IMPLANTABLE LAYERS FOR A SURGICAL INSTRUMENT

• US 20170049448A1
• Filed: 08/17/2015
• Published: 02/23/2017
• Est. Priority Date: 08/17/2015
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon Endo-Surgery LLC (Johnson & Johnson)
• Inventors: Sikes, Courtney Jason, Widenhouse, Christopher W., Miller, Michael J., Timmer, Mark D., Aronhalt, Taylor W., Barton, Trevor J., Schellin, Emily A., Vendely, Michael J., Weaner, Lauren S.
• Granted Patent: US 11,058,425 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: A61B 17/064 Surgical staples, i.e. penetrating the tissue
• CPC Class Codes: A61B 17/068 Surgical staplers , e.g. containing multiple staples or clampsstaplers containing only one staple A61B17/10; magazines or containers for staples A61B17/105; for performing anastomosis A61B17/115; staplers in general B25C5/00
• CPC Class Codes: A61B 17/072 for applying a row of staples in a single action , e.g. the staples being applied simultaneously
• CPC Class Codes: A61B 17/07292 Reinforcements for staple line, e.g. pledgets
• CPC Class Codes: A61B 17/105 Wound clamp magazines for packaging sharps A61B50/3001
• CPC Class Codes: A61B 2017/00004 (bio)absorbable, (bio)resorbable, resorptive for implantable prostheses A61F2210/0004
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: A61B 2017/00884 enhancing wound closure
• CPC Class Codes: A61B 2017/00893 pharmaceutically effective
• CPC Class Codes: A61B 2017/00938 hydrophobic
• CPC Class Codes: A61B 2017/00942 hydrophilic
• CPC Class Codes: A61B 2017/00964 composite
• CPC Class Codes: A61B 2017/07271 characterised by its cartridge
• CPC Class Codes: A61B 2090/0816 for preventing adhesion
• CPC Class Codes: A61L 31/146 Porous materials, e.g. foams or sponges
• CPC Class Codes: A61L 31/148 Materials at least partially resorbable by the body
• CPC Class Codes: A61L 31/16 Biologically active materials, e.g. therapeutic substances A61L31/047 takes precedence
• CPC Class Codes: B29C 35/16 Cooling cooling extruded material B29C48/911; cooling preforms for blow moulding B29C49/6427; cooling blown articles B29C49/66; cooling tyres during post cure inflation B29D30/0643
• CPC Class Codes: B29C 44/3415 Heating or cooling
• CPC Class Codes: B29C 44/5627 by mechanical deformation, e.g. crushing, embossing, stretching
• CPC Class Codes: B29C 70/70 : Completely encapsulating inserts B29C70/86 takes precedence
• CPC Class Codes: B29K 2105/04 : cellular or porous
• CPC Class Codes: B29L 2031/7546 : Surgical equipment

Abstract

A staple cartridge is disclosed. The staple cartridge can include a cartridge body, a plurality of staples, and an implantable layer. The implantable layer can include a piece of lyophilized foam and a plurality of fibers at least partially embedded in the piece of lyophilized foam. The implantable layer can further include a plurality of pores defined in piece of lyophilized foam, and a plurality of pockets, wherein a pocket at least partially surrounds a fiber. A method of forming an implantable layer for use with a surgical staple is also disclosed. The method can comprise obtaining a mold comprising a cavity, placing a plurality of fibers in the cavity of the mold, dispensing a solution into the cavity around the fibers, and lyophilizing the solution in the cavity.

Claims

1. A staple cartridge, comprising:

a cartridge body comprising a plurality of staple cavities;

a plurality of staples removably positioned in said staple cavities; and

an implantable layer, comprising;

a piece of lyophilized foam; and

a plurality of fibers at least partially embedded in said piece of lyophilized foam.

2. The staple cartridge of claim 1, wherein said implantable layer comprises:

a plurality of pores defined in said piece of lyophilized foam; and

a plurality of pockets, wherein a said pocket at least partially surrounds a said fiber.

3. The staple cartridge of claim 2, wherein said plurality of pockets comprises:

a first pocket; and

a second pocket transecting said first pocket.

4. The staple cartridge of claim 1, wherein said fibers are randomly oriented throughout said piece of lyophilized foam.

5. The staple cartridge of claim 1, wherein said fibers comprise an ordered matrix of fibers in said piece of lyophilized foam.

6. The staple cartridge of claim 1, wherein said fibers comprise:

a first fiber comprising a first geometry; and

a second fiber comprising a second geometry, wherein said second geometry is different than said first geometry.

7. The staple cartridge of claim 1, wherein said fibers comprise:

a first fiber comprising a first material; and

a second fiber comprising a second material, wherein said second material is different than said first material.

8. The staple cartridge of claim 1, wherein the foam of said piece of lyophilized foam encases and adheres to said fibers forming a plurality of foam-encased fibers.

9. The staple cartridge of claim 8, wherein said implantable layer comprises:

a plurality of pores defined in said piece of lyophilized foam; and

a plurality of pockets, wherein each said pocket is intermediate at least two foam-encased fibers.

10. The staple cartridge of claim 1, wherein said piece of lyophilized foam comprises a first absorption rate, wherein at least one said fiber comprise a second absorption rate, and wherein said second absorption rate is different than said first absorption rate.

11. The staple cartridge of claim 1, wherein said implantable layer comprises a tissue-contacting surface, and wherein at least one said fiber extends to said tissue-contacting surface.

12. A method of forming an implantable layer for use with a surgical stapler, the method comprising:

obtaining a mold comprising a cavity;

placing a plurality of fibers in the cavity of the mold;

dispensing a solution into the cavity around the fibers; and

lyophilizing the solution in the cavity.

13. The method of claim 12, wherein placing the plurality of fibers in the cavity comprises placing a woven mesh of fibers into the cavity.

14. The method of claim 12, wherein placing the plurality of fibers in the cavity comprises placing a plurality of loose fibers into the cavity.

15. The method of claim 12, wherein the solution comprises dioxane and water.

16. The method of claim 12, wherein the solution comprises at least one medicament.

17. A staple cartridge, comprising:

a cartridge body comprising a plurality of staple cavities;

a plurality of staples removably positioned in said staple cavities; and

an implantable layer, comprising;

a porous foam comprising a plurality of pores; and

a plurality of pockets defined between portions of said porous foam.

18. The staple cartridge of claim 17, wherein said implantable layer further comprises a plurality of fibers at least partially embedded in said porous foam.

19. The staple cartridge of claim 18, wherein said pockets at least partially surround said fibers.

20. The staple cartridge of claim 18, wherein said foam encases said fibers.