Method of manufacturing a flexible circuit electrode for electrosurgical instrument

Abstract

The disclosure provides a method of manufacturing a flexible circuit electrode assembly and an apparatus manufactured by said method. According to the method, an electrically conductive sheet is laminated to an electrically insulative sheet. An electrode is formed on the electrically conductive sheet. An electrically insulative layer is formed on a tissue contacting surface of the electrode. The individual electrodes are separated from the laminated electrically insulative sheet and the electrically conductive sheet. In another method, a flexible circuit is vacuum formed to create a desired profile. The vacuum formed flexible circuit is trimmed. The trimmed vacuum formed flexible circuit is attached to a jaw member of a clamp jaw assembly.

1 .- 25 . (canceled) 
     
     
         26 . A method of manufacturing a flexible circuit electrode assembly, the method comprising:
 vacuum forming a flexible circuit;   trimming the vacuum formed flexible circuit; and   attaching the trimmed vacuum formed flexible circuit to a jaw member of a clamp jaw assembly.   
     
     
         27 . The method of  claim 26 , further comprising:
 placing the vacuum formed flexible circuit in a molding tool; and   molding a substrate to support a profile of the vacuum formed flexible circuit.   
     
     
         28 . The method of  claim 27 , wherein attaching the trimmed vacuum formed flexible circuit to the jaw member of the clamp jaw assembly comprises molding the trimmed vacuum formed flexible circuit over the jaw member. 
     
     
         29 . The method of  claim 27 , wherein attaching the trimmed vacuum formed flexible circuit to a jaw member of a clamp jaw assembly comprises attaching the trimmed vacuum formed flexible circuit to a jaw member having a complementary jaw member profile to the profile of the vacuum formed flexible circuit. 
     
     
         30 . The method of  claim 26 , wherein attaching the trimmed vacuum formed flexible circuit to the jaw member of the clamp jaw assembly comprises adhering the trimmed vacuum formed flexible circuit to the jaw member with adhesive. 
     
     
         31 . The method of  claim 26 , wherein attaching the trimmed vacuum formed flexible circuit to the jaw member of the clamp jaw assembly comprises bonding the trimmed vacuum formed flexible circuit to the jaw member with an overmold. 
     
     
         32 . The method of  claim 26 , wherein attaching the trimmed vacuum formed flexible circuit to a jaw member of a clamp jaw assembly comprises attaching the trimmed vacuum formed flexible circuit to an upper jaw member of the clamp jaw assembly. 
     
     
         33 . The method of  claim 26 , wherein attaching the trimmed vacuum formed flexible circuit to a jaw member of a clamp jaw assembly comprises attaching the trimmed vacuum formed flexible circuit to a lower jaw member of the clamp jaw assembly.