Jaw structure with distal post for electrosurgical instruments

A method for making an end effector of an electrosurgical instrument, comprising:

• providing a first jaw of the end effector, wherein the first jaw comprises a first energy delivery surface, a first proximal end, and a first distal end;
• providing a second jaw of the end effector, wherein the second jaw comprises a second energy delivery surface, a second proximal end, a second distal end, and an electrically conductive member protruding from the second jaw in proximity to the second distal end;
• positioning a spacer comprising a predetermined thickness between the first jaw and the second jaw in proximity to the first proximal end and the second proximal end;
• moving at least one of the first jaw and the second jaw toward the other one of the first jaw and the second jaw until the movement of the at least one of the first jaw and the second jaw is limited by the spacer such that a proximal gap distance is defined between the first and second energy delivery surfaces which substantially equals the predetermined thickness of the spacer, and until the electrically conductive member is in contact with the first energy delivery surface such that a distal gap distance is defined by the electrically conductive member between the first and second energy delivery surfaces, wherein the proximal gap distance is different than the distal gap distance;
• positioning at least one pivot in proximity to the first and second proximal ends;
• fixing the at least one pivot to one of the first jaw and the second jaw;
• and
• removing the spacer.

A method for assembling an end effector of an electrosurgical instrument, comprising:

• providing a first jaw of the end effector, wherein the first jaw comprises a first energy delivery surface, a first proximal end, and a first distal end;
• providing a second jaw of the end effector, wherein the second jaw comprises a second energy delivery surface, a second proximal end, a second distal end, and an electrically conductive member protruding from the second jaw in proximity to the second distal end;
• sandwiching a spacer comprising a predetermined height between the first jaw and the second jaw to set a minimum gap between the first energy delivery surface and the second energy delivery surface in proximity to the first and second proximal ends while the electrically conductive member is in contact with the first energy delivery surface, wherein the predetermined height of the spacer is different than a height of the electrically conductive member;
• positioning at least one pivot in proximity to the first and second proximal ends;
• fixing the at least one pivot to one of the first jaw and the second jaw;
• and
• removing the spacer.