Jaw assemblies for electrosurgical instruments and methods of manufacturing jaw assemblies

A jaw assembly, comprising:

• a first jaw member including a first arm and a first support base extending from the first arm, wherein a first hole and a first slot are defined through an inwardly facing surface of the first arm;
• a second jaw member including a second arm and a second support base extending from the second arm, wherein a second hole and a second slot are defined through the second arm;
• an electrically insulative material including a first portion fixedly disposed on the inwardly facing surface, a second portion extending continuously from the first portion at least partially into the first hole defined in the first arm and fixedly disposed on an inner surface disposed within and defining the first hole, and a third portion extending continuously from the first portion at least partially into the first slot defined in the first arm and fixedly disposed on an inner surface disposed within and defining the first slot;
• a first pin disposed at least partially through the first hole of the first arm and at least partially through the second hole of the second arm;
• and
• a second pin disposed at least partially through the first slot of the first arm and at least partially through the second slot of the second arm.

A jaw assembly, comprising:

• a first jaw member including an arm having first and second openings defined through an inwardly facing surface of the arm;
• a second jaw member;
• an electrically insulative material fixedly bonded to the arm, the electrically insulative material including a first portion fixedly disposed on the inwardly facing surface of the arm, a second portion extending continuously from the first portion into, and fixedly disposed within, the first opening, and a third portion extending continuously from the first portion into, and fixedly disposed within, the second opening;
• and
• first and second pins disposed at least partially through the first and second openings, respectively, of the arm to couple the first and second jaw members with one another,
• wherein the electrically insulative material electrically isolates the first pin from the arm, and wherein the electrically insulative material electrically isolates the second pin from the arm.