Buttress and surgical stapling apparatus

Abstract

Multilayer structures including a porous layer and a non-porous layer are useful as buttresses when associated with a surgical stapling apparatus.

1 . (canceled) 
     
     
         2 . A method of forming a multilayered buttress, comprising:
 forming a first non-porous layer by pouring a first layer of a solution onto a flat hydrophobic support of a mold;   forming a second non-porous layer on the first non-porous layer by pouring a second layer of the solution over the first non-porous layer; and   applying a surgical mesh onto the second layer.   
     
     
         3 . The method of  claim 2 , further comprising diluting the solution prior to pouring the second layer. 
     
     
         4 . The method of  claim 2 , wherein the solution includes oxidized collagen and diluting the solution includes adding ethyl alcohol and water to the solution. 
     
     
         5 . The method of  claim 2 , wherein the mold includes protrusions machined onto a surface thereof, and forming the first non-porous layer includes forming holes therethrough via the protrusions. 
     
     
         6 . The method of  claim 2 , wherein applying the surgical mesh includes applying the surgical mesh on the second layer immediately after pouring the second layer. 
     
     
         7 . The method of  claim 2 , wherein applying the surgical mesh includes encapsulating the surgical mesh within the second non-porous layer. 
     
     
         8 . The method of  claim 2 , further comprising applying a porous layer onto the surgical mesh. 
     
     
         9 . The method of  claim 8 , further comprising forming the porous layer by pouring a solution onto a freeze-dry plate and freeze-drying the solution. 
     
     
         10 . The method of  claim 9 , wherein forming the porous layer includes heating the freeze-dried porous layer. 
     
     
         11 . The method of  claim 2 , further comprising drying the multilayered buttress. 
     
     
         12 . A multilayered buttress comprising:
 a first non-porous layer;   a second non-porous layer disposed on the first non-porous layer;   a surgical mesh encapsulated within the second non-porous layer; and   a porous layer disposed on the second non-porous layer.   
     
     
         13 . The multilayered buttress of  claim 12 , wherein the first and second non-porous layers comprise oxidized collagen. 
     
     
         14 . The multilayered buttress of  claim 13 , wherein a percentage of oxidized collagen in the first non-porous layer is greater than a percentage of oxidized collagen in the second non-porous layer. 
     
     
         15 . The multilayered buttress of  claim 12 , further comprising holes extending through the first non-porous layer, the second non-porous layer, the surgical mesh, and the porous layer. 
     
     
         16 . A surgical stapling apparatus comprising:
 a staple cartridge;   an anvil; and   a multilayered buttress positioned on the staple cartridge or the anvil, the multilayered buttress including:
 a first non-porous layer; 
 a second non-porous layer disposed on the first non-porous layer; 
 a surgical mesh encapsulated within the second non-porous layer; and 
 a porous layer disposed on the second non-porous layer. 
   
     
     
         17 . The surgical stapling apparatus of  claim 16 , wherein the first non-porous layer of the multilayered buttress is secured to a surface of the staple cartridge or the anvil. 
     
     
         18 . The surgical stapling apparatus of  claim 16 , wherein the multilayered buttress includes holes extending therethrough, and the staple cartridge or the anvil includes pins extending through the holes.