Compressible adjunct with crossing spacer fibers

• US 10,433,846 B2
• Filed: 09/30/2015
• Issued: 10/08/2019
• Est. Priority Date: 09/30/2015
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon, LLC (Johnson & Johnson)
• Inventors: Vendely, Michael J., Latham, Helen S., Shelton, IV, Frederick E., Harris, Jason L., Scheib, Charles J., Goldrein, Howell T., Moir, Robert S., Consonni, Sofia Maria, Akram, Ismail, Easter, Ashley D.
• Primary Examiner(s): Chukwurah, Nathaniel C
• Application Number:
  US14/871,071
• Publication Number:
  US 20170086837A1
• Time in Patent Office: 1,469 Days
• Field of Search: 2271761, 2271751, 227 19, 2271801
• 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 staple cartridge assembly for use with a surgical stapling instrument includes a staple cartridge including a plurality of staples and a cartridge deck. The staple cartridge assembly also includes a compressible adjunct positionable against the cartridge deck, wherein the staples are deployable into tissue captured against the compressible adjunct, and wherein the compressible adjunct comprises a first biocompatible layer comprising a first portion, a second biocompatible layer comprising a second portion, and crossed spacer fibers extending between the first portion and the second portion.

Claims

1. A staple cartridge assembly for use with a surgical stapling instrument, wherein the staple cartridge assembly comprises:

a staple cartridge, comprising;

a plurality of staples; and

a cartridge deck; and

a compressible adjunct positionable against the cartridge deck, wherein the staples are deployable into tissue captured against the compressible adjunct, and wherein the compressible adjunct comprises;

a first biocompatible layer comprising a first portion;

a second biocompatible layer comprising a second portion; and

crossed spacer fibers extending between the first portion and the second portion, wherein each crossed spacer fiber comprises a first end and a second end, and wherein the first end is at least partially embedded in the first portion and the second end is at least partially embedded in the second portion.

2. A staple cartridge assembly for use with a surgical stapling instrument, wherein the staple cartridge assembly comprises:

a staple cartridge, comprising;

a plurality of staples; and

a cartridge deck; and

a compressible adjunct positionable against the cartridge deck, wherein the staples are deployable into tissue captured against the compressible adjunct, and wherein the compressible adjunct comprises;

a tissue-facing layer, comprising;

a first bonding node; and

a second bonding node arranged in a first row with the first bonding node;

a deck-facing layer, wherein the tissue-facing layer is spaced apart from the deck-facing layer, and wherein the deck-facing layer comprises;

a third bonding node vertically aligned with the first bonding node; and

a fourth bonding node vertically aligned with the second bonding node, wherein the fourth bonding node is arranged in a second row with the third bonding node;

a first spacer fiber extending between the first bonding node and the fourth bonding node, wherein the first spacer fiber comprises a first end and a second end, and wherein the first end is at least partially embedded within the tissue-facing layer and the second end is at least partially embedded within the deck-facing layer; and

a second spacer fiber extending between the second bonding node and the third bonding node, wherein the first spacer fiber crosses the second spacer fiber, wherein the second spacer fiber comprises a third end and a fourth end, and wherein the third end is at least partially embedded within the tissue-facing layer and the fourth end is at least partially embedded within the deck-facing layer.

3. The staple cartridge assembly of claim 2, wherein the first row is parallel to the second row.

4. The staple cartridge assembly of claim 3, wherein the first row further comprises a fifth bonding node between the first bonding node and the second bonding node.

5. The staple cartridge assembly of claim 4, further comprising a first fiber portion interconnecting the first bonding node and the fifth bonding node.

6. The staple cartridge assembly of claim 5, further comprising a second fiber portion interconnecting the second bonding node and the fifth bonding node.

7. The staple cartridge assembly of claim 6, wherein the second row further comprises a sixth bonding node between the third bonding node and the fourth bonding node.

8. The staple cartridge assembly of claim 7, further comprising a third fiber portion interconnecting the third bonding node and the sixth bonding node.

9. The staple cartridge assembly of claim 8, further comprising a fourth fiber portion interconnecting the fourth bonding node and the sixth bonding node.

10. The staple cartridge assembly of claim 9, wherein the fifth bonding node is vertically aligned with the sixth bonding node.

11. A staple cartridge assembly for use with a surgical stapling instrument, wherein the staple cartridge assembly comprises:

a staple cartridge, comprising;

a plurality of staples; and

a cartridge deck defining a proximal end and a distal end; and

a compressible adjunct positionable against the cartridge deck, wherein the staples are deployable into tissue captured against the compressible adjunct, and wherein the compressible adjunct comprises;

a tissue-facing layer, comprising;

a first bonding node; and

a second bonding node arranged in a first row with the first bonding node;

a deck-facing layer, wherein the tissue-facing layer is spaced apart from the deck-facing layer, and wherein the deck-facing layer comprises;

a third bonding node; and

a fourth bonding node, wherein the fourth bonding node is arranged in a second row with the third bonding node;

a first spacer fiber extending from the first bonding node to the third bonding node, wherein the first spacer fiber comprises a first end and a second end, and wherein the first end is at least partially embedded within the tissue-facing layer and the second end is at least partially embedded within the deck-facing layer;

a second spacer fiber extending from the first bonding node toward the deck-facing layer in a proximal direction;

a third spacer fiber extending from the first bonding node toward the deck-facing layer in a distal direction; and

a fourth spacer fiber extending from the second bonding node to the fourth bonding node, wherein the fourth spacer fiber comprises a third end and a fourth end, and wherein the third end is at least partially embedded within the tissue-facing layer and the fourth end is at least partially embedded within the deck-facing layer.

12. The staple cartridge assembly of claim 11, further comprising a fifth spacer fiber extending from the second bonding node toward the deck-facing layer in the proximal direction.

13. The staple cartridge assembly of claim 12, further comprising a sixth spacer fiber extending from the second bonding node toward the deck-facing layer in the distal direction.

14. The staple cartridge assembly of claim 13, wherein the sixth spacer fiber crosses the second spacer fiber.

15. The staple cartridge assembly of claim 14, further comprising a seventh spacer fiber extending from the first bonding node to the third bonding node.

16. The staple cartridge assembly of claim 15, further comprising an eighth spacer fiber extending from the second bonding node to the fourth bonding node.

17. The staple cartridge assembly of claim 16, wherein the first bonding node is vertically aligned with the third bonding node.

18. The staple cartridge assembly of claim 17, wherein the second bonding node is vertically aligned with the fourth bonding node.

19. A staple cartridge assembly for use with a surgical stapling instrument, wherein the staple cartridge assembly comprises:

a staple cartridge, comprising;

a plurality of staples; and

a cartridge deck defining a proximal end and a distal end; and

a compressible adjunct positionable against the cartridge deck, wherein the staples are deployable into tissue captured against the compressible adjunct, and wherein the compressible adjunct comprises;

a tissue-facing layer;

a deck-facing layer, wherein the tissue-facing layer is spaced apart from the deck-facing layer, and wherein the deck-facing layer comprises;

an outer surface; and

an inner surface;

a first spacer fiber extending from the tissue-facing layer toward the inner surface;

a second spacer fiber extending from the tissue-facing layer toward the inner surface, wherein the first spacer fiber and the second spacer fiber extend through the deck-facing layer; and

a loop defined by the first spacer fiber and the second spacer fiber on the outer surface.

20. The staple cartridge assembly of claim 19, wherein the first spacer fiber and the second spacer fiber intersect at the deck-facing layer.

21. The staple cartridge assembly of claim 20, further comprising a third spacer fiber extending from the tissue-facing layer, wherein the third spacer fiber intersects the first spacer fiber and the second spacer fiber at the deck-facing layer.

22. A compressible adjunct positionable against a cartridge of a staple cartridge, wherein the staple cartridge comprises a plurality of staples deployable into tissue captured against the compressible adjunct, and wherein the compressible adjunct comprises:

a first biocompatible layer comprising a first portion;

a second biocompatible layer comprising a second portion; and

crossed spacer fibers extending between the first portion and the second portion, wherein each crossed spacer fiber comprises a first end and a second end, and wherein the first end is at least partially embedded in the first portion and the second end is at least partially embedded in the second portion.