Surgical Stapler Buttress Adhesive Profile Interchangeability
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Solution Overview
Problem
Surgical stapling instruments often face issues with staples pulling through tissue, leading to tissue tearing and reduced mechanical fastening effectiveness, particularly at the site of staple application.
Innovation Solution
A buttress applier cartridge system that includes a buttress assembly with a three-layer polymer construction and adhesive layers, which is releasably retained on a surgical instrument to provide structural support and prevent staple pull-through, featuring a pre-formed slit for knife cutting and a design that ensures secure attachment and separation from the tissue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If surgical staplers are used to fasten tissue layers, then tissue layers can be sealed and severed, but staples may pull through the tissue leading to tissue tearing and reduced mechanical fastening effectiveness
Solution Approach 1:
The patent applies composite materials by combining a first material layer (e.g., rigid or semi-rigid polymer) with a second material layer (e.g., soft polymer or foam) in the buttress assembly. The first layer provides structural support to prevent staple pull-through, while the second layer provides compliance and protects tissue from damage. This composite structure resolves the contradiction by simultaneously improving mechanical fastening strength and preventing staple penetration through tissue.
Solution Approach 2:
The buttress assembly applies local quality by positioning the first material layer primarily at the staple line region where mechanical support is most needed to prevent pull-through, while the second material layer is distributed to provide overall tissue protection and compliance. This localized differentiation of material properties optimizes both staple retention and tissue protection without requiring uniform thickening throughout the entire assembly.
2Strength
If a buttress assembly with multiple material layers is used to prevent staple pull-through, then mechanical fastening is improved, but the device complexity increases
Solution Approach 1:
The patent merges multiple functional layers into a single integrated buttress assembly that combines the first material layer for structural support, the second material layer for tissue protection, and adhesive layers for attachment. This unified structure simplifies the overall device by eliminating the need for separate components to perform these functions, reducing device complexity while maintaining the mechanical fastening improvements.
Solution Approach 2:
The buttress assembly achieves multi-functionality by incorporating layers that simultaneously provide structural support, tissue protection, adhesive attachment, and compliance. The first material layer serves both as a staple-reinforcing element and as part of the overall structural framework, while the second layer provides both cushioning and conformability to tissue contours. This multi-functional design reduces the number of separate components needed.
3Reliability
If the buttress assembly is designed for secure attachment to the surgical instrument, then reliability of stapling is improved, but ease of operation for attachment and separation is reduced
Solution Approach 1:
The adhesive layers are pre-applied to the buttress assembly during manufacturing, eliminating the need for clinicians to apply adhesive in the operating room. The adhesive is formulated to provide secure attachment when the buttress is positioned against the tissue, ensuring reliability without requiring complex attachment procedures. This preliminary preparation simplifies the surgical workflow while maintaining secure attachment.
Solution Approach 2:
The adhesive layers utilize parameter changes in their bonding characteristics - they may be designed with temperature-sensitive or pressure-sensitive adhesive properties that activate under specific conditions during attachment. This allows for secure bonding during the stapling procedure while enabling controlled separation after use, balancing attachment security with ease of removal without requiring complex mechanical fastening systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively reduces the risk of tissue tearing and enhances the mechanical fastening of staples by providing structural reinforcement, ensuring secure attachment and easy separation of the buttress assembly during stapling and cutting processes.
Implementation Method 1
a buttress assembly with a three-layer polymer construction and adhesive layers
Data Source
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AI summary
A surgical system and related methods includes a buttress applier cartridge, a first buttress assembly, and a second buttress assembly. The buttress applier cartridge has a housing and a platform. The first and second buttress assemblies respectively includes first and second buttresses and first and second adhesive layers thereon. The first adhesive layer is parallel to the first buttress and defines a first adhesive pattern having a first outer adhesive profile. The second adhesive layer is parallel to the second buttress and defines a second adhesive pattern having a second outer adhesive profile. The exposed second outer adhesive profile in the transverse direction is the same as the exposed first outer adhesive profile in an opposite transverse direction such that the first and second buttress assemblies are interchangeable with the first and second portions of the end effector of the surgical instrument.