MULTI-LAYER SURGICAL STAPLER BUTTRESS ASSEMBLY

• US 20170119392A1
• Filed: 10/29/2015
• Published: 05/04/2017
• Est. Priority Date: 10/29/2015
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon Endo-Surgery LLC (Johnson & Johnson)
• Inventors: Shelton, IV, Frederick E., Harris, Jason L., Vendely, Michael J.
• Granted Patent: US 10,441,286 B2
• Time in Patent Office: Days
• 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 17/07207 the staples being applied sequentially
• 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 2017/00398 using powered actuators, e.g. stepper motors, solenoids
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: A61B 2017/00951 adhesive

Abstract

A surgical stapler end effector assembly includes a staple cartridge, an end effector, and a buttress assembly. The cartridge included a plurality of staples and a deck. The cartridge is operable to drive the staples through the deck. The anvil includes an underside having a staple forming surface configured to receive staples driven through the deck. The buttress assembly is sized and configured to be coupled with the deck of the staple cartridge or the underside of the anvil. The buttress assembly includes a buttress body, a first adhesive layer, and a second adhesive layer. The first and second adhesive layers are formed of different materials. The first adhesive layer is laid over the buttress body. The second adhesive layer is laid over the first adhesive layer such that the first adhesive layer is interposed between the second adhesive layer and the buttress body.

Claims

1. A surgical stapler end effector assembly, the end effector assembly comprising:

(a) a staple cartridge, wherein the staple cartridge comprises;

(i) a plurality of staples, and

(ii) a deck, wherein the staple cartridge is operable to drive the staples through the deck;

(b) an anvil, wherein the anvil is movable from an open position toward the staple cartridge to reach a closed position, wherein the anvil includes an underside having a staple forming surface configured to receive staples driven through the deck; and

(c) a buttress assembly, wherein the buttress assembly is sized and configured to be coupled with the deck of the staple cartridge or the underside of the anvil, wherein the buttress assembly comprises;

(i) a buttress body,

(ii) a first adhesive layer laid over the buttress body, wherein the first adhesive layer is formed of a first adhesive material, and

(iii) a second adhesive layer laid over the first adhesive layer, such that the first adhesive layer is interposed between the second adhesive layer and the buttress body, wherein the second adhesive layer is formed of a second adhesive material, wherein the second adhesive material is different from the first adhesive material.

2. The end effector assembly of claim 1, wherein the second adhesive layer is positioned to face the underside of the anvil.

3. The end effector assembly of claim 1, wherein the second adhesive layer is positioned to face the deck of the staple cartridge.

4. The end effector assembly of claim 1, wherein the first adhesive material has greater pliability than the second adhesive material.

5. The end effector assembly of claim 1, wherein the first adhesive material has greater tackiness than the second adhesive material.

6. The end effector assembly of claim 1, wherein the second adhesive material is more resistant to moisture than the first adhesive material.

7. The end effector assembly of claim 1, wherein the second adhesive material is more resistant to temperature than the first adhesive material.

8. The end effector assembly of claim 1, wherein the first and second adhesive layers are configured to cooperate to adhere the buttress body to either the deck of the staple cartridge or the underside of the anvil.

9. The end effector assembly of claim 1, wherein the first and second adhesive materials have different molecular weight blends.

10. The end effector assembly of claim 1, wherein the first and second adhesive materials have different cross-linking properties.

11. The end effector assembly of claim 1, wherein the first and second adhesive materials are selected from different families of adhesive materials.

12. The end effector assembly of claim 1, wherein the second adhesive material comprises regions contacting the buttress body.

13. The end effector assembly of claim 12, wherein the buttress body and the regions of the second adhesive material contacting the buttress body cooperate to encapsulate the first adhesive material.

14. The end effector assembly of claim 12, wherein the first adhesive layer has a length, wherein the regions of the second adhesive material contacting the buttress body extend along the full length of the first adhesive layer.

15. The end effector assembly of claim 12, wherein the first adhesive layer has a width, wherein the regions of the second adhesive material contacting the buttress body extend along the full width of the first adhesive layer.

16. The end effector assembly of claim 1, wherein the buttress assembly is adhered to the underside of the anvil, wherein the staples are positioned to be driven through the buttress assembly.

17. A surgical stapler end effector assembly, the end effector assembly comprising:

(a) a lower jaw;

(b) an anvil, wherein the anvil is movable from an open position toward the lower jaw to reach a closed position, wherein the anvil includes an underside having a staple forming surface; and

(c) a buttress assembly secured to the underside of the anvil, wherein the buttress assembly comprises;

(i) a buttress body,

(ii) a first adhesive layer laid over the buttress body, wherein the first adhesive layer is formed of a first adhesive material, and

(iii) a second adhesive layer laid over the first adhesive layer, such that the first adhesive layer is interposed between the second adhesive layer and the buttress body, wherein the second adhesive layer is formed of a second adhesive material, wherein the second adhesive material is different from the first adhesive material

18. A method of making a buttress assembly for use with a surgical stapler end effector, wherein the end effector comprises a staple cartridge and an anvil, wherein the staple cartridge comprises a plurality of staples and a deck, wherein the staple cartridge is operable to drive the staples through the deck, wherein the anvil is movable from an open position toward the staple cartridge to reach a closed position, wherein the anvil includes an underside having a staple forming surface configured to receive staples driven through the deck, the method comprising:

(a) applying a first adhesive layer to a buttress body, wherein the buttress body is sized and configured to fit on the deck of the staple cartridge or the underside of the anvil, wherein the first adhesive layer comprises a first adhesive material; and

(b) applying a second adhesive layer to the first adhesive layer, such that the first adhesive layer is interposed between the second adhesive layer and the buttress body, wherein the second adhesive layer is formed of a second adhesive material, wherein the second adhesive material is different from the first adhesive material.

19. The method of claim 18, wherein the act of applying the second adhesive layer to the first adhesive layer comprises spraying the second adhesive layer over the first adhesive layer.

20. The method of claim 18, further comprising pressing the buttress assembly against the underside of the anvil, wherein one or both of the first or second adhesive materials secures the buttress assembly to the underside of the anvil in response to pressing the buttress assembly against the underside of the anvil.