WO2024176101A1

WO2024176101A1 - Anvil buttress attachment for surgical stapling apparatus

Info

Publication number: WO2024176101A1
Application number: PCT/IB2024/051600
Authority: WO
Inventors: Jacob C. Baril; Matthew J. Chowaniec
Original assignee: Covidien LP
Current assignee: Covidien LP
Priority date: 2023-02-24
Filing date: 2024-02-20
Publication date: 2024-08-29
Anticipated expiration: 2025-08-24

Abstract

An anvil buttress loading system includes an anvil assembly, an anvil buttress loading tool, and an anvil buttress. The anvil assembly includes a barb or barb assembly coupled to the anvil assembly. The anvil buttress is releasably retained on the anvil buttress loading tool and transferable from the anvil buttress loading tool to the anvil assembly such that the buttress body is secured to the barb or barb assembly of the anvil assembly.

Description

ANVIL BUTTRESS ATTACHMENT FOR SURGICAL STAPLING APPARATUS

[0001] This Application claims priority from U.S. Provisional Patent Application 63/447,928, filed 24 February 2023, the entire content of which is incorporated herein by reference.

FIELD

[0002] This disclosure relates generally to surgical devices, and more particularly, to anvil buttress attachment systems, assemblies, and methods for releasably securing an anvil buttress to a surgical stapling apparatus.

BACKGROUND

[0003] Surgical stapling apparatus are employed by surgeons to sequentially or simultaneously apply one or more rows of fasteners, e.g., staples or two-part fasteners, to body tissue for the purpose of joining segments of body tissue together. Such apparatus generally include a pair of jaws or finger-like structures between which the body tissue to be joined is placed. When the surgical stapling apparatus is actuated, or “fired”, longitudinally moving firing bars contact staple drive members in one of the jaws. The staple drive members push the surgical staples through the body tissue and into an anvil in the opposite jaw which forms the staples. If body tissue is to be removed or separated, a knife blade can be provided in the jaws of the apparatus to cut the body tissue between the lines of staples.

[0004] Surgical supports, e.g., meshes or buttress materials, may be used in combination with surgical stapling apparatus to bridge, repair, and/or reinforce tissue defects within a patient. A clinician may manually attach buttress material(s) to the surgical stapling apparatus in the operating room during a surgical procedure, or utilize a surgical stapling apparatus including the buttress material(s) pre-installed thereon. The buttress material reinforces the staple or suture line as well as covers the juncture of the tissues to reduce leakage prior to healing. SUMMARY

[0005] This disclosure relates to anvil side buttress material attachment onto a jaw assembly of a surgical stapling apparatus. Anvil buttress attachment systems, assemblies, and methods of this disclosure are designed to provide robust, releasable mechanical attachment of an anvil buttress to an anvil assembly, and to make anvil side buttress material attachment in the operating room a simple, straightforward, and cost-effective procedure.

[0006] In aspects, the anvil buttress attachment systems, assemblies, and methods of this disclosure include a proximal buttress constraint on an anvil assembly that provides single direction loading (e.g., proximal loading) of an anvil buttress on the anvil assembly. The proximal buttress constraint may include barbs or teeth designed to allow the anvil buttress to pass proximally without resistance past the barbs or teeth via an anvil buttress loading tool and, upon removal of the anvil buttress loading tool, the barbs or teeth engage and trap the anvil buttress onto the anvil assembly thereby preventing or minimizing loosening or shifting of the anvil buttress from the anvil assembly prior to firing a surgical stapling apparatus in which the loaded anvil assembly is utilized.

[0007] In one aspect, this disclosure provides an anvil buttress loading system including an anvil assembly, an anvil buttress loading tool, and an anvil buttress. The anvil assembly includes a tissue facing surface and a barb coupled to the tissue facing surface. The barb is movable relative to the tissue facing surface. The anvil buttress loading tool includes a carrier having a support plate, and the anvil buttress includes a buttress body. The anvil buttress is releasably retained on the anvil buttress loading tool with the buttress body positioned on the support plate. The anvil buttress is transferable from the anvil buttress loading tool to the anvil assembly such that the buttress body is secured to the barb. The barb is movable towards the tissue facing surface of the anvil assembly when advancing the anvil buttress loading tool onto the anvil assembly so that the barb does not engage the anvil buttress. The barb is engaged with the anvil buttress when separating the anvil buttress loading tool from the anvil assembly.

[0008] The barb may extend proximally at an acute angle relative to the tissue facing surface of the anvil assembly. The barb may be one of a plurality of barbs. In some aspects, the plurality of barbs is disposed on opposed sides of a central longitudinal slot defined through tissue facing surface of the anvil assembly. In certain aspects, the plurality of barbs is positioned proximal to staple forming pockets defined in the tissue facing surface of the anvil assembly.

[0009] The tissue facing surface of the anvil assembly may include a groove defined therein, and the anvil assembly may further include a barb plate disposed within the groove. The barb plate includes the barb.

[0010] The anvil buttress may include a proximal portion having proximal openings defined therethrough, and the anvil buttress loading tool may include proximal protrusions extending from the support plate. The proximal protrusions may be engaged with the proximal openings when the anvil buttress is releasably retained on the anvil buttress loading tool.

[0011] The anvil assembly may include an anvil tip and the anvil buttress may include a distal window defined through a distal portion of the anvil buttress. The distal window may be configured to engage the anvil tip to retain the distal portion of the anvil buttress on the anvil assembly.

[0012] The anvil buttress loading tool may further include a cover disposed over the support plate of the carrier. In some aspects, the cover includes a distal protrusion extending outwardly from an outer surface of the cover and a distal opening disposed proximal to the distal protrusion. The anvil buttress may include a distal tab, and the distal tab may extend through the distal opening and engage the distal protrusion when the anvil buttress is releasably retained on the anvil buttress loading tool.

[0013] The anvil buttress may include a diagonal slit extending therethrough. The diagonal slit may be configured to receive the barb and to extend over a central longitudinal slot defined through the tissue facing surface of the anvil assembly when the anvil buttress is transferred to the anvil assembly.

[0014] In another aspect, this disclosure provides an anvil buttress loading system including an anvil assembly, an anvil buttress loading tool, and an anvil buttress. The anvil assembly includes a tissue facing surface having a groove defined therein. The anvil assembly includes a barb assembly having a barb plate including teeth disposed at a proximal end of the barb plate. The teeth are biased to extend into the groove. Application of a force against the barb plate moves the teeth out of the groove . The anvil buttress loading tool includes a carrier having a support plate, and the anvil buttress includes a buttress body. The anvil buttress is releasably retained on the anvil buttress loading tool with the buttress body positioned on the support plate. The anvil buttress is transferable from the anvil buttress loading tool to the anvil assembly such that the buttress body is captured between the teeth and the tissue facing surface of the anvil assembly. The barb plate is movable out of the groove by the force provided by the support plate when advancing the anvil buttress loading tool onto the anvil assembly and back into the groove when separating the anvil buttress loading tool from the anvil assembly.

[0015] The barb plate may have a ramped surface extending proximally into the groove of the anvil plate. The barb assembly may include a base having a first segment secured to a side wall of the anvil assembly and a second segment extending transversely across the tissue facing surface of the anvil assembly. In some aspects, the barb plate extends proximally from the second segment of the base of the barb assembly. In some aspects, the barb plate is pivotable relative to the base. In some aspects, the second segment is positioned distal to the groove and, in some other aspects, the second segment extends partially over the groove.

[0016] The barb assembly may be one of two barb assemblies disposed on opposed sides of a central longitudinal slot defined through the tissue facing surface of the anvil assembly.

[0017] In yet another aspect, this disclosure provides an anvil assembly including an anvil plate and a barb assembly. The anvil plate includes a tissue facing surface having a groove defined therein. The barb assembly has a barb plate including teeth disposed at a proximal end of the barb plate. The teeth are biased to extend into the groove. Application of a proximal force against the barb plate moves the teeth out of the groove.

[0018] The details of one or more aspects of the disclosure are set forth in the accompanying drawings and the description below. Other aspects, as well as features, objects, and advantages of the aspects described in this disclosure will be apparent from the description and drawings, and from the claims. BRIEF DESCRIPTION OF DRAWINGS

[0019] FIG. 1 is a perspective view of a surgical stapling apparatus in accordance with aspects of the disclosure;

[0020] FIG. 2 is a close-up view of the area of detail 2 indicated in FIG. 1, showing a tool assembly of the surgical stapling apparatus of FIG. 1 ;

[0021] FIG. 3 is a bottom, perspective view of an anvil assembly of the tool assembly of FIG. 2;

[0022] FIG. 4 is a close-up view of the area of detail indicated in FIG. 3;

[0023] FIG. 5 is a perspective view, with parts separated, of the anvil assembly and barb plates in accordance with aspects of the disclosure;

[0024] FIG. 6 is a perspective view, with parts separated, of an anvil buttress attachment assembly including an anvil buttress and an anvil buttress loading tool suitable for use with the anvil assembly of FIG. 3 in accordance with aspects of the disclosure;

[0025] FIGS. 7 and 8 are side, perspective views of the anvil buttress loading tool of FIG. 6 loaded with the anvil buttress;

[0026] FIG. 9 is a bottom, perspective view of the anvil buttress loading tool of FIG. 6 loaded with the anvil buttress;

[0027] FIG. 10 is a bottom view of the anvil buttress attachment assembly of FIG. 9, shown with the anvil assembly of FIG. 3 partially loaded into the anvil buttress loading tool;

[0028] FIG. 11 is a cross-sectional view of the anvil buttress attachment assembly and the anvil assembly of FIG. 10, taken along section line 11-11 of FIG. 10;

[0029] FIG. 12 is a close-up view of the area of detail indicated in FIG. 11;

[0030] FIG. 13 is a cross-sectional view of the anvil buttress attachment assembly of

FIG. 10, shown with the anvil assembly fully loaded into the anvil buttress loading tool;

[0031] FIG. 14 is a close-up view of the area of detail indicated in FIG. 13; [0032] FIG. 15 is a botom, perspective view of the anvil assembly of FIG. 13, shown loaded with the anvil butress after removal of the anvil assembly from the anvil butress loading tool;

[0033] FIG. 16 is a botom, perspective view of a proximal portion of an anvil assembly in accordance with another aspect of the disclosure;

[0034] FIG. 17 is a botom, perspective view of a proximal portion of an anvil assembly in accordance with yet another aspect of the disclosure;

[0035] FIG. 18 is a top view of a proximal portion of a surgical butress in accordance with another aspect of the disclosure;

[0036] FIG. 19 is a botom, perspective view of an anvil assembly in accordance with another aspect of the disclosure;

[0037] FIG. 20 is a botom view of a proximal end portion of the anvil assembly of FIG. 19;

[0038] FIG. 21 is a close-up view of the area of detail indicated in FIG. 19;

[0039] FIG. 22 is a cross-sectional view of the anvil assembly of FIG. 21, taken along section line 22-22 of FIG. 21 ;

[0040] FIG. 23 is a perspective view of an anvil butress attachment assembly including an anvil butress and an anvil butress loading tool in accordance with another aspect of the disclosure;

[0041] FIG. 24 is a botom view of the anvil butress of FIG. 23 loaded onto the anvil butress loading tool of FIG. 23, and partially loaded onto the anvil assembly of FIG. 19;

[0042] FIG. 25 is a cross-sectional view of the anvil butress loading assembly and the anvil assembly of FIG. 24, taken along section line 25-25 of FIG. 24;

[0043] FIG. 26 is a cross-sectional view of the anvil butress loading assembly and the anvil assembly of FIG. 25, shown with the anvil butress loading tool removed and the anvil butress retained on the anvil assembly; and [0044] FIG. 27 is a bottom view of the anvil assembly of FIG. 26 loaded with the anvil buttress.

DETAILED DESCRIPTION

[0045] Aspects of this disclosure will now be described in detail with reference to the drawing figures wherein like reference numerals identify similar or identical elements. Throughout this description, the term “proximal” refers to a portion of a structure, or component thereof, that is closer to a user, and the term “distal” refers to a portion of the structure, or component thereof, that is farther from the user. It should be understood that various components of this disclosure, such as those numbered in the 100 series or plainly numbered, correspond to components of the disclosure similarly numbered in the 200 series or prime numbered, such that redundant explanation of similar components need not be repeated herein.

[0046] Referring now to FIG. 1, an exemplary surgical stapling apparatus or surgical stapler 100 is shown for use in stapling tissue in accordance with aspects of this disclosure. The surgical stapling apparatus 100 generally includes a handle assembly 110, an elongate tubular body 120 extending distally from the handle assembly 110, and a loading unit 130 extending distally from the elongate tubular body 120. The surgical stapling apparatus 100 may be manually driven, partially powered, or fully powered (e.g., by an electric motor) and includes actuators 112 (e.g., finger-actuated control buttons, knobs, toggles, slides, interfaces, and the like) for activating various functions of the surgical stapling apparatus 100.

[0047] For a detailed description of the structure and function of exemplary surgical stapling apparatus suitable for use with aspects of this disclosure, including exemplar manual and powered surgical devices, reference may be made to U.S. Patent Nos. 5,762,256, 5,865,361, and 10,426,468, the entire contents of each of which are incorporated herein by reference. It should be appreciated that principles of this disclosure are equally applicable to surgical stapling apparatus having other configurations such as, for example, the types described in U.S. Patent Nos. 5,810,240 and 7,334,717, the entire contents of each of which are incorporated herein by reference. Accordingly, it should be understood that a variety of surgical stapling apparatus may be utilized with aspects of the disclosure. For example, laparoscopic or open staplers, such as, for example, GIA™, Endo GIA™, TA™, and Endo TA™ staplers and/or linear and radial reloads with, for example, Tri-Staple™ technology, available through Medtronic (North Haven, CT) may be utilized with aspects of this disclosure.

[0048] The loading unit 130 may also be configured for use with other surgical apparatus, such as robotic devices/instruments. For a detailed description of the structure and function of exemplary robotic systems, reference may be made to U.S. Patent Nos. 6,231,565 and 8,828,023, the entire contents of each of which are incorporated herein by reference.

[0049] The loading unit 130 includes a tool or jaw assembly 132 including first and second jaw members 132a, 132b. One or both of the first and second jaw members 132a, 132b is pivotable with respect to the other such that the tool assembly 132 is movable between an open position in which the first and second jaw members 132a, 132b are spaced apart with respect to each other, and a closed position in which the first and second jaw members 132a, 132b are substantially adjacent each other.

[0050] The loading unit 130 is a disposable loading unit (“DLU”) that is releasably secured to the elongated tubular body 120 and thus, replaceable with a new loading unit 130. The loading unit 130 may be a single use loading unit (“SULU”) that is used one time and then replaced to facilitate multiples uses of the surgical stapling apparatus 100 on a patient. For example, during a surgical procedure, the surgical stapling apparatus 100 can be used to staple and cut tissue, and the entire SULU is replaced after each staple and cut operation of the surgical stapling apparatus 100. The loading unit 130 may be a multi-use loading unit (“MULU”) that is re-useable a predetermined number of times. For example, during a surgical procedure, the surgical stapling apparatus 100 can be used to staple and cut tissue, and a reload assembly (e.g., a staple cartridge 142, see FIG. 2) of the MULU is replaced after each staple and cut operation of the surgical stapling apparatus 100 a predetermined number of times before the entire MULU is replaced. Alternatively, the loading unit 130 may be permanently affixed to the elongated tubular body 120.

[0051] As shown in FIG. 2, the first jaw member 132a of the tool assembly 132 includes a staple cartridge assembly 140 and the second jaw member 132b of the tool assembly 132 includes an anvil assembly 150. The staple cartridge assembly 140 includes a staple cartridge 142 that may be removably and/or replaceably attached to a cartridge carrier 144 of the staple cartridge assembly 140. The staple cartridge 142 may be any staple cartridge used in surgical stapling apparatus within the purview of those skilled in the art that includes a plurality of fasteners (e.g., staples) releasably retained therein.

[0052] As shown in FIGS. 2 and 3, the anvil assembly 150 includes an anvil plate 152, an anvil cover 154 secured over the anvil plate 152, and an anvil tip 156 extending distally from the anvil plate 152. The anvil plate 152 has a central longitudinal slot 151 formed therein that extends along a central longitudinal axis “X” of the anvil assembly 150. The anvil plate 152 also includes a plurality of staple forming pockets or cavities 153 defined in an inward or tissue facing surface 158 thereof.

[0053] The anvil plate 152 includes barbs 160 coupled to the tissue facing surface 158 of the anvil plate 152 proximal to the staple forming pockets 153. The barbs 160 are disposed on opposed sides of the central longitudinal slot 151. Specifically, as seen in FIG. 4, a first set of barbs 160a is disposed on a first side of the central longitudinal slot 151 and a second set of barbs 160b is disposed on a second side of the central longitudinal slot 151. The barbs 160 are arranged in longitudinal rows that extend parallel to the central longitudinal axis “X” defined through the anvil assembly 150. Each of the barbs 160 extends outwardly from the anvil plate 152 at a proximally-extending angle (e.g., an acute angle) with respect to the tissue facing surface 158. Each of the barbs 160 has a generally triangular shape including a base 162 tapering to a tip 164. The base 162 is coupled to the tissue facing surface 158 of the anvil plate 152 and configured to enable the barb 160 to flex relative to anvil plate 152, and the tip 164 is configured to penetrate an anvil buttress 170 (FIG. 6) to secure a proximal portion 170a of the anvil buttress 170 to the anvil assembly 150, as described in further detail below. The barbs 160 may be formed from a metal or plastic that is flexible to allow for movement of the barbs 160 during loading of the anvil buttress 170 onto the anvil assembly 150, but is sufficiently strong to pierce and retain the anvil buttress 170 on the anvil assembly 150 once loaded.

[0054] As shown in FIG. 5, the anvil plate 152 further includes pockets 155 recessed in the tissue facing surface 158 on each side of the central longitudinal slot 151 that are sized and shaped to receive barb plates 165 therein. Each of the barb plates 165 includes a plate body 166 configured for positioning within the pocket 155 defined in the tissue facing surface 158 of the anvil plate 152. The plate body 166 is sized and shaped so that a tissue facing side 167 of the barb plate 165 is flush with the tissue facing surface 158 of the anvil plate when positioned within the pocket 155. The barb plates 165 are secured within the respective pockets 155 by, e.g., welding, using adhesives, interference fittings, among other securement methods within the purview of those skilled in the art. The barbs 160 are integrally formed with, or otherwise secured, to the tissue facing side 167 of the barb plate 165 and extend outwardly therefrom. In aspects, the barbs 160 are stamped from the plate body 166.

[0055] Turning now to FIG. 6, an anvil buttress 170 (also referred to herein generally as a surgical buttress) and an anvil buttress loading tool 180 is shown. The anvil buttress 170 includes a buttress body 172 having a generally rectangular shape that is sized to cover the tissue facing surface 158 (FIG. 3) ofthe anvil assembly 150. A proximal tab 174 extends proximally from a proximal end 172a of the buttress body 172. The proximal tab 174 includes proximal openings 175 defined therethrough. The proximal openings 175 are sized and shaped to receive proximal protrusions 188 of the anvil buttress loading tool 180 therethrough.

[0056] In some aspects, a plurality of perforations, a frangible joint, or the like is disposed between the proximal tab 174 and the buttress body 172 to aid in separating the proximal tab 174 from the buttress body 172 after the anvil buttress 170 is retained by the barbs 160 (FIG. 3) on the anvil assembly 150 during loading of the anvil buttress 170 onto the anvil assembly 150. In aspects, the proximal tab 174 is bent at an angle relative to the buttress body 172 to aid in releasably attaching the proximal tab 174 to the anvil buttress loading tool 180. In some aspects, the proximal tab 174 is stiffened to retain the bend relative to the buttress body 172 and, in other aspects, the proximal tab 174 is bent relative to the buttress body 172 by engagement of the proximal protrusions 188 of the anvil buttress loading tool 180 through the proximal openings 175 of the proximal tab 174.

[0057] A distal flap 176 extends distally from a distal end 172b of the buttress body 172 and defines a distal window 177 therethrough. The distal window 177 is sized and shaped to receive and frictionally engage the anvil tip 156 (FIG. 2) of the anvil assembly 150. A distal tab 178 extends distally from the distal flap 176 and defines a distal opening 179 therethrough. The distal opening 179 is sized and shaped to releasably engage a distal protrusion 190 of the anvil buttress loading tool 180.

[0058] In some aspects, a plurality of perforations, a frangible joint, or the like is disposed between the distal flap 176 and the distal tab 178 to aid in separating the distal tab 178 from the anvil buttress 170 after loading the anvil buttress 170 onto the anvil assembly 150 (FIG. 3). In aspects, the distal flap 176 and/or the distal tab 178 are bent at angles relative to the buttress body 172 to aid in securing the distal flap 176 onto the anvil tip 156 (FIG. 3) and/or the distal tab 178 to the anvil buttress loading tool 180. In some aspects, the distal flap 176 and/or the distal tab 178 are stiffened to retain their bend relative to the buttress body 172 and, in other aspects, the distal flap 176 and/or the distal tab 178 are bent relative to the buttress body 172 by engagement of the distal tab 178 with the distal protrusion 190 of the anvil buttress loading tool 180.

[0059] The anvil buttress 170 is fabricated from biocompatible materials which are bioabsorbable or non-absorbable, natural or synthetic materials. It should be understood that a single or combination of natural, synthetic, bioabsorbable, and/or non-bioabsorbable materials may be used to form the anvil buttress 170. In aspects, the anvil buttress 170 is formed from a single sheet of material that is cut to shape. In other aspects, the anvil buttress 170 is formed from a plurality of sheets of material, that are fabricated from the same or different materials, and/or the components (e.g., the buttress body, the tabs, the flap, etc.) of the anvil buttress 170 are formed from the same or different materials that are attached to one another by, for example, welding, using adhesive, tying sutures, etc.

[0060] The anvil buttress 170 may be porous, non-porous, or combinations thereof. Suitable porous structures include, for example, fibrous structures (e.g., knitted structures, woven structures, and non-woven structures) and/or foams (e.g., open or closed cell foams). Suitable non-porous structures include, for example, films. The anvil buttress 170 may be a single porous or non-porous layer, or may include a plurality of layers including any combination of porous and non-porous layers. For example, the anvil buttress may include multiple porous and non-porous layers that are stacked in an alternating manner. In another example, the anvil butress may be formed in a “sandwich-like” manner wherein the outer layers are porous, and the inner layer(s) are non-porous, or vice versa.

[0061] Porous layer(s) in a surgical butress may enhance the ability of the surgical butress to absorb fluid, reduce bleeding, and/or seal a wound. Also, the porous layer(s) may allow for tissue ingrowth to fix the surgical butress in place. Non-porous layer(s) in a surgical butress may enhance the ability of the surgical butress to resist tears and perforations during the manufacturing, shipping, handling, and/or stapling processes. Also, non-porous layer(s) may retard or prevent tissue ingrowth from surrounding tissues thereby acting as an adhesion barrier and preventing the formation of unwanted scar tissue.

[0062] With continued reference to FIG. 6, the anvil butress loading tool 180 is configured to releasably retain the anvil butress 170 therein and to receive the anvil assembly 150 (FIG. 3) therein for loading the anvil butress 170 onto the anvil assembly 150 (e.g., transferring the anvil butress 170 from the anvil butress loading tool 180 to the anvil assembly 150). The anvil butress loading tool 180 has a two-part construction including a carrier 182 and a cover 184. The carrier 182 and the cover 184 are releasably engaged with each other via snap fit connectors 185, however, other mating structures and relationships are contemplated to releasably secure the carrier 182 and the cover 184 together. Alternatively, the carrier 182 and the cover 184 may be formed as a single, non-separable piece.

[0063] Together, as shown in FIG. 7, the carrier 182 and the cover 184 define a proximal opening 181 into a cavity 183 defined between the carrier 182 and the cover 184. The proximal opening 181 and the cavity 183 correspond in size and shape with the anvil assembly 150 (FIG. 3) and thus, are configured to slidably receive the anvil assembly 150 in an orientation in which the tissue facing surface 158 (FIG. 3) of the anvil plate 152 faces the carrier 182.

[0064] The carrier 182 has a support plate 186 dimensioned to accommodate the butress body 172 of the anvil butress 170 thereon. A proximal end portion 182a of the carrier 182 includes proximal protrusions 188 extending proximally from the support plate 186 in spaced relation relative to each other. The proximal protrusions 188 are configured and dimensioned to engage the proximal tab 174 of the anvil buttress 170 to retain a proximal portion 170a of the anvil buttress 170 on the anvil buttress loading tool 180.

[0065] The cover 184 is sized and shaped to cover the support plate 186 of the carrier 182. The proximal end portion 182a of the carrier 182 (e.g., the proximal protrusions 188) is not covered by the cover 184. A distal end portion 184b of the cover 184 includes at least one distal protrusion 190 extending outwardly from an outer surface 189 of the cover 184 and at least one distal opening 191 defined through the cover 184 and disposed proximal to the distal protrusion 190. The distal opening 191 is configured and dimensioned for passage of the distal tab 178 out of the cavity 183 of the anvil buttress loading tool 180, and the distal protrusion 190 is configured and dimensioned to engage the distal tab 178 of the anvil buttress 170 to retain a distal portion 170b of the anvil buttress 170 on the anvil buttress loading tool 180. The cover 184 also includes a handle or finger grip 192 extending from the distal end portion 184b of the cover 184 for ease in handling by a user.

[0066] In a method of loading the anvil buttress loading tool 180 with the anvil buttress 170, the cover 184 of the anvil buttress loading tool 180 is separated from the carrier 182, as seen in FIG. 6, so that the anvil buttress 170 may be placed into the anvil buttress loading tool 180. The anvil buttress 170 is positioned on the carrier 182 with the buttress body 172 positioned against the support plate 186 and the proximal tab 174 engaged with the proximal protrusions 188. The distal tab 178 is positioned through the distal opening 191 in the cover 184 and the distal opening 179 in the distal tab 178 is engaged with the distal protrusion 190 on the cover 184. The cover 184 is then snap fitted onto the carrier 182, as shown in FIGS. 7-9, to load the anvil buttress 170 in the anvil buttress loading tool 180. In the loaded configuration, the buttress body 172 and the distal flap 176 are retained within the cavity 183 of the anvil buttress loading tool 180, the distal tab 178 extends distally out of the distal opening 191, and the proximal tab 174 is proximal to the proximal opening 181. The proximal tab 174 and the distal tab 178 help maintain alignment of the anvil buttress 170 on the anvil buttress loading tool 180. Alternatively, the anvil buttress 170 may be passed into (e.g., slid into) the cavity 183 of the anvil buttress loading tool 180 through the proximal opening 181, and the proximal and distal tabs 174, 178 are manipulated to engage the respective proximal and distal protrusions 188, 190. [0067] In a method of loading the anvil assembly 150 with the anvil buttress 170, the anvil buttress loading tool 180, loaded with the anvil buttress 170, as seen in FIG. 7, is positioned relative to the anvil assembly 150 (FIG. 3), with the proximal opening 181 into the cavity 183 of the anvil buttress loading tool 180 aligned with the anvil tip 156 of the anvil assembly 150, and with the anvil buttress 170 facing the tissue facing surface 158 of the anvil assembly 150. As shown in FIGS. 10-12, the anvil assembly 150 is slid distally into the cavity 183 of the anvil buttress loading tool 180 through the proximal opening 181 to advance the anvil assembly 150 into the anvil buttress loading tool 180 such that the tissue facing surface 158 of the anvil assembly 150 is adjacent to or in contact with the anvil buttress 170. Additionally, or alternatively, the anvil buttress loading tool 180 may be slid proximally over the anvil assembly 150.

[0068] During this sliding movement, the spaces “S” defined between the proximal protrusions 188 of the anvil buttress loading tool 180 are aligned with the barbs 160 on the anvil assembly 150 so that as the barbs 160 approach the anvil buttress loading unit 180, the barbs 160 are initially received within the spaces “S” and flex upwardly to allow the anvil assembly 150 to travel into the anvil buttress loading unit 180. When the anvil assembly 150 is fully advanced into the anvil buttress loading tool 180, as shown in FIGS. 13 and 14, the anvil tip 156 of the anvil assembly 150 extends through the distal window 177 defined through the distal flap 176 of the anvil buttress 170 and the barbs 160 of the anvil assembly 150 pierce the proximal portion 170a of the anvil buttress 170.

[0069] After the anvil assembly 150 is fully advanced into the anvil buttress loading tool 180, the anvil buttress loading tool 180 may be separated from the anvil assembly 150 by sliding the anvil assembly 150 and/or the anvil buttress loading tool 180 in opposite directions. Additionally, the distal tab 178 tears away from the anvil buttress 170 and is retained on the anvil buttress loading tool 180 during separation thereof from the anvil assembly 150. Alternatively, the distal tab 178 may rip or otherwise detach from the distal protrusion 190 of the anvil buttress loading tool 180 during separation of the anvil assembly 150 from the anvil buttress loading tool 180 and remain attached to the anvil buttress 170.

[0070] After the anvil assembly 150 is separated from the anvil buttress loading tool 180, as shown in FIG. 15, the anvil assembly 150 is loaded with the anvil buttress 170. Specifically, the proximal end portion 170a of the anvil buttress 170 is retained on the anvil assembly 150 by the barbs 160 and the distal end portion 170b of the anvil buttress 170 is retained on the anvil assembly 150 by engagement of the distal flap 176 with the anvil tip 156 through the distal window 177.

[0071] The surgical stapling apparatus 100 (FIG. 1), with the anvil assembly 150 loaded with the anvil buttress 170, is ready for use. In aspects, the staple cartridge assembly 140 is pre-loaded and/or loaded with a cartridge buttress 171 (FIG. 2). The cartridge buttress 171 may be releasably secured to the staple cartridge assembly 140 via any suitable attachment feature within the purview of those skilled in the art, such as, for example, mechanical attachment features (e.g., sutures, pins), chemical attachment features (e.g., adhesive), and/or attachment methods (e.g., welding).

[0072] In operation, with the tool assembly 132 loaded with the anvil buttress 170, as described above, the surgical stapling apparatus 100 is used in accordance with methods known by those skilled in the art. Once the staple cartridge and anvil assemblies 140, 150 are clamped onto tissue, the surgical stapling apparatus 100 is fired, thereby stapling the anvil buttress 170 to the tissue, as well as cutting and dividing the tissue and the anvil buttress 170 disposed between the rows of formed staples. When firing is complete and the staple cartridge and anvil assemblies 140, 150 are unclamped, the anvil buttress 170, which is now stapled to the tissue, pulls away from the anvil assembly 150, and the tool assembly 132 can be removed from the surgical site. In some aspects, the used staple cartridge 142 may be removed from the tool assembly 134 and replaced with a new staple cartridge 142 and, in some other aspects, the loading unit 130 may be replaced with a new loading unit 130. A new anvil buttress 170 may be installed onto the anvil assembly 150 by an anvil buttress loading tool 180, as needed or desired, as described above.

[0073] It should be understood that the barbs 160 on the anvil assembly 150 may have other configurations. For example, as shown in FIG. 16, a single row of barbs 160’ may be provided on each side of the central longitudinal slot 151’ of an anvil assembly 150’. As another example, as shown in FIG. 17, a single barb 160” may be provided on each side of the central longitudinal slot 151” of an anvil assembly 150”. Further, while the barbs 160 (FIG. 5) are shown associated with barb plates 165 that are secured to the anvil plate 152, as further seen in FIG. 17, the barbs 160” may be formed directly on the tissue facing surface 158” of the anvil plate 152” (e.g., cut into (e.g., stamped) or secured (e.g., welded) to the tissue facing surface 158” of the anvil plate 152”. Further still, while the barbs 160, 160’, 160” are shown as all being the same in each of the anvil assemblies 150, 150’, 150”, it should be understood that the configuration of the barbs may be different. Accordingly, the number, size, shape, and/or position of the barbs on the anvil assembly may vary depending upon, for example, desired fixation strength for a particular buttress material.

[0074] Further, as shown in FIG. 18, the anvil buttress 170’ may include diagonal slits 173’ defined through the proximal portion 170a’ of the anvil buttress 170’. The diagonal slits 173’ correspond to the position of the barbs 160” (FIG. 17) to enable the barbs 160” to lock into the anvil buttress 170’ during loading, and each of the diagonal slits 173’ extend over a midline of the anvil buttress 170’ that corresponds with the position of the central longitudinal slot 151” (FIG. 17) of the anvil assembly 150” such that upon firing the surgical stapling apparatus 100 (FIG. 1), a knife (not shown) of the surgical stapling apparatus 100 cuts the anvil buttress 170’ through the diagonal slits 173’ enabling the anvil buttress 170’ to be pulled around the barbs 160” when removing the surgical stapling apparatus 100 from the surgical site.

[0075] Referring now to FIG. 19, an anvil assembly 250 in accordance with another aspect of this disclosure is shown. The anvil assembly 250 is suitable for use in the loading unit 130 (FIG. 1) of the surgical stapling apparatus 100. The anvil assembly 250 includes an anvil plate 252, an anvil cover 254, and an anvil tip 256. The anvil plate 252 has a central longitudinal slot 251 formed therein and a plurality of staple forming pockets or cavities 253 defined in an inward or tissue facing surface 258 thereof. The anvil plate 252 includes grooves 255 defined in the tissue facing surface 258 of the anvil plate 252 on opposed sides of the central longitudinal slot 251. The grooves 255 are positioned within a proximal end portion 250a of the anvil assembly 250 proximal to the staple forming pockets 253. The anvil cover 254 includes side walls 254a extending outwardly towards the staple cartridge assembly 140 (FIG. 1) at the proximal end portion 250a of the anvil assembly 250 on opposed sides of the anvil plate 252. The anvil assembly 250 includes barb assemblies 260 coupled to the side walls 254a of the anvil cover 254 and extending into the grooves 255 of the anvil plate 252. [0076] As shown in FIGS. 20-22, each of the barb assemblies 260 includes a base 262 including a first segment 262a fixedly coupled to the side wall 254a of the anvil cover 254 and a second segment 262b extending the first segment 262a transversely across the tissue facing surface 258 of the anvil plate 252. The second segment 262b is disposed adjacent to, but outside of the groove 255. In some aspects, the second segment 262b is positioned distal to the groove 255 and, in certain aspects, the second segment 262b extends partially over the groove 255.

[0077] Each of the barb assemblies 260 further includes a barb plate 265 extending proximally from the second segment 262b of the base 262 and into the groove 255 of the anvil plate 252. The barb plate 265 is pivotably coupled to the second segment 262b of the base 262 so that the barb plate 265 is movable into and out of the groove 255. The barb plate 265 includes barbs or teeth 268 disposed at a proximal end of the barb plate 265 that are configured to engage the anvil buttress 270 (FIG. 23). The barb plate 265 has a ramped surface 265a extending proximally from the second segment 262b of the base 262 to the barbs 268. The ramped surface 265a faces the anvil plate 252 and is configured to engage the anvil buttress loading tool 280 (FIG. 23) to move the barb plate 265 out of the groove 255.

[0078] As shown in FIG. 23, an anvil buttress loading assembly 201 includes an anvil buttress 270 and an anvil buttress loading tool 280 for loading the anvil buttress 270 onto the anvil assembly 250 (FIG. 19). The anvil buttress 270 is substantially the same as the anvil buttress 170 of FIG. 6, except that the anvil buttress 270 does not include a distal tab 178 (FIG. 6) and the proximal tab 274 is modified for engagement with the proximal posts 288 of the anvil buttress loading tool 280.

[0079] The anvil buttress loading tool 280 is configured to releasably retain the anvil buttress 270 thereon and to engage the anvil assembly 250 (FIG. 19) for loading the anvil buttress 270 onto the anvil assembly 250 (e.g., transferring the anvil buttress 270 from the anvil buttress loading tool 280 to the anvil assembly 250). The anvil buttress loading tool 280 is formed from a rigid material (e.g., a polymer or metal) and supports the anvil buttress 270 thereon. The anvil buttress loading tool 280 includes a carrier 282 having a support plate 286 dimensioned to accommodate the buttress body 272 of the anvil buttress 270 thereon. A proximal end portion 282a of the carrier 282 includes proximal posts 288 configured to engage the proximal tab 274 of the anvil buttress 270. The proximal posts 288 are laterally spaced, and sized and shaped to extend through the openings 275 of the proximal tab 274. A handle or finger grip 292 may extend distally from the support plate 286 (e.g., be an extension of the support plate 286) for grasping by a user.

[0080] In a method of loading the anvil buttress 270 onto the anvil buttress loading tool 280, the buttress body 272 of the anvil buttress 270 is positioned on the support plate 286 of the anvil buttress loading tool 280 and the proximal posts 288 of the anvil buttress loading tool 280 are slid through the proximal openings 275 of the proximal tab 274 of the anvil buttress 270 to releasably secure the proximal end portion 270a of the anvil buttress 270 to the anvil buttress loading tool 280. The anvil buttress 270 is engaged with the anvil buttress loading tool 280 only at the proximal tab 274.

[0081] In a method of loading the anvil buttress 270 onto the anvil assembly 250, the proximal end 280a of the anvil buttress loading tool 280, loaded with the anvil buttress 270, as described above, is aligned with the anvil assembly 250 such that the anvil buttress 270 faces the tissue facing surface 258 of the anvil assembly 250 and the proximal posts 288 of the anvil buttress loading tool 280 are aligned with the barb assemblies 260. The proximal end portion 270a of the anvil buttress 270, as described above, is retained on the anvil buttress loading tool 280 by the proximal posts 288 and a distal end portion 270b of the anvil buttress 270 may be held against the carrier 282 of the anvil buttress loading tool 280 by the user during installation. The anvil buttress loading tool 280 is placed adjacent to the anvil assembly 250 with the buttress body 272 of the anvil buttress 270 in contact with the tissue facing surface 258 of the anvil assembly 250 (e.g., the user releases the distal end portion 270b of the anvil buttress 270 onto the tissue facing surface 258).

[0082] The anvil buttress loading tool 280 is slid proximally towards the barb assemblies 260 such that the support plate 286 contacts the ramped surface 265a of the barb plates 265 pivoting and lifting the barb plates 265 upwardly out of the grooves 255 and away from the tissue facing surface 258 of the anvil assembly 250, as shown in FIGS. 24 and 25. Once the anvil buttress 270 is positioned over the tissue facing surface 258 of the anvil assembly 250 and the anvil tip 256 (FIG. 19) is received within the distal window 277 (FIG. 23) of the distal flap 276, the anvil buttress loading tool 280 is slid distally relative to the anvil assembly 250 to separate the anvil buttress loading tool 280 from the anvil buttress 270.

[0083] During this distal sliding movement, the proximal posts 288 of the anvil buttress loading tool 280 disengage from the proximal tab 274 of the anvil buttress 270 as the frictional force between the anvil buttress 270 and the anvil assembly 250 is greater than that of the anvil buttress 270 to the anvil buttress loading tool 280. As the anvil buttress loading tool 280 is removed and clears the barb plates 265, the barb plates 265 of the barb assembly 260 snap back down into the grooves 255. As the barb plates 265 return to their biased position within the grooves 255, the teeth 268 engage the anvil buttress 270, as seen in FIGS. 26 and 27, thereby capturing the proximal end portion 270a of the anvil buttress 270 to the anvil assembly 250. Thus, the proximal end portion 270a of the anvil buttress 270 is retained on the anvil assembly 250 by the barb assemblies 260 and the distal end portion 270b (FIG. 23) of the anvil buttress 270 is retained on the anvil assembly 250 by the distal flap 276. The loading unit 130 (FIG. 1), with the anvil assembly 250 loaded with the anvil buttress 270, is ready for use. In aspects, as seen in FIG. 1, the staple cartridge assembly 140 is pre-loaded and/or loaded with a cartridge buttress 171.

[0084] While aspects of the disclosure have been shown in the drawings, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. It is to be understood, therefore, that the disclosure is not limited to the precise aspects described, and that various other changes and modifications may be made by one skilled in the art without departing from the scope or spirit of the disclosure. Therefore, the above description should not be construed as limiting, but merely as exemplifications of aspects of the disclosure. Thus, the scope of the disclosure should be determined by the appended claims and their legal equivalents, rather than by the examples given.

Claims

WHAT IS CLAIMED IS:

1. An anvil buttress loading system comprising: an anvil assembly including a tissue facing surface and a barb coupled to the tissue facing surface, the barb movable relative to the tissue facing surface; an anvil buttress loading tool including a carrier having a support plate; and an anvil buttress including a buttress body, the anvil buttress releasably retained on the anvil buttress loading tool with the buttress body positioned on the support plate, the anvil buttress transferable from the anvil buttress loading tool to the anvil assembly such that the buttress body is secured to the barb, the barb movable towards the tissue facing surface of the anvil assembly when advancing the anvil buttress loading tool onto the anvil assembly so that the barb does not engage the anvil buttress, the barb engaged with the anvil buttress when separating the anvil buttress loading tool from the anvil assembly.

2. The anvil buttress loading system according to claim 1, wherein the barb extends proximally at an acute angle relative to the tissue facing surface of the anvil assembly.

3. The anvil buttress loading system according to claim 1, wherein the barb is one of a plurality of barbs.

4. The anvil buttress loading system according to claim 3, wherein the plurality of barbs is disposed on opposed sides of a central longitudinal slot defined through tissue facing surface of the anvil assembly.

5. The anvil buttress loading system according to claim 4, wherein the plurality of barbs is positioned proximal to staple forming pockets defined in the tissue facing surface of the anvil assembly.

6. The anvil buttress loading system according to claim 1, wherein the tissue facing surface of the anvil assembly includes a groove defined therein, and the anvil assembly further includes a barb plate disposed within the groove, the barb plate including the barb.

7. The anvil buttress loading system according to claim 1, wherein the anvil buttress includes a proximal portion having proximal openings defined therethrough, and the anvil buttress loading tool includes proximal protrusions extending from the support plate, the proximal protrusions engaged with the proximal openings when the anvil buttress is releasably retained on the anvil buttress loading tool.

8. The anvil buttress loading system according to claim 1, wherein the anvil assembly includes an anvil tip, and the anvil buttress includes a distal window defined through a distal portion of the anvil buttress, the distal window configured to engage the anvil tip to retain the distal portion of the anvil buttress on the anvil assembly.

9. The anvil buttress loading system according to claim 1, wherein the anvil buttress loading tool further includes a cover disposed over the support plate of the carrier.

10. The anvil buttress loading system according to claim 9, wherein the cover includes a distal protrusion extending outwardly from an outer surface of the cover and a distal opening disposed proximal to the distal protrusion, and the anvil buttress includes a distal tab, the distal tab extending through the distal opening and engaged with the distal protrusion when the anvil buttress is releasably retained on the anvil buttress loading tool.

11. The anvil buttress loading system according to claim 1, wherein the anvil buttress includes a diagonal slit extending therethrough, the diagonal slit configured to receive the barb and to extend over a central longitudinal slot defined through the tissue facing surface of the anvil assembly when the anvil buttress is transferred to the anvil assembly.

12. An anvil buttress loading system comprising: an anvil assembly including a tissue facing surface having a groove defined therein, the anvil assembly including a barb assembly having a barb plate including teeth disposed at a proximal end of the barb plate, the teeth biased to extend into the groove, wherein application of a force against the barb plate moves the teeth out of the groove; an anvil buttress loading tool including a carrier having a support plate; and an anvil buttress including a buttress body, the anvil buttress releasably retained on the anvil buttress loading tool with the buttress body positioned on the support plate, the anvil buttress transferable from the anvil buttress loading tool to the anvil assembly such that the buttress body is captured between the teeth and the tissue facing surface of the anvil assembly, the barb plate movable out of the groove by the force provided by the support plate when advancing the anvil buttress loading tool onto the anvil assembly and back into the groove when separating the anvil buttress loading tool from the anvil assembly.

13. The anvil buttress loading system according to claim 12, wherein the barb plate has a ramped surface extending proximally into the groove of the anvil plate.

14. The anvil buttress loading system according to claim 12, wherein the barb assembly includes a base having a first segment secured to a side wall of the anvil assembly and a second segment extending transversely across the tissue facing surface of the anvil assembly.

15. The anvil buttress loading system according to claim 14, wherein the barb plate extends proximally from the second segment of the base of the barb assembly.

16. The anvil buttress loading system according to claim 14, wherein the barb plate is pivotable relative to the base.

17. The anvil buttress loading system according to claim 14, wherein the second segment is positioned distal to the groove.

18. The anvil buttress loading system according to claim 14, wherein the second segment extends partially over the groove.

19. The anvil buttress loading system according to claim 12, wherein the barb assembly is one of two barb assemblies disposed on opposed sides of a central longitudinal slot defined through the tissue facing surface of the anvil assembly.

20. An anvil assembly comprising: an anvil plate including a tissue facing surface having a groove defined therein; and a barb assembly having a barb plate including teeth disposed at a proximal end of the barb plate, the teeth biased to extend into the groove, wherein application of a proximal force against the barb plate moves the teeth out of the groove.