure, the electrode protrudes from the tissue treatment surface of the second jaw member toward the first jaw member to a height of approximately 0.018 inches to approximately 0.024 inches.

[0011] In yet another aspect of the present disclosure, the electrode includes an exposed portion of the conductive element at or toward the proximal end portion of the conductive element for connecting an electrical lead wire to the conductive element to provide RF energy to the conductive element.

[0012] In other embodiments of the present disclosure, the electrode includes a main body portion and a tapered distal portion extending distally from the main body portion to the distal tip of the electrode.

[0013] In yet another aspect of this disclosure, the electrode is characterized by a gradual decrease in width along at least a portion of the height of the electrode, which extends from a long basal surface to a long tissue treatment surface.

[0014] In yet another aspect of this disclosure, the electrode defines a transition at the interface between a long tissue treatment surface and at least one of the proximal or distal end portions.

[0015] In other aspects of this disclosure, the electrical insulating coating is glass.

[0016] In yet another aspect of this disclosure, the flexible electrical insulating member is disposed within the first jaw member and positioned to face the electrode in close proximity. In such an aspect, the flexible electrical insulating member may define an exposed surface that is substantially coplanar with the tissue treatment surface of the first jaw member.

[0017] In yet another aspect of this disclosure, the flexible electrical insulating material defines a durometer of about 55D to about 65D. Additionally or alternatively, the flexible electrical insulating material may define a depth of about 0.035 inches to about 0.045 inches.

[0018] In yet another aspect of this disclosure, the tissue treatment surfaces of the first and second jaw members are adapted to be connected to an RF energy source to excite the tissue treatment surfaces of the first and second jaw members with RF energies of different potentials.

[0019] In other embodiments of the present disclosure, one of the first jaw member or the second jaw member is fixed, and the other of the first jaw member or the second jaw member is movable relative to the fixed jaw member.

[0020] Other end-effector assemblies of surgical instruments provided by this disclosure include first and second jaw members that define tissue treatment surfaces, respectively. At least one of the first or second jaw member is movable from a spaced-out position to a close position relative to the other jaw member in order to grasp tissue between the tissue treatment surfaces of the first and second jaw members. An electrode is supported by the second jaw member and extends longitudinally between the proximal and distal ends of the electrode along at least a portion of the length of the second jaw member and protrudes from the second jaw member toward the first jaw member into a long upper range of the electrode. The electrode is adapted to be connected to a radio frequency (RF) energy source to excite the electrode with RF energy. The electrode defines a first transition between the long upper range of the electrode and the proximal end of the electrode, and a second transition between the long upper range of the electrode and the distal end of the electrode.

[0021] In some aspects of this disclosure, the first transition is gentler than the second transition.

[0022] In other aspects of this disclosure, the first transition defines a first radius of curvature, and the second transition defines a second radius of curvature that is smaller than the first radius of curvature.

[0023] In yet another aspect of the present disclosure, the electrode includes a conductive element and an electrically insulating coating. The electrically insulating coating substantially covers the conductive element except for a portion along a long upper range of the electrode, whereby the conductive element is exposed along the long upper range of the electrode.

[0024] In yet another aspect of the present disclosure, the tissue treatment surfaces of the first and second jaw members are adapted to be connected to an RF energy source to excite the tissue treatment surfaces of the first and second jaw members with RF energy of different potentials.

[0025] In yet another aspect of the present disclosure, one of the first jaw member or the second jaw member is fixed, and the other of the first jaw member or the second jaw member is movable relative to the fixed jaw member.

[0026] The above and other aspects of the present disclosure will become apparent by reading the following detailed description in conjunction with the accompanying drawings, in which like reference numerals indicate similar or identical elements.

Brief Description of the Drawings

[0027] [Figure 1] It is a perspective view of a shaft-type electrosurgical forceps provided by the present disclosure, shown in a state of being connected to an electrosurgical generator. [Figure 2] It is a perspective view of a hemostatic electrosurgical forceps provided by the present disclosure. [Figure 3] It is a schematic view of a robotic surgical instrument provided by the present disclosure. [Figure 4] It is a perspective view of an end effector assembly of the forceps of FIG. 1, including first and second jaw members. [Figure 5A] It is a perspective view of the first jaw member of the end effector assembly of the forceps of FIG. 1. [Figure 5B] It is a perspective view of the second jaw member of the end effector assembly of the forceps of FIG. 1. [Figure 6]This is a cross-sectional view of one jaw member of the forceps end effector assembly shown in Figure 1, including the tissue treatment electrode according to this disclosure. [Figure 7] Figure 6 is a perspective view of the tissue treatment electrode, including the attached electrical connector. [Figure 8] This is a top view of the distal portion of another tissue treatment electrode configured for use with one of the jaw members of the forceps end effector assembly shown in Figure 1, according to the present disclosure. [Figure 9-1] Figure 1 is a side view of the jaw members of the forceps end effector assembly, showing the portion including other tissue treatment electrodes according to this disclosure, where the jaw members of the end effector assembly are positioned at a spaced-out position and a close-up position, respectively. [Figure 9-2] The configuration of the transition section according to this disclosure, to be used with the tissue treatment electrode of this disclosure or any other suitable tissue treatment electrode, is shown. [Figure 10A] Figure 1 is a cross-sectional view of the end effector assembly of forceps, in which one jaw member includes a tissue treatment electrode and the other jaw member includes a flexible member facing the tissue treatment electrode. [Figure 10B] Figure 10A is a cross-sectional view of a jaw member including a flexible member. [Modes for carrying out the invention]

[0028] Referring to Figure 1, a shaft-type electrosurgical forceps provided by this disclosure is shown, generally identified by reference numeral 10. Aspects and features of forceps 10 that are not closely related to understanding this disclosure are omitted so as not to obscure the aspects and features of this disclosure with unnecessary detail.

[0029] The forceps 10 includes a housing 20, a handle assembly 30, a rotary assembly 70, a first actuation switch 80, a second actuation switch 90, and an end effector assembly 100. The forceps 10 further includes a shaft 12 having a distal end portion 14 configured to engage (directly or indirectly) with the end effector assembly 100, and a proximal end portion 16 that engages (directly or indirectly) with the housing 20. The forceps 10 also includes a cable "C" connecting the forceps 10 to an energy source, for example, an electrosurgical generator "G". The cable "C" includes wires (multiple wires) (not shown) extending therein, which are long enough to connect through the shaft 12 to one or both of the tissue treatment surfaces 114, 124 of the jaw members 110, 120 of the end effector assembly 100 to provide them with energy. The first actuation switch 80 is connected to the tissue treatment surfaces 114, 124 and the electrosurgical generator "G" to selectively activate the supply of energy to the jaw members 110, 120 for treating tissue, such as coagulating, cauterizing / drying, and / or sealing the tissue. The second actuation switch 90 is connected to the electrode 130 (see Figure 4) of the jaw member 120 and the electrosurgical generator "G" to selectively activate the supply of energy to the electrode 130 (Figure 4) for treating tissue, such as performing incision, spot coagulation, scoring, fistula creation, etc. As an alternative to the first and second actuation switches 80, 90, multi-stage switches may be provided, and / or the electrosurgical generator "G" may identify appropriate components to be actuated (e.g., tissue treatment surfaces 114, 124 and / or electrodes 130 (Figure 4)) in combination thereof or in any other suitable manner, according to a tissue treatment algorithm, based on the detected characteristics of feedback, forceps and / or tissue.

[0030] Instead of providing a separate electrosurgical generator "G", the forceps 10 may be configured as a cordless device including, for example, an onboard electrosurgical generator (not shown) powered by an onboard power supply (not shown), such as a DC battery and an onboard power supply, to provide energy to the electrodes 130 (Figure 4) and / or the tissue treatment surfaces 114, 124.

[0031] The handle assembly 30 of the forceps 10 includes a fixed handle 50 and a movable handle 40. The fixed handle 50 is integrally associated with the housing 20, and the handle 40 is movable relative to the fixed handle 50. The movable handle 40 of the handle assembly is operably connected to a drive assembly (not shown), and together they mechanically cooperate to move one or both of the jaw members 110, 120 of the end effector assembly 100 between separated and close positions around the pivot 103 to grasp tissue between the tissue treatment surfaces 114, 124 of the jaw members 110, 120. As shown in Figure 1, the movable handle 40 is initially separated from the fixed handle 50, and correspondingly the jaw members 110, 120 of the end effector assembly 100 are positioned in the separated position. The movable handle 40 can be pushed down from its initial position to a pushed-down position corresponding to the close position of the jaw members 110, 120. The rotating assembly 70 includes a rotating wheel 72 which is selectively rotatable in any direction, and in correspondence rotates the end effector assembly 100 relative to the housing 20.

[0032] Referring to Figure 2, the hemostatic electrosurgical forceps provided in this disclosure are shown and are generally identified by reference number 210. Aspects and features of forceps 210 that are not closely related to understanding this disclosure are omitted so as not to obscure the aspects and features of this disclosure with unnecessary detail.

[0033] The forceps 210 includes two shaft members 212a, 212b, each having proximal end portions 216a, 216b and distal end portions 214a, 214b, respectively. The forceps 210 is configured to be used with an end effector assembly 100' similar to the end effector assembly 100 (Figures 1 and 4). More specifically, the end effector assembly 100' includes first and second jaw members 110', 120', which are attached to the respective distal end portions 214a, 214b of the shaft members 212a, 212b. The jaw members 110', 120' are connected so as to be rotatable around a pivot 103'. Each shaft member 212a, 212b includes handles 217a, 217b located on its proximal end portions 216a, 216b. Each handle 217a, 217b defines finger holes 218a, 218b through it for receiving the user's fingers. As can be understood, the finger holes 218a, 218b make it easier to move the shaft members 212a, 212b relative to each other, and thus rotate the jaw members 110', 120' from a spaced-out position where the jaw members 110', 120' are positioned spaced apart from each other, to a close-up position where the jaw members 110', 120' cooperate to grasp tissue between them.

[0034] One of the shaft members 212a, 212b of the forceps 210, for example shaft member 212b, includes a proximal shaft connector 219 configured to connect the forceps 210 to an energy source, for example, an electrosurgical generator "G" (Figure 1). The proximal shaft connector 219 secures a cable "C" to the forceps 210, allowing the user to supply energy to the jaw members 110', 120' for treating tissue. More specifically, a first actuation switch 280 is provided to supply energy to the jaw members 110', 120' for treating tissue when the shaft members 212a, 212b are sufficiently close together, for example, when the first actuation switch 280 is activated via shaft member 212a. A second actuation switch 290, located on either or both of the shaft members 212a and 212b, is connected to an electrode (similar to the electrode on one of the jaw members 120 of the jaw members 110' and 120' of the end effector assembly 100' (Figure 4), not shown) and an electrosurgical generator "G" to enable selective operation of the energy supply to the electrode for treating tissue. Alternatively, the second actuation switch 290 may be omitted, and the electrosurgical generator "G" (Figure 1) may be configured to automatically excite the electrode and / or jaw members 110' and 120' according to an algorithm, for example, based on detected feedback. In particular, the electrosurgical generator "G" (Figure 1) may provide control to enable or disable the operation of the electrode and / or jaw members 110' and 120' based on jaw position, handle position, etc. Similar functionality may also be provided for the forceps 10 (Figure 1).

[0035] The jaw members 110' and 120' define a curved configuration in which each jaw member 110' and 120' is similarly curved, offset laterally from the longitudinal axis of the end effector assembly 100'. However, other suitable curved configurations are also conceivable, including curvature toward one side (and thus away from each other), multiple curvatures in the same plane, and / or multiple curvatures in different planes. The jaw members 110 and 120 of the end effector assembly 100 (Figure 1) can also be curved according to any of the above configurations or in any other suitable manner.

[0036] Referring to Figure 3, the robotic surgical instruments provided in this disclosure are shown and are generally identified by reference number 1000. Aspects and features of robotic surgical instruments 1000 that are not closely related to understanding this disclosure are omitted so as not to obscure the aspects and features of this disclosure with unnecessary detail.

[0037] The robotic surgical instrument 1000 includes a plurality of robotic arms 1002, 1003, a control device 1004, and an operating console 1005 connected to the control device 1004. The operating console 1005 may include a display device 1006 which can be configured in particular to display three-dimensional images, and manual input devices 1007, 1008 which can thereby allow the surgeon to perform telemanipulation of the robotic arms 1002, 1003 in a first operating mode. The robotic surgical instrument 1000 may be configured for use on a patient 1013 lying on an operating table 1012 to be treated minimally. The robotic surgical instrument 1000 may further include a database 1014 connected in particular to the control device 1004, which stores preoperative data, for example, from the patient 1013 and / or anatomical diagrams.

[0038] Each of the robot arms 1002 and 1003 may include multiple members connected through joints and mounting devices 1009 and 1011 to which, for example, end effector assemblies 1100 and 1200 can be attached, respectively. The end effector assembly 1100 is similar to the end effector assembly 100 (Figure 4), but other end effector assemblies suitable for connection to the mounting device 1009 are also possible. The end effector assembly 1200 may be any end effector assembly, such as an endoscope camera or other surgical instrument. The robot arms 1002 and 1003 and the end effector assemblies 1100 and 1200 may be driven by an electric drive, such as a motor, and these are connected to the control device 1004. The control device 1004 (e.g., a computer) may be configured to operate the motors, in particular by a computer program, in such a way that the robot arms 1002, 1003, their mounting devices 1009, 1011, and end effector assemblies 1100, 1200 perform desired movements and / or functions in accordance with corresponding inputs from manual input devices 1007, 1008, respectively. The control device 1004 may also be configured to coordinate the movements of the robot arms 1002, 1003, and / or the motors.

[0039] Referring to Figures 4-5B, the end effector assembly 100 includes first and second jaw members 110, 120, as described above. Each jaw member 110, 120 may include a structural frame 111, 121, jaw housings 112, 122, and tissue treatment plates 113, 123 defining their respective tissue treatment surfaces 114, 124. Alternatively, only one of the jaw members, for example jaw member 120, may include a structural frame 121, a jaw housing 122, and a tissue treatment plate 123 defining the tissue treatment surface 124. In this embodiment, the other jaw member, for example jaw member 110, may function as a standalone unit, for example, a structural frame 111 and a jaw housing 112, and may be formed as a conductive material piece defining the tissue treatment surface 114. In this embodiment, the outer surface of the jaw housing 112 may be covered with an insulating material at least partially or left exposed. In one embodiment, the tissue treatment plates 113, 123 may be placed in jaw housings 112, 122 or in jaw inserts (not shown) which are also placed within jaw housings 112, 122, for example, via sputtering. Alternatively, the tissue treatment plates 113, 123 may be preformed and engaged with jaw inserts (not shown) which are placed within jaw housings 112, 122 and / or jaw housings 112, 122, for example, via overmolding, adhesive, mechanical engagement, etc.

[0040] Referring particularly to Figures 4 and 5A, the jaw member 110 may be configured similarly to the jaw member 120 as described above, or may be formed as a standalone unit, or may be formed in any other suitable way that defines a tissue treatment surface 114 facing the tissue treatment surface 124 of the structural frame 111 and the jaw member 120. The structural frame 111 includes a proximal flange portion 116 around which the jaw member is pivotably connected to the jaw member 120, and a distal body portion extending distally from the proximal flange portion 116 (see Figure 10A). In shaft-type or robotic configurations, the proximal flange portion 116 may further include a hole 117a for receiving the pivot 103, and at least one projection 117b extending therefrom and receiving in a hole defined within a drive sleeve of a drive assembly (not shown), configured to cause the jaw member 110 to pivot around the pivot 103 between a spaced-out position and a close-to-the-jaw member 120 when the drive sleeve translates in response to the operation of the movable handle 40 (Figure 1) or robotic drive. However, other suitable drive mechanisms are also conceivable, such as cam pins and cam slots, closure tubes, screw drive mechanisms, etc.

[0041] Regardless of the specific configuration of the jaw member 110, the jaw member 110 may include a longitudinally extending insulating member 115 that extends along at least a portion of the length of the tissue treatment surface 114. The insulating member 115 may be centered laterally on or offset from the tissue treatment surface 114. Furthermore, the insulating member 115 may be positioned on the tissue treatment surface 114 and, for example, deposited, coated, etc., or positioned within channels or recesses defined within the tissue treatment surface 114, or define any other suitable configuration. In addition, the insulating member 115 may be substantially coplanar with the tissue treatment surface 114 (within manufacturing tolerances and / or usage tolerances), or may protrude from the tissue treatment surface 114, or may be recessed relative to the tissue treatment surface 114, or may include different portions that are coplanar with the tissue treatment surface 114, protruding, and / or recessed. The insulating member 115 may be formed from, for example, a plastic elastomer (TPE), silicone, polybenzimidazole, ceramic, parylene, nylon, PTFE, or a suitable material (including a combination of insulating and non-insulating materials).

[0042] Referring to Figures 4 and 5B, as previously described, the jaw member 120 includes a structural frame 121, a jaw housing 122, and a tissue treatment plate 123 defining its tissue treatment surface 124. The jaw member 120 further includes an electrode 130. The structural frame 121 defines a proximal flange portion 126 and a distal body portion (see Figure 10A) extending distally from the proximal flange portion 126. The proximal flange portion 126 defines a pair of bifurcated and spaced-apart proximal flange portion segments, between which aligning holes 127 receive the proximal flange 116 of the structural frame 111 of the jaw member 110, which are configured to receive a pivot 103 between them, connecting the jaw members 110 and 120 so as to be rotatable relative to each other.

[0043] The jaw housing 122 of the jaw member 120 is positioned around the distal main body portion of the structural frame 121, for example by overmolding, adhesive, mechanical engagement, etc., and supports the tissue treatment plate 123 thereon, for example by overmolding, adhesive, mechanical engagement, deposition (e.g., via sputtering), etc. The tissue treatment plate 123 defines the tissue treatment surface 124 as described above. A longitudinally extending slot 125 is defined through the tissue treatment plate 123 and positioned to face the insulating member 115 (Figure 5A) of the jaw member 110 in proximity. The slot 125 may extend through the jaw housing 122, the jaw insert (if provided so) and / or at least part of other components of the jaw member 120, so that the electrode 130 can be received at least partially within the slot 125.

[0044] More specifically, the electrode 130 is positioned in close proximity within a longitudinally extending slot 125 such that the electrode 130 faces the insulating member 115 (Figure 5A) of the jaw member 110. The electrode 130 may be configured to contact the insulating member 115 (Figure 5A) in close proximity to adjust or contribute to adjusting the gap distance between the tissue treatment surfaces 114, 124 in close proximity. Alternatively or additionally, one or more stop members (not shown) associated with the jaw member 110 and / or jaw member 120 may be provided to adjust the gap distance between the tissue treatment surfaces 114, 124 in close proximity.

[0045] The electrode 130 may be electrically insulated from the tissue treatment plate 123 by being surrounded by an insulating member 128 positioned within the slot 125. The insulating member 128 may be separated from or formed as part of a portion of the jaw housing 122 (or a jaw insert, if provided, not shown). Alternatively or additionally, the electrode 130 may include an insulating coating at least on its sides for a similar purpose. The electrode 130 and the insulating member 128 may, similarly or differently, be substantially coplanar with the tissue treatment surface 124 (within manufacturing tolerances, material tolerances and / or use tolerances), or may protrude from the tissue treatment surface 124, or may be recessed relative to the tissue treatment surface 124, or may include different portions that are coplanar with, protrude, and / or recessed relative to the tissue treatment surface 124. Although the electrode 130 is shown to be engaged within the jaw member 120, the reverse configuration may also be provided, for example, with the electrode 130 engaged within the jaw member 110 (Figure 4) and the insulating member 115 engaged within the jaw member 120.

[0046] In a configuration in which the end effector assembly 100 or a part thereof is curved, the longitudinally extending slot 125 and electrode 130 may also be curved, for example, the longitudinally extending slot 125 and electrode 130 (or their corresponding parts) may be configured relative to a curved arc (or multiple arcs) rather than to a longitudinal axis. Therefore, when used herein, terms such as longitudinal and transverse are not limited to, for example, linear configurations along a linear axis, but also apply equally to curved configurations along, for example, a curved arc. In such a curved configuration, the insulating member 115 of the jaw member 110 (Figure 5A) is also curved.

[0047] Generally referring to Figures 1-5B, the tissue treatment plates 113 and 123 are formed from a conductive material to conduct electrical energy between them for the purpose of treating tissue, for example. Alternatively, the tissue treatment plates 113 and 123 may be configured to conduct any suitable energy, such as heat, microwaves, light, ultrasound, etc., into the tissue held between them for energy-based tissue treatment. As previously mentioned, the tissue treatment plates 113 and 123 are connected to the operating switch 80 and the electrosurgical generator "G" (Figure 1) so that energy is selectively supplied to the tissue treatment plates 113 and 123 and can be conducted through the tissue placed between them and between the jaw members 110 and 120 to treat the tissue and, for example, seal the tissue extending across the electrode 130 on either side. In other words, in one embodiment, the electrosurgical generator "G" (Figure 1) is configured to excite tissue treatment plates 113 and 123 with radio frequency (RF) electrosurgical energy in a bipolar configuration, in which case the tissue treatment plate 113 is excited to a first potential and the tissue treatment plate 123 is excited to a second different potential, thereby establishing an energy potential gradient between the tissue treatment plates 113 and 123 and through the tissue held between them for treatment, for example, to seal the tissue.

[0048] On the other hand, the electrode 130 is connected to the electrosurgical generator "G" (Figure 1) and a second operating switch 90, positioned between the jaw members 110 and 120 (for example, to cut pre-sealed tissue into first and second sealed tissue portions to perform scissor-like tissue cutting, etc.), located proximal to the jaw members 110 and 120, or otherwise near the electrode 130, for treating tissue, such as cutting, excision, spot cauterization, scoring, fistula creation, etc., and is configured to allow selective operation of energy supply to the electrode 130. The electrode 130 can be excited by RF electrosurgical energy in a first configuration in which the electrosurgical generator "G" (Figure 1) excites the electrode 130 as an active electrode configured to deliver energy to the tissue in contact with it, and another return device (not shown) (e.g., remote return pad, another return device, e.g., tenacula or probe, etc.) functions as a return electrode to recover energy and return it to the electrosurgical generator "G" (Figure 1) to complete the circuit. Alternatively or additionally, electrode 130 may also be excited in a second configuration in which the electrosurgical generator "G" (Figure 1) is excited with electrode 130 as the active electrode, and a local return located on or within the end effector assembly 100 functions as a return electrode to recover energy and return it to the electrosurgical generator "G" (Figure 1) to complete the circuit. For example, the local return electrode may include either or both of the tissue treatment plates 113, 123 and / or other parts of either or both of the jaw members 110, 120, such as a return wire, a return plate, a conductive surface of either or both of the jaw members 110, 120, or any other suitable return conductor or part.

[0049] Various configurations of the electrode 130 and / or other embodiments of the jaw members 110, 120 configured to facilitate tissue treatment with the electrode 130 are described below in detail. Unless contradictory, any or all of these features can be used together or in any suitable combination. Furthermore, although this specification describes the end effector assembly 100, the embodiments and features described below also apply to use with other suitable end effectors and instruments.

[0050] Referring to Figures 6 and 7, the electrode 630 is shown to be engaged within the jaw member 120, but the electrode 630 may alternatively be engaged within the jaw member 110 (Figure 4). The electrode 630 may include, to the extent that they do not contradict each other, any features of the electrode 130 (Figure 4), any of the other electrodes detailed herein, or combinations thereof. The electrode 630 includes a conductive element 632 and an electrically insulating coating 634 surrounding a portion of the conductive element 632. The conductive element 632 may be formed of stainless steel, titanium, or other suitable conductive material, and may also be formed by etching, grinding, or any other suitable method. The conductive element 632 includes a long basal surface 638, a long tissue treatment surface 636 opposite the long basal surface 638, a pair of long sides 640, a proximal end portion 642, and a distal end portion 644. In one embodiment, the conductive element 632 defines a configuration in the shape of a long triangular prism (or a long triangular prism placed on a long rectangular prism), where the long vertices of the long triangular prism define a long tissue treatment surface 636, rather than a long edge. In this and other embodiments, the long base surface 638 may define a relatively wide width compared to the relatively narrow width of the long tissue treatment surface 636. In other embodiments, either surface 636, 638 may define a configuration of relatively narrow width or similar or different widths. Other suitable shapes and configurations for the conductive element 632 are also conceivable, including configurations in which some or all of the surfaces 636, 638, 640 have curves, corners, steps and / or other features.

[0051] The electrical insulating coating 634 is placed on the long base surface 638, the long oblique side surface 640, the proximal end portion 642, and the distal end portion 644 of the conductive element 632. However, the long tissue treatment surface 636 of the conductive element 632 is left exposed (e.g., not covered or only partially covered by the electrical insulating coating 634), and the electrode 630 is configured to direct most of the electrosurgical energy supplied to it toward the long tissue treatment surface 636 to facilitate tissue treatment thereby. In one embodiment, the electrode 630 defines a width "W1" of about 0.0005 inches to about 0.003 inches along the exposed long tissue treatment surface 636, and in other embodiments, about 0.001 inches to about 0.002 inches. The width "W1" along the long tissue treatment surface 636 is selected to balance the advantages of providing a narrower width, which facilitates energy concentration at the long tissue treatment surface 636, reduces the required power, and improves electrical cutting performance, with the need to provide a wider width to reduce mechanical sharpness and prevent mechanical cutting. In one embodiment, the conductive element 632 is configured to generate plasma at the long tissue treatment surface 636 by energy concentration at the long tissue treatment surface 636, thereby facilitating the cutting of tissue in contact with the long tissue treatment surface 636, for example, via plasma-assisted RF tissue cutting.

[0052] The electrode 630 may further define a width "W2" along the long basal surface 638 (including any thickness created by the electrical insulating coating 634 on the long side surface 640) in one embodiment about 0.002 inches to about 0.010 inches, and in other embodiments about 0.003 inches to about 0.008 inches. In other embodiments, the width "W2" (including any thickness created by the electrical insulating coating 634 on the long side surface 640) is about 0.016 inches to about 0.020 inches or 0.018 inches. In one embodiment, the ratio of the width of the electrode 630 along the long basal surface 638 to the width of the electrode 630 along the long tissue treatment surface 636 is about 8:1 to about 2:1, and in one embodiment about 5:1 to about 3:1. In one embodiment, the long side surface 640 is substantially flat and angled such that the conductive element 632 defines a smooth taper from the long base surface 638 to the long tissue treatment surface 636; however, other configurations are also possible, including long side surfaces 640 that are curved (convex or concave), stepped, multi-angled, or a combination thereof. Furthermore, in addition to or instead of the gradual reduction in the width of the conductive element 632 from the long base surface 638 to the long tissue treatment surface 636, the thickness of the electrical insulating coating 634 may also be gradually reduced from the long base surface 638 to the long tissue treatment surface 636 at a similar rate or a different allocation as the gradual reduction of the conductive element 632. In one embodiment, the thickness of the electrical insulating coating 634 (on each side of the conductive element 632) is about 0.002 inches to about 0.006 inches at the long base surface 638 of the conductive element 632 and gradually reduces to the uncoated (or slightly coated) portion at the long tissue treatment surface 636 of the conductive element 632. In other embodiments, the thickness of the electrical insulating coating 634 (on each side of the conductive element 632) is approximately 0.004 inches on the long base surface 638.

[0053] The electrical insulating coating 634 may be formed of glass. In other embodiments, the electrical insulating coating 634 may be formed of ceramic, polyamide, TPE, polyphthalamide (PPA), polyetheretherketone (PEEK), polybenzimidazole (PBI), polytetrafluoroethylene (PTFE), silicone, or other suitable material. The electrical insulating coating 634 may be coated onto the conductive element 632 by spray, dip coating, molding, or any other suitable method. In some embodiments, the electrical insulating coating 634 may be provided in multiple coating layers of the same or different materials, for example, two or more coating layers. Regardless of the specific configuration, the electrical insulating coating 634 provides dielectric strength of at least 400 volts in some embodiments, at least 600 volts in other embodiments, at least 800 volts in yet another embodiment, and at least 1000 volts in yet another embodiment.

[0054] As shown in Figure 7, the electrical lead wire 646 can be electrically connected toward the proximal end portion 642 of the conductive element 632 or the long base surface 638 of the conductive element 632 to supply electrosurgical energy to the conductive element 632 to excite the electrode 630. The electrical lead wire 646 can be attached to the exposed portion 648 of the conductive element 632 by soldering or other means. To provide the exposed portion 648 of the conductive element 632 so that the electrical lead wire 646 can be attached thereto, the exposed portion 648 of the conductive element 632 can be masked during the deposition of the electrical insulating coating 634 so that the exposed portion 648 is not covered by the electrical insulating coating 634 and thus remains exposed so that the electrical lead wire 646 can be connected thereto. Alternatively, a slit can be made in the electrical insulating coating 634 to access the exposed portion 648 of the conductive element 632 and to allow the electrical lead wire 646 to be connected thereto. Other suitable mounting methods for the electrical lead wires 646 are also possible, including the use of intermediate structures such as tabs, contact pads, male / female electrical connectors, etc.

[0055] The RF electrosurgical energy delivered to electrode 630 may have an energy waveform with a maximum peak-to-peak voltage of approximately 1000V or less and a root mean square voltage (VRms) of approximately 360V or less. The waveform may or may not be pulsed. As described above, the supplied energy may generate plasma together with the configuration of electrode 630 to facilitate tissue cutting (or other appropriate tissue treatment).

[0056] Returning to Figure 6, a portion of the electrode 630 is engaged within the jaw member 120. The electrode 630 may be engaged within the jaw member 120 by capturing a portion of the electrode 630 with one or more overmoldings, such as the jaw housing 122 or a jaw insert (not shown), or by any other suitable method (for example, as described above with respect to the electrode 130 (Figure 4)). Regardless of how the electrode 630 is engaged within the jaw member 120, the electrode 630 is positioned to extend a height "H" from the tissue treatment surface 124 of the tissue treatment plate 123 of the jaw member 120 toward the jaw member 110. The height "H" is selected to balance limiting the height to which the electrode 630 extends from the tissue treatment surface 124, thereby preventing a reduction in the jaw gripping force applied to the tissue gripped between the tissue treatment surfaces 114 and 124 of the jaw members 110 and 120 (Figure 4), respectively, with the extension of the electrode 630 from the tissue treatment surface 124 to improve the tissue treatment performance using the electrode 630, such as tissue cutting. In some embodiments, the height "H" is approximately 0.010 inches to approximately 0.025 inches, and in other embodiments, it is approximately 0.015 inches to approximately 0.025 inches. In some embodiments, the height "H" varies along at least a portion of the length of the tissue treatment surface 124 of the tissue treatment plate 123 of the jaw member 120. For example, the height "H" may gradually decrease from distal to proximal, from proximal to distal, from one or both ends towards the center, or from the center towards one or both ends. This gradual reduction may follow an inclined plane, a curved section, one or more steps, or any other suitable configuration. In the gradual reduction configuration, the aforementioned height range may be the average height, maximum height, or minimum height.

[0057] Referring to Figure 8, the electrode 830 includes a conductive element 832 and an electrically insulating coating 834. The electrode 830 may include any of the features of electrode 130 (Figure 4), electrode 630 (Figures 6 and 7), any of the other electrodes detailed herein, or combinations thereof, unless otherwise contradictory. The electrode 830 includes a body portion 831a and a tapered distal portion 831b. The tapered distal portion 831b of the electrode 830 narrows in width from the body portion 831a to the distal tip 831c. The distal surface 844 of the conductive element 832 defines a substantially flat configuration having a width of about 0.0005 inches to about 0.0020 inches, and in other embodiments, about 0.0005 inches to about 0.0010 inches. In one embodiment, the distal surface 844 is omitted, and the conductive element 832 terminates at the edge of the distal tip 831c of the electrode 830. Such a narrow distal surface 844 (or distal edge) facilitates the performance of incision, fistula creation, and other electrical tissue treatments (e.g., amputation). Other configurations are also possible.

[0058] In one embodiment, the electrical insulating coating 834 surrounds the distal surface 844. Furthermore, the thickness of the electrical insulating coating 834 extending, for example, from the main body portion 831a to the distal tip 831c around the tapered distal portion 831b may be substantially constant or vary (for example, gradually decreasing, similar to the higher of the widths of the electrode 830).

[0059] Referring to Figures 9A and 9B, an end effector assembly 100 is shown, including an electrode 930 (similar to the one previously described with respect to electrode 630 (Figure 6)) that engages within the jaw member 120. Electrode 930 may include, to the extent that they do not contradict each other, any of the features of electrode 130 (Figure 4), electrode 630 (Figures 6 and 7), any other electrode detailed herein, or combinations thereof.

[0060] The electrode 930 is configured to improve the insulation of the coating and reduce current concentration, and includes a long upper range 936 (e.g., upper surface or upper edge), a long base range 938 (Figures 9C-9E, e.g., base surface or edge), a pair of long sides 940 (only one of which is shown in Figures 9A and 9B), a proximal range 942 (e.g., proximal surface or proximal edge), and a distal range 944 (e.g., distal surface or distal edge). A first transition 950 is defined between the long upper range 936 and the proximal range 942, and a second transition 960 is defined between the long upper range 936 and the distal range 944. The first and second transitions 950, 960 may be configured to be similar to or different from each other. In some embodiments, the first and second transitions 950, 960 define a radius of curvature. For example, in one embodiment, the first transition 950 may define a first radius of curvature, and the second transition 960 may define a second radius of curvature. The first radius of curvature is greater than the second range of curvature, and the first transition 950 may define a gentler, more curved, or more pronounced transition compared to the second transition 960. In one embodiment, the ratio of the first radius of curvature to the second radius of curvature may be, for example, about 1.5:1 to about 6:1, and in other embodiments, about 2:1 to about 4:1. The opposite configuration is also conceivable, such as a configuration in which the radii of curvature are substantially similar. Other suitable geometric shapes of the electrode 930 configuration are also conceivable to improve insulation by coating and reduce current concentration.

[0061] Rather than both transitions 950, 960 defining a radius of curvature, the first and second transitions 950, 960 may define inclined surfaces having similar or different lengths. For example, in one embodiment, the first transition 950 defines an inclined surface having a first length, and the second transition 960 defines a second, shorter inclined surface. The opposite configuration is also possible.

[0062] Furthermore, the first transition section 950 may define one of the first configurations, such as a radius of curvature or an inclined surface, and the second transition section 960 may define a second configuration different from the first configuration, such as the other of the radius of curvature or an inclined surface.

[0063] The above-described configuration of the first transition section 950 prevents mechanical cutting by the electrode 930 when the first and second jaw members 110 and 120 move from separated positions to close positions to grasp tissue between them, minimizing the concentration of energy on the first transition section 950 and preventing erosion in the first transition section 950. Additionally or alternatively, the above-described configuration of the second transition section 960 prevents mechanical cutting by the electrode 930, minimizes the concentration of energy on the second transition section 960 and prevents erosion in the second transition section 960. The positioning of the first and second transition sections 950 and 960 along the jaw member 120 can also take different configurations as described above. For example, the second transition section 960 is further from the pivot 103 than the first transition section 950, and faces away from the pivot 103, whereas the first transition section faces the pivot 103. Therefore, mechanical cutting in the first transition section 950 in proximity to the jaw members 110, 120 is at greater risk than in the second transition section 960, and thus the second transition section 960 does not need to be as gentle, curved, or prominent as the first transition section 950. As a result, the second transition section 960 can be configured (positioned) to facilitate tissue treatment, such as incision, fistula creation, etc. In other embodiments, the first and second transition sections 950, 960 can define the same configuration.

[0064] Referring to Figures 9C to 9E, the various transition section configurations 952, 954, and 956 according to this disclosure are shown. Although shown at the distal end of electrode 930, the transition section configurations 952, 954, and 956 are configured to be used as first and / or second transition sections 950 and 960 of electrode 930 at the proximal and / or distal ends of electrode 930 (Figures 9A and 9B).

[0065] Referring to Figure 9C, the transition section configuration 952 defines a convex curved surface extending between the long upper range 936 and the distal range 944 of the electrode 930, and thus the edges at the interface between the long upper range 936 and the distal range 944 are removed. The convex curved surface of the transition section configuration 952 extends in the width direction between the edges formed at the interface between the distal range 944 and each of the long sides 940. The convex curved surface of the transition section configuration 952 therefore increases in width as it extends from the long upper range 936 toward the distal range 944 toward the long base range 938, which is due to the electrode 930 increasing in width from the long upper range 936 toward the long base range 938.

[0066] As shown in Figure 9D, the transition section configuration 954 defines a convex curved surface extending between the long upper range 936 and the distal range 944 of the electrode 930, and thus the edges at the interface between the long upper range 936 and the distal range 944 are removed. Furthermore, a long transition section 955, for example, a rounded surface or other suitable transition section, is defined at the interface between the distal range 944 and each of the long side surfaces 940. The long transition section 955 is substantially constant along the height of the interface between the distal range 944 and each of the long side surfaces 940. In this configuration, the convex curved surface of the transition section configuration 954 does not increase in width as it extends from the long upper range 936 towards the distal range 944 and the long base range 938, but rather the convex curved surface of the transition section configuration 954 defines a relatively wide intermediate portion and a relatively narrow end portion.

[0067] Referring to Figure 9E, the configuration of the transition section 956 is similar to that of the transition section 954 (Figure 9D), except that the long transition section 957 defined at the interface between the distal range 944 and each of the long side surfaces 940 defines a radius of curvature that increases from the long upper range 936 toward the long base range 938, and thus defines the conical distal portion of the electrode 930.

[0068] In the above-described transition section configuration, mechanical cutting at electrode 930 and erosion at the interface between different surfaces of electrode 930 are prevented, thus improving performance. Other suitable transition section configurations are also conceivable.

[0069] Referring to Figures 10A and 10B, in one embodiment, as described above, the jaw member 110 may include an insulating member 1015 that extends longitudinally along at least a portion of the length of the tissue treatment surface 114, for example, within a channel defined longitudinally by the tissue treatment plate 113. The insulating member 1015 is positioned in close proximity to the jaw members 110 and 120, facing the electrode 130 of the jaw member 120. In one embodiment, the exposed surface of the insulating member 1015 is substantially coplanar with the tissue treatment surface 114. In another embodiment, the exposed surface of the insulating member 1015 protrudes from or is recessed relative to the tissue treatment surface 114. The extent to which the insulating member 1015 protrudes, is recessed, or is coplanar may vary along the length of the tissue treatment surface 114, as has already been described in detail with respect to the gradual decrease in height of the electrode 630 (Figure 6).

[0070] The insulating member 1015 is at least partially flexible, so that it is at least partially elastically compressed when the electrodes 130 are biased to contact the insulating member 1015 as the jaw members 110 and 120 are moved to a proximity position. The material and construction of the insulating member 1015 are selected to prevent the jaw gripping force applied to the tissue gripped between the tissue treatment surfaces 114 and 124 of the jaw members 110 and 120 from being reduced by the presence of the electrodes 130, and to facilitate the electrical disconnection of the tissue gripped between the jaw members 110 and 120 using the electrodes 130, by making it easier to pull the tissue placed between the electrodes 130 and the insulating member 1015. In some embodiments, the insulating member 1015 defines a durometer of about 55D to about 65D, and in other embodiments, about 58D to about 62D.

[0071] In one embodiment, the insulating member 1015 may define a rectangular prism shape defining a width "W3" and a depth "D". The width "W3" may define a maximum and / or average value of approximately 0.025 inches to approximately 0.095 inches in one embodiment, and approximately 0.030 inches to approximately 0.090 inches in other embodiments. The insulating member 1015 may define a width "W3" that gradually decreases in the proximal to distal direction. In such embodiments, for example, the maximum value of the width "W3" at the proximal end of the tissue treatment surface 114 may be approximately 0.075 inches to approximately 0.095 inches in other embodiments, and approximately 0.080 inches to approximately 0.090 inches in other embodiments. For example, the midpoint of the width "W3" at a midpoint along the tissue treatment surface 114 may be approximately 0.025 inches to approximately 0.045 inches in one embodiment, and approximately 0.030 inches to approximately 0.040 inches in other embodiments. For example, the minimum width "W3" at the distal end of the insulating member 1015 (where the opposing lateral edges of the insulating member 1015 form an angle of approximately 90 degrees) may be approximately 0.008 inches to approximately 0.018 inches, and in other embodiments, approximately 0.011 inches to approximately 0.015 inches. In some embodiments, for example, the difference between the maximum and minimum widths "W3" at the proximal and distal ends of the insulating member 1015 may be approximately 0.060 inches to approximately 0.085 inches. In some embodiments, the maximum width, minimum width and / or average width may be provided according to the aforementioned width ranges. Other suitable shapes and / or dimensions of the insulating member 1015 are also conceivable.

[0072] The depth "D" of the insulating member 1015 may be approximately 0.03 inches to approximately 0.05 inches, and in other embodiments, approximately 0.035 inches to approximately 0.045 inches. Larger depths "D" are also possible. Furthermore, in some embodiments, the depth "D" may gradually decrease from bottom to top (for example, towards the jaw member 120), and the depth "D" at the bottom of the insulating member 1015 may be approximately 0.005 to approximately 0.015 inches greater than, for example, the depth "D" at the top of the insulating member 1015. In such embodiments, the maximum depth, minimum depth and / or average depth may be provided according to the width range described above.

[0073] Aspects of this disclosure may be further described by reference to the following numbered paragraphs.

[0074] 1. An end effector assembly for a surgical instrument, comprising first and second jaw members that define tissue treatment surfaces, wherein at least one of the first or second jaw members is movable from a spaced-out position to a close position relative to the other jaw member in order to grasp tissue between the tissue treatment surfaces of the first and second jaw members, and an electrode supported by the second jaw member that extends longitudinally along at least a portion of the length of the second jaw member and protrudes from the second jaw member toward the first jaw member. An end effector assembly comprising a conductive element and an electrical insulating coating, wherein the conductive element comprises electrodes defining a long basal surface, a long tissue treatment surface opposite the long basal surface, first and second long sides, a proximal end portion and a distal end portion, and the electrical insulating coating covers the long basal surface, first and second long sides, the proximal end portion and the distal end portion, leaving the long tissue treatment surface exposed, and the conductive element is adapted to be connected to an RF energy source to excite the conductive element with radio frequency (RF) energy and concentrate the RF energy on the exposed long tissue treatment surface.

[0075] 2. The electrode defines a width of approximately 0.001 inches to approximately 0.002 inches on the long tissue treatment surface, as defined by the end effector assembly in paragraph 1.

[0076] 3. The thickness of the electrical insulating coating on each of the first and second long sides gradually decreases in the direction from the long base surface to the long tissue treatment surface, according to paragraph 1 or 2 of the end effector assembly.

[0077] 4. The maximum thickness of the electrical insulation coating on each of the first and second long sides is approximately 0.002 inches to approximately 0.006 inches, according to paragraph 3 of the end effector assembly.

[0078] 5. The electrode protrudes approximately 0.018 inches to 0.024 inches in height from the tissue treatment surface of the second jaw member toward the first jaw member, in an end effector assembly according to any of paragraphs 1 to 4.

[0079] 6. An end effector assembly according to any of paragraphs 1 to 5, in which the electrodes include an exposed portion of the conductive element at or toward the proximal end portion of the conductive element in order to connect electrical lead wires to the conductive element and provide RF energy to the conductive element.

[0080] 7. An end effector assembly according to any of paragraphs 1 to 6, comprising a main body portion and a tapered distal portion extending distally from the main body portion to the distal tip of the electrode.

[0081] 8. The electrode is an end-effector assembly according to any of paragraphs 1-7, wherein the width gradually decreases along at least a portion of the electrode's height, extending from a long basal surface to a long tissue treatment surface.

[0082] 9. The first and second long sides are angled inward toward each other to define a taper, as shown in paragraph 8, for the end effector assembly.

[0083] 10. An end effector assembly according to any of paragraphs 1 to 9, wherein the electrode defines a transition zone at the interface between the long tissue treatment surface and at least one of the proximal or distal end portions.

[0084] 11. An end effector assembly according to any of paragraphs 1 to 10, wherein the electrode defines a first transition at the interface between the long tissue treatment surface and the proximal end portion, and a second transition at the interface between the long tissue treatment surface and the distal end portion.

[0085] 12. The first transition is gentler than the second transition, according to paragraph 11, for the end effector assembly.

[0086] 13. An end effector assembly according to paragraph 11 or 12, wherein the first transition section defines a first radius of curvature, and the second transition section defines a second radius of curvature smaller than the first radius of curvature.

[0087] 14. An end effector assembly according to any of paragraphs 1 to 13, further comprising a flexible electrical insulating member disposed within a first jaw member and positioned to face an electrode in close proximity.

[0088] 15. The flexible electrical insulating material defines a durometer of approximately 55D to approximately 65D, as per paragraph 14 of the end effector assembly.

[0089] 16. The tissue treatment surfaces of the first and second jaw members are adapted to be connected to an RF energy source to excite the tissue treatment surfaces of the first and second jaw members with RF energy of different potentials, according to any of paragraphs 1 to 15 of the end effector assembly.

[0090] 17. An end effector assembly according to any of paragraphs 1 to 16, wherein one of the first jaw member or the second jaw member is fixed, and the other of the first jaw member or the second jaw member is movable relative to the fixed jaw member.

[0091] 18. The electrical insulating coating is glass, according to any of paragraphs 1-17 of the end effector assembly.

[0092] 19. An end effector assembly for a surgical instrument, comprising: first and second jaw members defining tissue treatment surfaces, at least one of the first or second jaw members being movable from a spaced-out position to a close position relative to the other jaw member for grasping tissue between the tissue treatment surfaces of the first and second jaw members; and an electrode supported by the second jaw member, extending longitudinally between the proximal and distal ends of the electrode along at least a portion of the length of the second jaw member and projecting from the second jaw member toward the first jaw member to a long upper range of the electrode, and adapted to be connected to an RF energy source for exciting the electrode with radio frequency (RF) energy, the electrode defining a first transition between the long upper range of the electrode and the proximal end of the electrode, and a second transition between the long upper range of the electrode and the distal end of the electrode.

[0093] 20. The first transition is gentler than the second transition, according to paragraph 19 of the end effector assembly.

[0094] 21. An end effector assembly according to paragraph 19 or 20, wherein the first transition section establishes a first radius of curvature, and the second transition section defines a second radius of curvature smaller than the first radius of curvature.

[0095] 22. The electrode comprises a conductive element and an electrical insulating coating, the electrical insulating coating substantially covering the conductive element except for portions along the long upper range of the electrode, thereby exposing the conductive element along the long upper range of the electrode, as per any of paragraphs 19-21 of the end effector assembly.

[0096] 23. The tissue treatment surfaces of the first and second jaw members are adapted to be connected to an RF energy source to excite the tissue treatment surfaces of the first and second jaw members with RF energy of different potentials, according to any of paragraphs 19-22 of the end effector assembly.

[0097] 24. An end effector assembly according to any of paragraphs 19 to 23, wherein one of the first jaw member or the second jaw member is fixed, and the other of the first jaw member or the second jaw member is movable relative to the fixed jaw member.

[0098] While several aspects of this disclosure are shown in the drawings, this disclosure is not intended to be limited thereto, as this disclosure is technically as broad as possible, and this specification should be read accordingly. Therefore, the above description should be interpreted not as an limitation, but merely as an example of a particular configuration. Those skilled in the art will likely conceive of other modifications within the scope and spirit of the claims accompanying this specification.

Claims

1. An end effector assembly for a surgical instrument, First and second jaw members defining tissue treatment surfaces, wherein at least one of the first jaw member or the second jaw member is movable from a spaced-out position to a close-to-the-other position in order to grasp tissue between the tissue treatment surfaces of the first and second jaw members, An electrode supported by the second jaw member, extending longitudinally along at least a portion of the length of the second jaw member and projecting from the second jaw member toward the first jaw member, comprising a conductive element and an electrically insulating coating, wherein the conductive element defines a long basal surface, a long tissue treatment surface opposite the long basal surface, first and second long sides, a proximal end portion and a distal end portion, and the electrode and Includes, The electrical insulating coating covers the long base surface, the first and second long sides, the proximal end portion, and the distal end portion, leaving the long tissue treatment surface exposed. An end effector assembly wherein the conductive element is adapted to be connected to an RF energy source to excite the conductive element with radio frequency (RF) energy and to concentrate the RF energy on the exposed long tissue treatment surface.

2. The end effector assembly according to claim 1, wherein the electrode defines a width of about 0.001 inches to about 0.002 inches on the long tissue treatment surface.

3. The end effector assembly according to claim 1 or 2, wherein the thickness of the electrical insulating coating on each of the first and second long sides is gradually reduced in the direction from the long base surface to the long tissue treatment surface.

4. The end effector assembly according to claim 3, wherein the maximum thickness of the electrical insulating coating on each of the first and second long sides is about 0.002 inches to about 0.006 inches.

5. The end effector assembly according to any one of claims 1 to 4, wherein the electrode protrudes from the tissue treatment surface of the second jaw member toward the first jaw member at a height of approximately 0.018 inches to approximately 0.024 inches.

6. The end effector assembly according to any one of claims 1 to 5, wherein the electrode includes an exposed portion of the conductive element at or toward the proximal end portion of the conductive element for connecting an electrical lead wire to the conductive element to provide the RF energy to the conductive element.

7. The end effector assembly according to any one of claims 1 to 6, wherein the electrode includes a main body portion and a tapered distal portion extending distally from the main body portion to the distal tip of the electrode.

8. The end effector assembly according to claim 7, wherein the first and second long sides are angled inward toward each other to define the taper.

9. The end effector assembly according to any one of claims 1 to 8, wherein the electrode defines a transition portion at the interface between the long tissue treatment surface and at least one of the proximal end portion or the distal end portion.

10. The end effector assembly according to any one of claims 1 to 9, wherein the electrode defines a first transition at the interface between the long tissue treatment surface and the proximal end portion, and a second transition at the interface between the long tissue treatment surface and the distal end portion, the first transition being gentler than the second transition.

11. The end effector assembly according to any one of claims 1 to 10, further comprising a flexible electrical insulating member disposed within the first jaw member and positioned to face the electrode at the proximity position.

12. The end effector assembly according to claim 11, wherein the flexible electrical insulating member defines a durometer of approximately 55D to approximately 65D.

13. The end effector assembly according to any one of claims 1 to 12, wherein the tissue treatment surfaces of the first and second jaw members are adapted to be connected to an RF energy source to excite the tissue treatment surfaces of the first and second jaw members with RF energy of different potentials.

14. The end effector assembly according to any one of claims 1 to 13, wherein one of the first jaw member or the second jaw member is fixed, and the other of the first jaw member or the second jaw member is movable relative to the fixed jaw member.

15. The end effector assembly according to any one of claims 1 to 14, wherein the electrical insulating coating is glass.

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