Surgical clamp having replaceable pad

[0002] The present application is a divisional of U.S. application Ser. No. 09/594,291, filed on Jun. 15, 2000, now U.S. Pat. No. 6,387,112 which is a continuation-in-part and claims the benefit of earlier filed U.S. application Ser. No. 09/491,237, filed Jan. 25, 2000, now U.S. Pat. No. 6,273,902 which is a continuation-in-part of U.S. application Ser. No. 09/336,131 filed Jun. 18, 1999, now U.S. Pat. No. 6,228,104, each of which is incorporated herein by reference in its entirety.

[0003] 1. Field of the Invention

[0004] The present invention relates to surgical clamps. In particular, the invention relates to surgical clamps having replaceable pads.

[0005] 2. Description of the Related Art

[0006] Surgical clamps exist in many sizes with many different types of clamp shapes (e.g., curved jaws, straight jaws, etc.). In addition, many different types of jaw surfaces exist, as adapted to the specific function performed by the clamp. When a different function is to be performed, either one must use a different clamp, or in some circumstances replaceable pads may be added to the jaws.

[0007] Many existing surgical clamps have jaws with hard clamping surfaces. Some replaceable pads for these clamps are designed to fit over the jaws to provide a softer clamping surface. However, these pads are often bulky, reducing the sleekness of the clamp and jaws. In addition, these pads are typically designed to fit over only straight jaws and are generally straight themselves, so there is a need for other shapes such as curved or S-shaped.

[0008] Other existing surgical clamps have curved, replaceable pads that are sleek, but these sleek pads are not soft and may be inappropriate for many applications.

[0009] Still other existing surgical clamps have soft pads but these pads are not replaceable. This makes the pads harder to clean. Autoclaving may cause soft or delicate pads to deteriorate or wear out more quickly; with the result that the pad surfaces may become less soft or less delicate. As an alternative, the pad surfaces may be constructed to as to be less soft or less delicate in order to have a longer lifetime.

[0010] Some surgical clamps (e.g., U.S. Pat. No. 3,503,398) have replaceable pads that are soft, but have other concerns. The pads are installed from the distal end, and may slip off from that direction. Decreasing the possibility of the pads slipping off may increase the effort necessary to install the pads. In addition, the portion of the pad that attaches to the clamp may not be flexible.

[0011] Finally, some existing surgical clamps have replaceable pads that are not tightly secured to the jaws. With such clamps, the pads may move laterally after the vessel or tissue has been clamped. This lateral movement makes for an insecure clamp subject to wobbling, that may shear the vessel or tear the tissue. So there is a need to tightly secure the pads to the jaws.

[0012] The present invention addresses these and other problems of existing devices by providing a surgical clamp having a jaw with an elongate cavity or channel to receive a replaceable pad.

[0013] According to one embodiment, the surgical clamp of the present invention comprises a pair of elongate jaws connected together for movement toward each other, at least one of the jaws having an outer surface in opposition to the other jaw. An elongate cavity extends longitudinally within the jaw. The cavity is adapted for slidably receiving a clamp pad. An elongate channel opens through the outer surface and longitudinally connects the cavity to the outer surface. The channel is generally commensurate with the cavity longitudinally.

[0014] In an alternative embodiment, at least one of the jaws includes an elongate channel opening to both an engaging surface of the jaw and a backing surface of the jaw generally opposite the engaging surface. A breech portion is in communication with the elongate channel and opens to both the engaging and the backing surfaces. The breech portion and channel are adapted to slidably receive a clamp pad.

[0015] The invention is also directed to a method of making a replaceable pad, the method comprising the steps of providing a flexible elongate attachment member, and forming a pad around the attachment member.

[0016] The invention also provides methods of installing a replaceable pad in the jaw of a surgical clamp. One method comprises the steps of providing a pad having a flexible elongate attachment member, and a draw cord extending generally longitudinally from the pad, and providing a surgical clamp having at least one elongate jaw with an outer clamping surface. The jaw has an elongate cavity extending longitudinally therein and a hole opening therefrom at one end of the cavity. The cavity is configured to slidably receive the attachment member. The method also includes the steps of inserting the draw cord into the cavity, directing the draw cord through the hole, and applying tension to the draw cord to draw the attachment member into the cavity and secure the pad in place on the clamping surface of the jaw.

[0017] Another method of installation involves the steps of providing a similar pad and a surgical clamp having a breech portion and an elongate channel extending longitudinally within the jaw and opening to both the engaging surface and backing surface of the jaw. The pad is inserted into the breech and the attachment member is drawn into the elongate channel such that the pad body extends over the engaging surface of the jaw and a securing portion of the attaching member tracks along the backing surface of the jaw. The pad can include a detachable tab to aid in pulling the pad onto the jaw. Once in place, the tab can then be detached from the pad. Alternatively, the pad can include a guide hole extending through the pad to aid in installing the pad onto the jaw. A pull string or pull strap can be secured through the guide hole, used to pull the pad onto the jaw, and then cut away once the pad is in place.

[0018] The replaceable pad of the present invention can comprise an elongate body configured to extend over an outer surface of a jaw of a surgical clamp, and a flexible elongate attachment member connected to the body and configured for slidable receipt within an elongate cavity or channel extending longitudinally of the jaw. The attachment member can include a stabilizing portion disposed within the pad body to internally reinforce the pad body, as well as a securing portion configured to extend through the channel or fit within cavity. The securing portion can be continuous, or alternatively can be discontinuous to further enhance the flexibility of the pad for even easier installation, especially onto curvilinear jaws.

[0019] A principal object of these embodiments of the invention is to provide a surgical clamp with replaceable pads that are easily installable without special tools.

[0020] Another object is to provide a draw cord, tab, pull string or pull strap on the pad to allow a pulling force for easier installation and/or removal.

[0021] Yet another object is to provide a surgical clamp with replaceable pads that resist lateral movement between the clamp and the pads.

[0022] Still another object is to provide a surgical clamp with replaceable pads that are sleek and compact.

[0023] A further object is to provide a surgical clamp with replaceable pads that are flexible such that one pad configuration may be used on a wide variety of jaw shapes.

[0024] These and other objects will become apparent when viewed in light of the following detailed description and accompanying drawings which set forth illustrative embodiments in which the principles of the invention are utilized.

[0025] FIG. 1 is a perspective view of a surgical clamp constructed according to a first embodiment of the present invention;

[0026] FIG. 2 is an exploded perspective view of a jaw of the surgical clamp of FIG. 1, with parts thereof broken away, showing a detached pad for the clamp;

[0027] FIG. 2A is an exploded perspective view of a jaw according to a second embodiment of the present invention, with parts thereof broken away;

[0028] FIG. 3 is a cross-sectional view taken on the plane designated by line 3—3 of FIG. 2;

[0029] FIG. 4 is a cross-sectional view taken on the plane designated by line 4—4 of FIG. 2;

[0030] FIGS. 5-8 are enlarged perspective views of a jaw of the surgical clamp of FIG. 1, showing the steps of installing the pad in the jaw;

[0031] FIG. 9 is an enlarged perspective view of a jaw of the clamp of FIG. 1 showing the pad being removed from the jaw;

[0032] FIG. 10 is a perspective view of a draw cord with mesh for a first embodiment of the pad of the present invention;

[0033] FIG. 10A is a perspective view of a draw cord with stabilizing elements for a third embodiment of the present invention;

[0034] FIG. 11 is a cross-sectional view taken on the plane designated by line 11—11 of FIG. 10;

[0035] FIG. 12 is a cross-sectional view taken on a plane perpendicular to a longitudinal line of a pad constructed according to a second embodiment of the present invention;

[0036] FIG. 13 is a perspective view of the pad of FIG. 12 with portions thereof cut away;

[0037] FIG. 14 is a cross-sectional view of a mold suitable for forming the pad of the present invention;

[0038] FIG. 15 is an exploded perspective view of a jaw of a surgical clamp according to a second embodiment of the present invention, with parts thereof broken away, showing a clamp with a curved jaw;

[0039] FIG. 16A is a perspective view, with parts broken away, of a surgical clamp jaw and detached pad according to another embodiment of the invention, showing an elongate channel extending through the jaw and an engaging surface of the jaw;

[0040] FIG. 16B is a cross-sectional view of the jaw of FIG. 16A taken along the plane designated by line 16B—16B of FIG. 16A;

[0041] FIG. 17 is another perspective view of the jaw of FIG. 16A, showing a backing surface of the jaw;

[0042] FIGS. 18A-18B are perspective views of the jaw and pad of FIG. 16A showing the pad being installed onto the jaw;

[0043] FIG. 18C is a cross-sectional view of the assembled jaw and pad of FIG. 18B taken on line 18C—18C of FIG. 18B;

[0044] FIG. 18D is a side elevation view of the assembled jaw and pad of FIG. 18B;

[0045] FIG. 19A is a perspective view, with parts broken away, of a variation of the jaw shown in FIG. 16A;

[0046] FIGS. 19B and 19C are cross-sectional views of the jaw of FIG. 19A taken along the plane designated by lines 19B—19B and 19C—19C respectively of FIG. 19A;

[0047] FIG. 20A is another perspective view of the jaw of FIG. 19A, showing a backing surface of the jaw;

[0048] FIG. 20B is a perspective view of the jaw of FIG. 19A showing a pad according to the invention being installed onto the jaw;

[0049] FIGS. 21A-21E are alternative embodiments of the pad shown in FIG. 18C.

[0050] FIGS. 22A-22C are perspective views, with parts broken away, of pads according to additional embodiments of the invention;

[0051] FIG. 23 is a top view of the pad of FIG. 22A being installed onto a surgical clamp of the invention having a curved jaw;

[0052] FIG. 24 is a side view of a pad according to the embodiment of FIG. 22A being removed from a surgical clamp of the invention;

[0053] FIG. 25 is a perspective view of a pad according to another embodiment of the invention; and

[0054] FIG. 26 is a side view of the pad of FIG. 25.

[0055] FIG. 1 shows an exemplary surgical clamp 50 according to one embodiment of the present invention. The clamp 50 is shown in the process of clamping a vessel V. It may also be used to clamp organs or other bodily tissue.

[0056] The clamp 50 includes finger and thumb rings 52 and 54 for operating the clamp. A pawl 56 and ratchet teeth 58 lock the clamp 50 when it is applied to vessel V. Handles 60 and 62 are pivotally connected by pin 64. Jaws 66 and 68 apply the clamping force to vessel V, as cushioned by pads 80.

[0057] FIG. 2 shows an enlarged view of the jaw 66 and the pad 80 in a detached condition. A channel 82 extends longitudinally along the jaw 66. The channel 82 forms a groove communicating with a generally cylindrical cavity 90 within the jaw 66 coextensive with the groove. One end of the channel 82 forms an enlarged mouth 83 opening into the cavity 90. The end of the cavity 90 opposite the mouth 83 is formed with a hole 84. A draw cord 86 for the pad 80 passes through the hole 84 when the pad 80 is attached to the jaw 66, as more fully described with reference to FIGS. 5-9 and the accompanying text. An attachment member 85 is coextensive with the pad 80 and is preferably a portion of the draw cord 86. The draw cord 86 may also be referred to as a filament.

[0058] FIG. 3 is a cross-section of the jaw 66 taken on line 3—3 of FIG. 2. The jaw 66 has a generally U-shaped lower surface for smoothness. The cavity 90 extends longitudinally within the jaw 66. The channel 82 connects the cavity 90 to outer surfaces 92 of the jaw 66. The outer surfaces 92 are generally flat to facilitate installation of the pad 80, and may be angled. The angling helps keep the pad 80 from moving laterally with respect to the jaw 66. The cavity 90 has a larger cross-sectional width than the channel 82, to secure the pad 80 within the cavity 90.

[0059] FIG. 4 is a cross-section of the pad 80 taken on line 44 of FIG. 2. A neck 96 connects the draw cord 86 to a pad body 98. The pad body 98 fits against the outer surfaces 92 (see FIG. 3) when the pad 80 is attached to the jaw 66. The draw cord 86 fits within the cavity 90 (see FIG. 3) when the pad 80 is attached to the jaw 66. The neck 96 may be slightly shorter than the channel 82 (see FIG. 3) so that when the pad 80 is attached to the jaw 66, the pad body 98 is pulled tightly against the outer surfaces 92, to inhibit lateral movement there between. Alternatively, the neck 96 may fit snugly within the channel 82 to inhibit lateral movement between the pad body 98 and the outer surfaces 92. Reducing lateral movement between the pad 80 and the jaw 66 is important to minimize wobbling of the pad relative to the jaw and reduce possible trauma resulting from application of the clamp 50 to bodily tissues, organs or vessels.

[0060] The neck 96 is preferably made of a thermoplastic elastomer, as further detailed below. The geometry and materials in the neck 96 may be modified for adjusting the fit in the channel 82. For example, the neck 96 may be made from a relatively hard plastic or from a relatively soft plastic, or may be slightly wider than the channel 82.

[0061] The pad body 98 preferably has a clamping surface 100 as shown in FIG. 4 and as further detailed with reference to FIGS. 10-13 and the accompanying text. The particular structure is pyramidal, similar to that of Model DSAFE33 FOGARTY DOUBLE SAFEJAW insert set from Baxter Corp. However, pad body 98 may instead have a wide variety of other surfaces. For example, the surface may be hard, soft, smooth, bumpy, etc. as currently exist on other surgical clamps. The pad body 98 is preferably made of a thermoplastic elastomer, as further detailed below.

[0062] Draw cord 86 may be a polyester monofilament with a diameter of 0.062 inches. Draw cord 86 may also be nylon or polypropylene having adequate column strength to track through the channel.

[0063] FIG. 2A shows a portion of a modified jaw 66awhich may be referred to as a reverse or keyhole configuration. The jaw 66aincludes a neck 96aand an attaching element 86a, with the attaching element wider than the neck. A pad 80ais adapted to attach to the neck 96aand the attaching element 86a, and is otherwise similar to pad 80. The pad 80amay be installed from the distal end or the proximal end of the jaw 66a.

[0064] FIGS. 16A, 16B and 17 illustrate an alternative embodiment of a surgical clamp jaw according to the invention. Jaw 166 includes elongate channel 182 extending longitudinally along the jaw length. The channel extends through the jaw, opening to both engaging and backing surfaces 183 and 184 that are generally opposed to one another. As seen in FIG. 16B, the channel has a generally rectangular cross-section. Breech portion 185 is located proximal to the channel and is in communication with the channel. The breech portion is configured to receive pad 180 that includes an elongate pad body 198 and elongate attachment member 186. Attachment member 186 further includes a securing portion 188 and a stabilizing portion 194. Breech portion 185 is slightly wider than channel 182 to accommodate the receipt of the securing portion of the pad.

[0065] FIGS. 18A-18D show pad 180 installed on jaw 166. When installed onto the jaw, pad body 198 is engaged with and secured against engaging surface 183 of the jaw. Attachment member 186 extends through channel 182 and securing portion 188 engages backing surface 184, to secure the pad in place on the jaw. Unlike jaw 66 of FIG. 2, jaw 166 does not include a hole at the distal end of the jaw to accommodate a draw cord. To aid in installing pad 180 onto the jaw, the pad includes tab 190, which can be broken away from the pad once the pad is installed. Pad 80 of FIG. 2 can also be installed onto jaw 166, with neck 96 extending through channel 182 and draw cord 86 engaging backing surface 184 of jaw 166.

[0066] FIGS. 19A-19C depict yet another embodiment of a jaw according to the invention. Jaw 166alikewise includes elongate channel 182 extending longitudinally through along the jaw length and opening to engaging and backing surfaces 183 and 184 of the jaw. In this embodiment, breech portion 185ais configured to receive a pad from the backing surface side of the jaw. As seen in FIG. 19B, in order to receive a pad in this orientation for installation onto the jaw, breech portion 185ahas a cross-section wide enough to accept the pad body width.

[0067] FIGS. 22A and 22C show alternative embodiments of a pad according to the invention having guide holes extending through the pad. These guide holes likewise aid in installing the pad onto a jaw, as is also more fully described herein. Pad 280aof FIG. 22A includes guide tab 290athat extends from attachment member 286ain the same general plane as the attachment member. Guide hole 291aextends through the guide tab. The guide tab is preferably constructed of the same material as attachment member 286a, most preferably a thermoplastic of 40 D-80 D shore durometer. Pull string 292ais secured through guide hole 291 a and can be formed of any suitable filament that can withstand a pulling force, such as a string, suture, monofilament, or multifilament, e.g. braided KEVLAR™ (DuPont) filament. Pad 280bof FIG. 22B includes guide tab 290bsimilar to guide tab 290aof pad 280a, but which extends from attachment member 286bin a plane generally parallel to the pad surface. Guide hole 291blikewise extends through guide tab 290b. Pull strap 292bis secured through, and is preferably formed of the same thermoplastic as the attachment member. Pad 280cof FIG. 22C includes guide hole 291 c which extends directly through attachment member. Pull string 292c, which can be formed of the same materials as described for pull string 292aof pad 280a, is secured through the guide hole. Other locations for guide holes are also contemplated. For example, a guide hole can extend through the pad cushion. In such a configuration, the hole can be reinforced to prevent against tearing of the cushion under a pulling force.

[0068] FIGS. 25 and 26 show yet another embodiment of a pad according to the invention. Pad 380 is similar to pad 180 of FIG. 16A, and includes elongate pad body 398 and attachment member 386. Securing portion 388 however is discontinuous, specifically being formed of segments 389 spaced intermittently along attachment member 386 with gaps in between. As more fully described herein, a pad of this configuration can be easily installed manually onto a jaw, even a curved jaw, without the need for a draw cord, pull string or other installation aid.

[0069] Pad Attachment

[0070] FIGS. 5-9 illustrate the steps for attaching the pad 80 to the jaw 66. FIG. 5 shows that a distal end of the draw cord 86 is inserted into the mouth 83 at the proximal end of the channel 82 and cavity 90. FIG. 6 shows that the draw cord 86 is fed through the cavity 90 until it emerges from the hole 84. At this point, the neck 96 is about to enter the channel 82.

[0071] FIG. 7 shows the draw cord 86 being pulled to engage the pad 80 within the jaw 66, and shows the finger of a person installing the pad guiding the pad into the mouth 83. The draw cord 86 applies a generally uniform pulling force on the pad 80. This decreases the tendency for the pad 80 to expand at its distal end and bind against the inner surfaces of the cavity 90 and the channel 82, as would be likely from insertion with only a pushing force. Pad 80 may also be pushed by the finger during the engagement process. Such a combination of pushing and pulling allows the pad 80 to move through the inner surfaces of the jaw 66 better than pulling alone.

[0072] Note that the attachment member 85 flexes as it enters the mouth 83. This flexibility allows the attachment member 85 to be inserted into a cavity without requiring the cavity to be uniformly straight.

[0073] FIG. 8 shows the pad 80 fully engaged with the jaw 66 and the draw cord 86 being cut, as it is no longer needed. FIG. 9 shows that the pad 80 may be removed by grasping it at its proximal end with a grasping tool and applying a backward and upward force to draw the pad out of the mouth 83.

[0074] Besides the advantage of a generally uniform pulling force described above, the draw cord 86 has a number of other advantages. By fitting within the cavity 90, the draw cord 86 functions to attach the pad 80 to the jaw 66, so that a single structure (the draw cord 86) may perform both attaching and installation functions. The draw cord 86 enables attachment of the pad 80 to the jaw 66 without the need for special tools during installation.

[0075] FIGS. 18A-18D illustrate steps for installing pad 180 onto jaw 166. Pad 180 is first inserted into breech portion 185 where the breech portion opens to engaging surface 183. As the pad is fed through the breech portion, it engages channel 182 of the jaw, which is in communication with the breech portion. As the pad engages the channel, pad body 198 extends over engaging surface 183 of the jaw, as shown in FIG. 18A. Attachment member 186 extends through channel 184 with securing portion 188 tracking along backing 184 surface of the jaw, thereby securing the pad to the jaw.

[0076] The pad can be inserted into the breech and guided along the channel manually, or alternatively once the pad is pushed through the breech, the pad can be grasped with an instrument, for example, forceps, and guided into the breech and pulled along the channel. As mentioned, jaw 166 does not include a hole at its distal end. Indeed, it may be desirable for the distal end of the jaw to be smooth and rounded in order to minimize trauma to tissue during use. For ease of installation then, pad 180 is provided with detachable tab 190, which is configured to pass through breech portion 185 and which extends from attaching member 186. Once the pad is fed into the breech, tab 190 can be grasped and pulled along the backing surface side of the jaw to bring the pad into place. Once the pad is installed by this method, the tab can be removed, for example, by twisting or snapping it off, or by cutting it off.

[0077] FIGS. 20A and 20B illustrate the installation of pad 180aonto jaw 166a. The pad is installed in a similar fashion, the difference being breech portion 185ais configured to receive pad 180afrom the backing surface side of the jaw. As seen in FIG. 20B, pad body 198ais fed through breech portion 185a, which is wide enough to accommodate the pad body width, until attachment member 186aengages channel 182. The pad can then be moved into position onto the jaw using like methods to those described above. The pad can also include a tab (not shown) extending from the attaching member, similar to the tab shown for the pad of FIG. 16A, to aid in installing the pad.

[0078] Pads 280a-280care also configured for ease of installation. As seen in FIG. 22A, pad 280ais provided with guide tab 290aand pull string 292asecured through guide hole 291 a of the guide tab. The guide tab extends in the same general plane as the attachment member 286a, and a portion or all of the guide tab can likewise be drawn into the jaw channel (not shown). The pull string 292acan be grasped and pulled, imparting tension to the guide tab, to bring the pad into place on the jaw. This method is especially advantageous when installing a pad on a curvilinear jaw. As illustrated in FIG. 23, the pad will most easily be pulled onto a curvilinear jaw when the force applied to the pad is tangential to the curve. The use of the pull string allows for easy and quick adjustments to the direction of the pulling force applied to the pad, and in the case of a curvilinear jaw, allows for simple and easy maintenance of force along the curve tangent, which in turn, allows for easier installation of the pad. Pad 280bshown in FIG. 22B, includes guide tab 290b, which also extends from attachment member 286b. Pull strap 292bis secured through guide hole 291b, and can be used like the pull string of pad 280ato install the pad in similar fashion. Pad 280cincludes pull string 292csecured through guide hole 291c, which likewise can be used to install the pad onto the jaw. Once installed, pull strings 292a, 292cor pull strap 292bcan be cut away, and the clamp deployed for use.

[0079] The configuration of the guide tabs also aid in the installation of the pads. Guide tab 290b, which extends in a plane generally parallel to the pad surface, can track along the outer or engaging surface of the jaw, and slides more easily over the jaw surface-than does the elastomeric material of the pad body. Similarly, guide tab 290a, which extends in the same general plane as the attachment member, can easily track and slide along the jaw channel.

[0080] In any of the replaceable pads of the invention, a second tab can be provided at the other end of the pad to aid in removal of an installed pad from the clamp jaw. This second tab can also include a guide hole extending therethrough. By applying a pulling or tension force to the second tab, the attachment member is drawn from the elongate cavity or channel of the jaw. When a second tab is provided, it may be convenient to apply tension to the tab by means of a grasping tool, e.g., forceps, pincers, etc. In FIG. 24, pad 280dincludes a second guide tab 292dand a second guide hole 291d. A towel clamp T has engaged the guide tab and is secured through guide hole 291d. By applying force to the towel clamp, the attachment member of the pad can be removed from its engaging relationship with the jaw (not shown).

[0081] Pad 380 of FIGS. 25 and 26 is also configured for ease of installation, and is provided with securing portion 388 which is discontinuous, in particular, being formed of intermittently spaced segments 389 with gaps in between, as previously described. The segments function much as the continuous securing portion of pad 180 to secure the pad onto either jaw 66 or 166. The provision of gaps between the segments imparts a greater degree of flexibility to the pad, especially lateral flexibility. This increased flexibility in turn makes the pad easier to install onto a jaw, especially a curvilinear jaw. In particular, the segmented nature of the securing portion makes the pad even less resistant to lateral bending, thereby facilitating installation onto a curved jaw. The segments can be uniform or non-uniform. In an alternative embodiment (not shown) the most proximal segment can be longer and slightly wider in diameter than the other segments. With such a configuration, when installed, this proximal segment will have a tighter compression fit in a receiving jaw cavity, thereby “locking” the pad in place.

[0082] Pads of this configuration can easily be installed manually onto a curved jaw, without the need, for example, of a pull tab, or a draw cord and corresponding through hole at the jaw end. If desired, to increase pad flexibility even more, the gaps between the segments can extend further up into the attachment member (not shown), provided the attachment member still retains adequate structural integrity to remain securely attached to the pad body. Alternatively, these pads can also be provided with draw cords, tabs, and/or guide holes and pull strings or pull straps as described above.

[0083] The provision of removable pads has a number of advantages over clamps without removable pads. The pads can be individually sterilized and provided for installation under sterile conditions. Clamps with removable pads are also easier to clean. The pads may be removed and the clamp autoclaved, then new pads installed. (Autoclaving may degrade or otherwise wear out soft or otherwise non-metallic parts of the clamp, so many clamps omit pads. Similarly, soft or otherwise fragile pads may wear out, so these may be easily replaced.) The pads may have different surfaces, so when a different surface is desired the appropriate pad may be easily installed. In addition, the pad may be flexible for installation in curved or S-shaped jaws, as shown, e.g., for pad 80 in FIG. 15, and pad 280ain FIG. 23. In such a case, advantages of convenience and economics can be achieved as the same pad configuration may be used for a number of clamp shapes (straight, curved, S-shaped, etc.).

[0084] Pad Construction

[0085] FIGS. 10-13 illustrate various stages in the manufacture of pad 80 that includes reinforcing mesh 110. FIG. 10 shows that the draw cord 86 may have a length of approximately 6-8 inches for all lengths of pads. The actual pad portion, as represented by a mesh 110, may have a length appropriate to the jaws to which the pad is to be installed. For example, the pad 80 may have a length from approximately 25 to 86 millimeters.

[0086] The mesh 110 may be a plain weave fabric (e.g., a filter cloth) and preferably has 46 threads per inch, with a range from approximately 20 to 100 threads per inch. A preferred material is nylon mesh. The mesh 110 is preferably cut on a bias of 45 degrees so that the threads extend at an angle from the direction of cutting.

[0087] In a preferred method of manufacture of the pad 80, the mesh 110 is folded in half longitudinally and placed in a longitudinal first mold, forming a V-shape. Then, nylon or polypropylene is injection molded in the fold to form the draw cord 86. The injection molding process also attaches the draw cord 86 to the threads of the mesh 110.

[0088] Next, the mesh and pull string structure is removed from the first mold and placed in a longitudinal second mold 120, a cross-section of which is shown in FIG. 14. The second mold 120 has a body space 124, a neck space 126, and a draw cord space 128. The draw cord 86 fits within the draw cord space 128. The other spaces mold a thermoplastic elastomeric material, when it is injected into the second mold, to form the neck 96 and pad body 98 of the pad 80 shown in FIG. 4.

[0089] The mesh 110 is again placed into a V-shape in the mold 120. Then, the thermoplastic elastomer is injected into the second mold to form the pad 80 on the draw cord 86 and around the mesh 110. The elastomer is preferably of 30 durometer and shore “A”, with a range from approximately 15 to 70 durometer. A preferred elastomer is the brand Kraton from Shell Corp. Other elastomeric materials include silicone and urethane. Alternatively, the neck 96 may be formed from a material different from that of pad body 98, such as plastic.

[0090] The triangular clamping surface 100 may be formed by a suitable covering portion of the mold 120. Once the elastomer has cured, the pad 80 is removed from the second mold 120.

[0091] In a modified preferred method, the pad 80 may be fabricated with only one web of the mesh 110. Preferably once the draw cord 86 has been attached, one web of the resulting V-shaped mesh 110 is cut off before the pad 80 is molded. This results in a single web mesh structure being formed in the pad 80, instead of the two webs of the V-shaped mesh. Another option is for the draw cord 86 to be attached along one edge of an unfolded web of the mesh 110.

[0092] In a second method, the draw cord 86 is provided and a longitudinal slit is made in the draw cord. The mesh 110 is then folded and the folded edge portion is placed in the slit. FIG. 11 shows a cross-sectional view of this construction. The mesh 110 may then be attached to the draw cord 86 with glue or other adhesive. Then the elastomer is molded as described above in the preferred method.

[0093] FIG. 12 is a cross-section of the pad 80 showing a preferred orientation of the mesh 110 within the pad. The pad body 98 provides support for the mesh 110. In turn, the mesh 110 provides support for the pad body 98 and neck 96. Thus, the mesh 110 and pad body 98 provide mutual reinforcement. This mutual reinforcement is helpful during the installation process of the pad 80 in the jaw 66. In addition, the mutual reinforcement is helpful when the neck 96 pulls the pad body 98 against the outer surfaces 92 of the jaw 66.

[0094] FIG. 13 is a perspective view of pad 80 with portions cut away to show detail. This figure shows that the elastomeric material of the pad body 98 and neck 96 has flowed between the filaments of the mesh 110 during the molding process. Upon curing, the elastomeric material encapsulates the filaments, binding them to one another and to the cured pad, forming a web-like structure. This encapsulation is more fully detailed in the co-pending application Ser. No. 09/336,018 entitled “Surgical Clamp Pads With Elastomer Impregnated Mesh” filed Jun. 18, 1999, commonly owned by the assignee of the present application and incorporated by reference herein. This copending application further details that the mesh itself may protrude from the pad body 98 to form the clamping surface 100.

[0095] FIG. 10A shows that stabilizing elements 112 may be used in place of mesh 110 to internally reinforce the pad. The stabilizing elements 112 may be made from the same material as draw cord 86, e.g., nylon or polypropylene. The stabilizing elements 112 may be molded concurrently with the molding of draw cord 86. As earlier detailed, the attachment member 85 is preferably the portion of draw cord 86 commensurate with the stabilizing elements 112.

[0096] Pad 180, as depicted in FIG. 18C, can be formed in like fashion, with stabilizing portion 194 concurrently molded with attachment member 186, and then pad body 198 molded over the formed stabilizing portion. The stabilizing portion and attachment member are likewise formed of materials such as nylon or polypropylene that are stiffer and less easily deflectable material than pad body itself, thereby strengthening the pad against lateral movement. Pads 280a-280dand 380 can also be formed in a similar fashion. For pads 280a-280d, it is preferable that the guide tabs be integrally formed with the attachment member. Pad 380 can be formed in like fashion as well. Segments 389 of securing portion 388 can be molded directly or, alternatively, the securing portion can first be formed continuously, and then gaps or notches can be cut out of the continuous portion to form segments 389.

[0097] FIGS. 21A-21D show alternative embodiments of pads that include stabilizing elements having varying configurations. Each pad 180a-180dincludes attachment members 186a-186d, respectively, each having securing portions 192a-192dand stabilizing portions that further include one or more stabilizing elements 196a-196dthat extend into the pad bodies. In each case, the stabilizing elements terminate below the pad surface.

[0098] Pad 180aincludes stabilizing element 196athat extends into pad body 198agenerally perpendicular to the tissue engaging surface of the pad. Pad 180bincludes two stabilizing elements 196bthat diverge from one another. Pad 180cincludes stabilizing element 196cthat extends laterally within the pad body, that is, generally parallel to the tissue engaging surface of the pad. Pad 180dincludes stabilizing element 196dthat extends laterally within the pad, but that also includes portions extending upward, i.e., generally vertical to the tissue engaging surface of the pad.

[0099] One skilled in the art will appreciate that the invention contemplates a wide variety of configurations of stabilizing elements, provided they function to promote lateral stability while still allowing for adequate compressibility of the pad itself to minimize trauma to engaged tissue. For example, the relative thickness of the elements as well as depth the elements extend into the pad can be adjusted to obtain the desired resistance to lateral movement and compressibility. The stabilizing elements can also extend within and along the entire length of the pad, or alternatively they can extend within only certain portions of the pad. In this manner, the configuration of stabilizing elements can be adjusted to alter the overall flexibility of the pad.

[0100] FIG. 21E depicts a modification of the pads of FIGS. 21A-D. Pad 180eis similar to pad 180dand includes stabilizing element 196e, a portion of which extends laterally within pad body 198e. A portion of stabilizing element 196ehowever extends from the pad body and is in directed contact with the corresponding engaging surface of clamp jaw according to the invention when the pad is attached to the jaw (not shown) according to methods previously described. The direct contact of the stabilizing element with the jaw surface facilitates installation of the pad on the jaw, as the element more easily slides over the jaw surface than the elastomeric material of the pad body.

[0101] From the foregoing detailed description, it is believed that the present invention enables the attainment of the objects initially set forth herein. In particular, the invention provides a surgical clamp having a cavity or channel to receive a replaceable pad. The pad can include a draw cord, tab, pull string or pull strap for easy installation and removal.

[0102] Such a surgical clamp has a number of general advantages over many existing clamps in addition to the advantages discussed above. The replaceable pads according to the present invention are sleeker and have a lower profile, and may be made of softer and more delicate materials. Such pads also increase the clamp shapes available to use pads, because many existing pads conform only to straight jaws.

[0103] It should be understood that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention. It is intended that the following claims define the scope of the invention and that structures within the scope of these claims and their equivalents are covered thereby.