Surgical stapler and method of applying plastic staples to body tissue

• US 20020190093A1
• Filed: 07/25/2002
• Published: 12/19/2002
• Est. Priority Date: 06/30/1999
• Status: Active Grant

• Current Assignee: Tornier Incorporated
• Original Assignee: Axya Medical, Inc. (Tornier Incorporated)
• Inventors: Fenton, Paul V. Jr.
• Granted Patent: US 6,722,552 B2
• Time in Patent Office: Days
• US Class Current: 227/176.1
• 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 2017/00004 (bio)absorbable, (bio)resorbable, resorptive for implantable prostheses A61F2210/0004
• CPC Class Codes: A61B 2017/00504 Tissue welding
• CPC Class Codes: A61B 2017/07214 Stapler heads
• CPC Class Codes: A61B 2017/07278 characterised by its sled or its staple holder
• CPC Class Codes: Y10S 227/902 Surgical clips or staples

Abstract

A surgical stapler utilizing plastic staples and ultrasonic welding to secure the staples in body tissue. The stapler includes a pair of jaws movable between open and closed positions, a handle and trigger assembly for controlling operation of the jaws, and an elongated tubular structure connecting the handle and trigger assembly to the jaws. The stapler also includes an ejection assembly for ejecting at least one staple from one of the jaws against the other of the jaws. An anvil and a horn are positioned in the other of the jaws and are arranged to receive ends of the ejected staple such that the ends overlap between the anvil and the horn. The horn is for melting and bonding at least a portion of the overlapping ends of the staple upon being energized by a predetermined form of energy, and one of the anvil and the horn is movable from within the bonded staple to allow the jaws to be moved to an open position.

Claims

1. A surgical stapler comprising:

a pair of jaws movable between open and closed positions;

a handle and trigger assembly for controlling operation of the jaws;

an elongated tubular structure connecting the handle and trigger assembly to the jaws;

means for ejecting at least one staple from one of the jaws against the other of the jaws; and

an anvil and a horn in the other of the jaws arranged to receive ends of the ejected staple such that the ends overlap between the anvil and the horn, the horn for melting and bonding at least a portion of the overlapping ends of the staple upon being energized by a predetermined form of energy, and wherein one of the anvil and the horn is movable from within the bonded staple to allow the Jaws to be moved to an open position.

2. A surgical stapler according to claim 1, wherein the anvil is movable from within the bonded staple.

3. A surgical stapler according to claim 2, further including a rotatable shaft extending into the other of the jaws and operatively connected to the anvil such that rotation of the shaft slides the anvil from within the bonded staple.

4. A surgical stapler according to claim 1, wherein the predetermined form of energy comprises vibration energy.

5. A surgical stapler according to claim 1, further including at least one staple comprised of a thermoplastic material bondable by vibration energy.

6. A surgical stapler according to claim 5, wherein the staple is bio-absorbable.

7. A surgical stapler according to claim 1, wherein the stapler comprises a linear surgical stapler and the jaws are elongated and provide parallel rows of multiple bonded staples.

8. A surgical stapler according to claim 1, wherein the means for ejecting comprises:

a platform for ejecting the staple upon being moved towards the other of the jaws;

a cam for moving the platform towards the other of the jaws upon being rotated; and

a bar for rotating the cam upon being linearly moved.

9. A method of stapling body tissue comprising:

clamping body tissue between a pair of jaws;

ejecting at least one staple from one of the jaws, so that ends of the staple pass through the clamped tissue towards the other of the jaws;

receiving the ends of the ejected staple between an anvil and a horn in the other of the jaws such that the ends overlap;

energizing the horn with a predetermined form of energy so that the horn melts and bonds at least a portion of the overlapping ends of the staple; and

moving one of the anvil and the horn from between the bonded staple and the body tissue to allow the jaws to be opened.

10. A method of stapling according to claim 9, wherein the anvil is moved from within the bonded staple.

11. A method of stapling according to claim 9, wherein the predetermined form of energy comprises vibration energy.

12. A method of stapling according to claim 9, wherein the at least one staple comprises a plurality of staples ejected in a predetermined pattern.

13. A method of stapling according to claim 9, wherein the at least one staple comprises a plurality of staples ejected in two pairs of linear, parallel, staggered rows.

14. A method of stapling according to claim 13, further comprising cutting the body tissue between the two pairs of linear, parallel, staggered rows of staples.

16. A stapler according to claim 15, wherein the posts comprise first portions extending at angles relative to the parallel legs of the staple for allowing a base member of the staple to pass over the posts during ejection of the staple, and second portions extending from the first portions for maintaining the distal portions of the legs of the staple in parallel positions prior to ejection.

17. A surgical stapler according to claim 15, further including at least one staple comprising a single piece of resilient thermoplastic material having a base member and two legs extending from the base member to sharp ends and wherein the legs include overlapping distal portions for engaging body tissue.

18. A surgical stapler according to claim 17, wherein the staple is bio-absorbable.

19. A surgical stapler according to claim 15, wherein the stapler comprises a linear surgical stapler and the jaws are elongated and provide parallel rows of multiple staples.

20. A surgical stapler according to claim 15, wherein the means for ejecting comprises:

a platform for ejecting the staple upon being moved towards the other of the jaws;

a cam for moving the platform towards the other of the jaws upon being rotated; and

a bar for rotating the cam upon being linearly moved.

15. A stapler for ejecting at least one staple of resilient thermoplastic material having a base member and two legs extending from the base member to sharp ends and wherein the legs include overlapping distal portions for engaging body tissue, the stapler comprising:

a pair of jaws movable between open and closed positions;

a handle and trigger assembly for controlling operation of the jaws;

an elongated tubular structure connecting the handle and trigger assembly to the jaws;

means for ejecting at least a staple from one of the jaws against the other of the jaws; and

posts for holding normally overlapping distal portions of legs of the staple generally parallel until after the staple is ejected from the stapler.

21. A method of stapling body tissue comprising:

providing at least one staple comprising a single piece of resilient thermoplastic material having a base member and two legs extending from the base member to sharp ends, and wherein the legs include overlapping distal portions for securing the staple to body tissue;

clamping body tissue between a pair of jaws;

securing the base member of the staple in one of the jaws;

supporting the distal portions of the staple so that the distal portions are parallel and the sharp ends of the staple are directed towards the other of the jaws;

ejecting the staple from the jaw so that the ends of the staple pass through the clamped tissue towards the other of the jaws;

allowing the distal portions of the ejected staple to overlap; and

releasing the base member of the ejected staple.

22. A method of stapling according to claim 21, wherein the at least one staple comprises a plurality of staples ejected in two pairs of linear, parallel, staggered rows.

23. A method of stapling according to claim 22, further comprising cutting the body tissue between the two pairs of linear, parallel, staggered rows of staples.

25. A surgical stapler according to claim 24, further including a plurality of thermoplastic staples positioned on the platform with sharp ends of the staples directed towards the other of the jaws.

24. A surgical stapler comprising:

a pair of jaws movable between open and closed positions;

a handle and trigger assembly for controlling operation of the jaws;

an elongated tubular structure connecting the handle and trigger assembly to the jaws;

a platform for ejecting a plurality of staples from one of the jaws against the other of the jaws upon being moved towards the other of the jaws;

a cam for moving the platform towards the other of the jaws upon being rotated; and

a bar for rotating the cam upon being linearly moved by the handle and trigger assembly.