Implantable layer comprising plastically deformed fibers

• US 10,327,777 B2
• Filed: 09/30/2015
• Issued: 06/25/2019
• Est. Priority Date: 09/30/2015
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon, LLC (Johnson & Johnson)
• Inventors: Harris, Jason L., Shelton, IV, Frederick E., Vendely, Michael J.
• Primary Examiner(s): Chukwurah, Nathaniel C
• Application Number:
  US14/871,036
• Publication Number:
  US 20170086835A1
• Time in Patent Office: 1,364 Days
• Field of Search: 2271761, 2271751, 2271781, 2271801, 227 19
• CPC Class Codes: A61B 17/00491 Surgical glue applicators surgical adhesives A61L24/00; two-component delivery syringes A61M5/19
• CPC Class Codes: A61B 17/0644 penetrating the tissue, deformable to closed position
• 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 17/07207 the staples being applied sequentially
• CPC Class Codes: A61B 17/07292 Reinforcements for staple line, e.g. pledgets
• CPC Class Codes: A61B 17/08 Wound clamps or clips, i.e. not or only partly penetrating the tissue suture bridges A61B17/0466; Devices for bringing together the edges of a wound
• CPC Class Codes: A61B 17/105 Wound clamp magazines for packaging sharps A61B50/3001
• CPC Class Codes: A61B 17/32 Surgical cutting instruments A61B18/042 takes precedence; suture cutters A61B17/0467; instruments for ligaturing or cutting A61B17/128; instruments for rupturing the amniotic membrane A61B17/4208; specially adapted knives for eye surgery A61F9/0133
• CPC Class Codes: A61B 2017/00004 (bio)absorbable, (bio)resorbable, resorptive for implantable prostheses A61F2210/0004
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: A61B 2017/00831 Material properties
• CPC Class Codes: A61B 2017/00862 elastic or resilient for sutures A61B2017/0618
• CPC Class Codes: A61B 2017/00893 pharmaceutically effective
• CPC Class Codes: A61B 2017/00955 thermoplastic
• CPC Class Codes: A61B 2017/00964 composite
• CPC Class Codes: A61B 2017/07214 Stapler heads
• CPC Class Codes: A61B 2017/07221 curved
• CPC Class Codes: A61B 2017/07228 Arrangement of the staples
• CPC Class Codes: A61B 2017/07235 : containing different staples, e.g. staples of different shapes, sizes or materials
• CPC Class Codes: A61B 2017/07242 : achieving different staple heights during the same shot, e.g. using an anvil anvil having different heights or staples of different sizes
• CPC Class Codes: A61B 2017/0725 : with settable gap between anvil and cartridge, e.g. for different staple heights at different shots
• CPC Class Codes: A61B 2017/07257 : characterised by its anvil
• CPC Class Codes: A61B 2017/07271 : characterised by its cartridge
• CPC Class Codes: A61B 2017/07278 : characterised by its sled or its staple holder
• CPC Class Codes: A61B 2017/07285 : characterised by its cutter
• CPC Class Codes: A61L 17/105 : Polyesters not covered by A61L17/12
• CPC Class Codes: A61L 17/12 : Homopolymers or copolymers of glycolic acid or lactic acid
• CPC Class Codes: A61L 2420/02 : Methods for coating medical devices
• CPC Class Codes: B05D 1/007 : using an electrostatic field B05D1/02 - B05D1/16 take precedence
• CPC Class Codes: B05D 1/30 : performed by gravity only, i.e. flow coating
• CPC Class Codes: B29C 44/3453 : Feeding the blowing agent to solid plastic material
• CPC Class Codes: B29C 44/358 : Foamed of foamable fibres
• CPC Class Codes: B29C 48/0012 : combined with shaping by internal pressure generated in the material, e.g. foaming
• CPC Class Codes: B29C 48/0022 : combined with cutting
• CPC Class Codes: B29C 48/05 : Filamentary, e.g. strands
• CPC Class Codes: B29C 48/16 : Articles comprising two or more components, e.g. co-extruded layers
• CPC Class Codes: B29L 2031/753 : Medical equipment; Accessories therefor bloodbags, medical bags B29L2031/7148; artificial eyes B29L2011/0008
• CPC Class Codes: B29L 2031/7546 : Surgical equipment
• CPC Class Codes: B32B 2250/03 : 3 layers
• CPC Class Codes: B32B 2250/40 : Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2307/50 : having particular mechanical properties
• CPC Class Codes: B32B 2307/54 : Yield strength; Tensile strength
• CPC Class Codes: B32B 2307/72 : Density
• CPC Class Codes: B32B 2307/732 : Dimensional properties
• CPC Class Codes: B32B 2307/736 : Shrinkable
• CPC Class Codes: B32B 2535/00 : Medical equipment, e.g. bandage, prostheses, catheter medical patches B32B2556/00
• CPC Class Codes: B32B 3/02 : characterised by features of form at particular places, e.g. in edge regions non-uniform thickness B32B3/263
• CPC Class Codes: B32B 3/08 : characterised by added members at particular parts layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18
• CPC Class Codes: B32B 3/20 : of hollow pieces, e.g. tubes; of pieces with channels or cavities
• CPC Class Codes: B32B 3/266 : characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/026 : Knitted fabric
• CPC Class Codes: B32B 5/10 : characterised by a fibrous or filamentary layer reinforced with filaments
• CPC Class Codes: B32B 5/12 : characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/245 : another layer next to it being a foam layer
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 7/05 : the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection using interposed adhesives or bonding materials applied in spaced arrangements B32B7/14
• CPC Class Codes: D01D 5/0023 : the material being a polymer melt
• CPC Class Codes: D01D 5/18 : by means of rotating spinnerets
• CPC Class Codes: D04H 1/565 : by melt-blowing
• CPC Class Codes: D10B 2331/041 : derived from hydroxy-carboxylic acids, e.g. lactones
• CPC Class Codes: D10B 2509/00 : Medical; Hygiene

Abstract

A surgical stapling instrument including staples and an implantable layer is disclosed. The implantable layer comprises fibers which have undergone a kinking process. The kinked fibers, once interwoven together, create a resilient body that can dynamically adapt to the thickness of the tissue captured within the staples.

Claims

1. A staple cartridge assembly, comprising:

a cartridge body comprising a deck;

a plurality of staples;

an implantable layer positioned over said deck, wherein said implantable layer comprises a plurality of interwoven fibers, wherein each said fiber comprises a strand having a kinked configuration, wherein said kinked fibers are interwoven into a first woven zone and a second woven zone, wherein said first woven zone has a first density and said second woven zone has a second density, and wherein said first density is different than said second density and;

an anchor extending over said implantable layer to releasably hold said implantable layer to said cartridge body, wherein said second density is greater than said first density, and wherein said anchor is aligned with said second woven zone.

2. The staple cartridge assembly of claim 1, wherein said cartridge body further comprises a longitudinal slot, wherein said longitudinal slot is configured to receive a cutting member, and wherein the cutting member is configured to transect said anchor as the cutting member moves within said longitudinal slot.

3. The staple cartridge assembly of claim 2, further comprising a proximal end, wherein said anchor and said second woven zone are adjacent said proximal end.

4. The staple cartridge assembly of claim 1, wherein said cartridge body comprises a first longitudinal row of staple cavities and a second longitudinal row of staple cavities, and wherein said first woven zone is aligned with said first longitudinal row of staple cavities and said second woven zone is aligned with said second longitudinal row of staple cavities.

5. A staple cartridge assembly, comprising:

a cartridge body comprising a deck;

a plurality of staples; and

an implantable layer positioned over said deck, wherein said implantable layer comprises a plurality of interwoven fibers, and wherein each said fiber comprises a strand having a kinked configuration,

wherein said kinked fibers are interwoven into a first woven zone and a second woven zone, wherein said first woven zone has a first density and said second woven zone has a second density, wherein said first density is different than said second density,

wherein said staple cartridge assembly further comprises an anchor extending over said implantable layer to releasably hold said implantable layer to said cartridge body, wherein said second density is greater than said first density, wherein said anchor is aligned with said second woven zone,

wherein said cartridge body further comprises a longitudinal slot, wherein said longitudinal slot is configured to receive a cutting member, wherein the cutting member is configured to transect said anchor as the cutting member moves within said longitudinal slot,

wherein said staple cartridge assembly further comprises a proximal end, wherein said anchor and said second woven zone are adjacent said proximal end, and

wherein said staple cartridge assembly further comprises;

a distal end opposite said proximal end;

a distal anchor extending over said implantable layer to releasably hold said implantable layer to said cartridge body; and

a third woven zone defined in said implantable layer having a third density which is greater than said first density, wherein said distal anchor is aligned with said third woven zone.

6. A staple cartridge assembly, comprising:

a cartridge body comprising a deck;

a plurality of staples; and

an implantable layer positioned over said deck, wherein said implantable layer comprises a plurality of interwoven fibers, wherein each said fiber comprises a strand having a kinked configuration, wherein said kinked fibers are interwoven into a first woven zone and a second woven zone, wherein said first woven zone has a first modulus of elasticity and said second woven zone has a second modulus of elasticity, and wherein said first modulus of elasticity is different than said second modulus of elasticity.

7. The staple cartridge assembly of claim 6, wherein said implantable layer comprises a perimeter, wherein said second modulus of elasticity is greater than said first modulus of elasticity, and wherein said second woven zone is defined along said perimeter.

8. The staple cartridge assembly of claim 6, wherein said cartridge body comprises a longitudinal slot configured to receive a cutting portion, wherein said first modulus of elasticity is less than said second modulus of elasticity, and wherein said first woven zone is aligned with said longitudinal slot.

9. The staple cartridge assembly of claim 6, further comprising an anchor extending over said implantable layer to releasably hold said implantable layer to said cartridge body, wherein said second modulus of elasticity is greater than said first modulus of elasticity, and wherein said anchor is aligned with said second woven zone.

10. The staple cartridge assembly of claim 9, wherein said cartridge body further comprises a longitudinal slot, wherein said longitudinal slot is configured to receive a cutting member, and wherein the cutting member is configured to transect said anchor as the cutting member moves within said longitudinal slot.

11. The staple cartridge assembly of claim 10, further comprising a proximal end, wherein said anchor and said second woven zone are adjacent said proximal end.

12. The staple cartridge assembly of claim 11, further comprising:

a distal end opposite said proximal end;

a distal anchor extending over said implantable layer to releasably hold said implantable layer to said cartridge body; and

a third woven zone defined in said implantable layer having a third modulus of elasticity which is greater than said first modulus of elasticity, wherein said distal anchor is aligned with said third woven zone.

13. The staple cartridge assembly of claim 6, wherein said cartridge body comprises a first longitudinal row of staple cavities and a second longitudinal row of staple cavities, and wherein said first woven zone is aligned with said first longitudinal row of staple cavities and said second woven zone is aligned with said second longitudinal row of staple cavities.