Implantable layers for a surgical instrument

• US 10,835,249 B2
• Filed: 08/17/2015
• Issued: 11/17/2020
• Est. Priority Date: 08/17/2015
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon, LLC (Johnson & Johnson)
• Inventors: Schellin, Emily A., Aronhalt, Taylor W., Barton, Trevor J., Miller, Michael J., Vendely, Michael J., Weaner, Lauren S., Widenhouse, Christopher W., Zeiner, Mark S., Hansen, Christian T., Shelton, IV, Frederick E.
• Primary Examiner(s): Desai, Hemant
• Assistant Examiner(s): Neacsu, Valentin
• Application Number:
  US14/827,856
• Publication Number:
  US 20170049444A1
• Time in Patent Office: 1,919 Days
• Field of Search: 2271761
• 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 an inner portion, an outer portion positioned at least partially around the inner portion, and a plurality of passages formed through the outer portion toward the inner portion. The implantable layer can be porous. An implantable layer can include an outer portion including a plurality of fibers. A method of forming an implantable layer for use with a surgical stapler is also disclosed. The method can include forming at least one passage through an outer surface toward an inner portion of the implantable layer.

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;

a dissolvable insert; and

a porous implantable layer, comprising;

an inner portion;

an outer portion positioned at least partially around said inner portion;

a plurality of pores embedded within said inner portion and said outer portion; and

a plurality of passages formed through said outer portion toward said inner portion as said dissolvable insert dissolves, wherein at least one of said passages extends entirely through said inner portion and said outer portion of said porous implantable layer, wherein some of said plurality of passages are formed before an implantation of said porous implantable layer, and wherein some of said plurality of passages are formed after the implantation of said porous implantable layer.

2. The staple cartridge of claim 1, wherein said plurality of passages comprises:

a first passage; and

a second passage angularly-oriented relative to said first passage.

3. The staple cartridge of claim 2, wherein said second passage traverses said first passage.

4. The staple cartridge of claim 1, wherein said outer portion comprises a tissue-contacting surface, and wherein at least one said passage extends through said tissue-contacting surface.

5. The staple cartridge of claim 1, wherein said porous implantable layer comprises a lyophilized foam material.

6. The staple cartridge of claim 5, wherein said lyophilized foam material comprises an open cellular structure.

7. A staple cartridge, comprising:

a cartridge body comprising a plurality of staple cavities;

a plurality of staples removably positioned in said staple cavities;

a dissolvable web; and

a porous implantable layer, comprising;

a plurality of pores;

an inner portion;

an outer portion positioned at least partially around said inner portion, wherein said plurality of pores is embedded within said inner portion and said outer portion; and

a plurality of passages formed through said outer portion toward said inner portion once said dissolvable web dissolves, wherein said plurality of passages transect at least one pore within said porous implantable layer, wherein some of said plurality of passages are formed before a placement of said porous implantable layer, and wherein some of said plurality of passages are formed after the placement of said porous implantable layer.

8. A staple cartridge, comprising:

a cartridge body comprising a plurality of staple cavities;

a plurality of staples removably positioned in said staple cavities;

a dissolvable insert; and

a porous implantable layer, comprising;

a plurality of pores;

an inner portion;

an outer portion positioned at least partially around said inner portion, wherein said plurality of pores is embedded within said inner portion and said outer portion; and

a plurality of tissue ingrowth passages formed through said outer portion and said inner portion as said dissolvable insert dissolves, wherein said tissue ingrowth passages are configured to intersect said plurality of pores, wherein some of said tissue ingrowth passages are formed before an implantation of said porous implantable layer, and wherein some of said plurality of passages are formed after the implantation of said porous implantable layer.

9. A staple cartridge for use with a surgical stapler, comprising:

a cartridge body comprising a plurality of staple cavities;

a plurality of staples removably positioned in said staple cavities;

a dissolvable mold; and

a porous implantable layer, comprising;

a plurality of pores;

an inner portion;

an outer portion positioned at least partially around said inner portion, wherein said plurality of pores is embedded within said inner portion and said outer portion; and

a plurality of passages formed through said outer portion toward said inner portion by said dissolvable mold as said dissolvable mold dissolves, wherein at least one of said plurality of passages is configured to be compressed during a firing motion of the surgical stapler and is configured to surround said plurality of pores of said porous implantable layer during said firing motion, wherein some of said plurality of passages are formed before a placement of said porous implantable layer, and wherein some of said plurality of passages are formed after the placement of said porous implantable layer.