BACKGROUND

1. Technical Field

The present disclosure relates to smoke evacuation systems.

2. The Relevant Technology

As is known to those skilled in the art, modern surgical techniques typically employ radio frequency (RF) power to cut tissue and coagulate bleeding encountered in performing surgical procedures. Such electrosurgery is widely used and offers many advantages including the use of a single surgical instrument for both cutting and coagulation. A monopolar electrosurgical generator system has an active electrode, such as in the form of an electrosurgical instrument having a hand piece and a conductive electrode or tip, which is applied by the surgeon to the patient at the surgical site to perform surgery and a return electrode to connect the patient back to the generator.

The electrode or tip of the electrosurgical instrument is small at the point of contact with the patient to produce an RF current with a high current density in order to produce a surgical effect of cutting or coagulating tissue through cauterization. The return electrode carries the same RF signal provided to the electrode or tip of the electrosurgical instrument, after it passes through the patient, thus providing a path back to the electrosurgical generator.

Electrosurgical instruments communicate electrical energy to a target tissue of a patient to cut the tissue and/or cauterize blood vessels within and/or near the target tissue. This cutting and cauterization results in smoke released into the air that can be distracting or otherwise unpleasant. Many electrosurgical systems may therefore employ an evacuation system that captures the resulting smoke and directs it through a filter and exhaust port, away from practitioners and/or patients. A smoke evacuation system typically creates suction directed at the smoke using fans to draw the smoke through a tube connecting the surgical instrument to an exhaust port.

Smoke evacuation systems typically comprise a pump and a filter. The pump creates suction that draws smoke through a vacuum tube into the filter. A vacuum tube may terminate at the hand piece that includes the electrode tip so that the smoke is sucked in at the hand piece. Other electrosurgical systems may include separate hand pieces that are used to suck the smoke into the system. The smoke travels to the filter via a vacuum tube and offensive smells and particulate are filtered out as the smoke moves through the filter. Filtered air may then exit the smoke evacuation system as exhaust. Periodically replacing the filters is necessary for the smoke evacuation system to remain effective.

The subject matter claimed herein is not limited to embodiments that solve any disadvantages or that operate only in environments such as those described above. Rather, this background is only provided to illustrate one exemplary technology area where some embodiments described herein may be practiced.

BRIEF SUMMARY

The present disclosure relates to smoke evacuation systems used in electrosurgical systems.

In one embodiment, a smoke evacuation system includes a housing surrounding an enclosure and an airflow path extending inside the enclosure from an inlet port to an outlet port of the smoke evacuation system. The system also includes a motor and pump disposed within the enclosure. A cooling mechanism is configured to induce airflow through the enclosure to cool the enclosure. The induce airflow is proportionate to the work output of the motor.

In one embodiment, a smoke evacuation system includes an inlet port, outlet port, an airflow path extending between the inlet port and the outlet port, and one or more cooling vents. The smoke evacuation system also includes an exhaust mechanism near the outlet port. The exhaust mechanism is configured to diffuse air exiting at the outlet port.

In one embodiment, a smoke evacuation system includes an airflow control mechanism, an exhaust diffuser, and a rotary mechanism. The airflow control mechanism reduces a pressure within the smoke evacuation system when abnormal flow or high pressures are detected. The exhaust diffuser reduces the exit noise of the filtered air without baffling or redirecting flow causing an exit head pressure. The rotary mechanism induces an airflow through the smoke evacuation system at a flow rate that is proportional to the rate at which a pump is pumping filtered air through the smoke evacuation system.

In one embodiment, a filter connection for a smoke evacuation system includes a filter canister and a socket. The filter canister comprises first and second ends, a body extending between the first and second ends, a connection nipple, a seal disposed around the connection nipple, and a first electronic connector. The socket comprises a first recess configured to receive the canister body, a second recess configured to receive the connection nipple, and a second electronic connector. The longitudinal distance between the seal and the first electronic connector is greater than the longitudinal distance between the second recess of the socket and the second electronic connector.

In one embodiment, a filter canister for a smoke evacuation system includes a first end having an inlet port, a second end, an electronic connector, and a connection nipple disposed at the second end. The cross-sectional shape of the second end of the filter canister has only one line of symmetry. The electronic connector is disposed at the second end of the filter canister.

In one embodiment, a method for connecting a filter in a smoke evacuation system includes the following steps: providing a filter canister; providing a socket in the smoke evacuation system; inserting the filter canister a first distance into the socket so that the filter canister creates an airtight boundary between the filter canister and the socket; and inserting the filter canister a second distance into the socket so that an a electronic connection is made between the filter canister and the socket. The second distance is greater than the first distance.

In one embodiment, a smoke evacuation system includes a filter, a pump that has a sealed positive displacement airflow path, and a motor that drives the pump. The sealed positive displacement airflow path of the pump may comprise one or more circulation paths of a gas within the pump. In one embodiment, the pump has a first operating pressure and a second operating pressure. The flow rate of a gas being pumped may be the same regardless of the operating pressure. The pump may compress incoming gas to create a pressure difference between various zones of airflow within the smoke evacuation system.

In one embodiment, a smoke evacuation system may include various vibration absorption mechanisms. The system may have a first housing enclosing the motor and the pump and a second housing enclosing the entire system. Vibration mechanisms may be disposed between the two housings and outside the second housing. Flexible tubing may also be incorporated to absorb vibrations.

A method of reducing the vibrations and noise of a smoke evacuation system may include regulating the motor engaged with the pump. The regulation of the motor may include varying a supply of current to the motor in order to operate the motor in at least two distinct operating levels. Regulation of the motor may depend on sensory inputs, such as temperature or pressure. Orifices may also be provided within the airflow path that allow communication with ambient surroundings of the system in order to relieve excessive resistance pressures in the system caused by blockages or clogging of the airflow path.

In an embodiment, a fluid trap for minimizing the escape of contaminated fluids from the fluid trap when an orientation of the fluid trap changes during removal or transport includes (i) a front cover defining an inlet port that extends a first distance into an interior chamber of the fluid trap, (ii) a rear cover coupled to the front cover and which defines an exhaust port extending a second distance away from the rear cover of the fluid trap and positioned above the inlet port when the fluid trap is in an upright position, and (iii) an interior chamber defined by the front and rear covers. The interior chamber includes a maximum fluid volume at least partially defined by the lesser of a fluid reservoir volume, a front cover volume, and a rear cover volume.

In one or more embodiments, the fluid reservoir volume is the volume defined by the interior sidewalls of the fluid trap below the inlet port, the front cover volume is equivalent to a product of the surface area of the front cover and an average depth of the front cover with respect to the first distance of the inlet port, and the rear cover volume is the volume of the interior chamber defined by interior sidewalls of the fluid trap and bounded by a line tangent to a lowest interior-facing sidewall of the exhaust port that is parallel with a surface upon which the exhaust port lies.

In an embodiment, a fluid trap for minimizing the escape of contaminated fluids includes an interior chamber defined by sidewalls of the fluid trap, an inlet port extending into the interior chamber that is or includes a notched cylindrical body that directs smoke in a defined direction, and an exhaust port positioned opposite and above the inlet port. The exhaust port defines an open channel between the interior chamber of the fluid trap and an area outside the fluid trap. Additionally, the fluid trap can include a splash canopy positioned between the inlet port and the exhaust and extending laterally across a width of the inlet port, and in an embodiment, the fluid trap additionally includes a splash wall spanning opposing sidewalls of the interior chamber and extending vertically from a first point coplanar with at least a portion of the splash canopy to a second point coplanar with at least a portion of the exhaust port. The splash canopy and/or the splash wall can, in some embodiments, include a fibrous fluid wicking material that enables removal of aerosols and/or small droplet fluids and additionally, or alternatively, act as condensation promoting surfaces.

In an embodiment, a smoke evacuation system includes a suction pump, a filter connected to the suction pump, and a fluid trap connected to the filter. The fluid trap includes an interior chamber, a sensor disposed within the interior chamber for monitoring a fluid level within the fluid trap, and a visual indicator in electrical communication with the sensor that represents the fluid level within the fluid trap. Additionally, in an embodiment, the sensor is an optical emitter and detector pair, an ultrasonic detector, a resistive strip, or a combination thereof that senses the amount of fluid in the fluid trap and activates a corresponding visual indicator to communicate the fill status of the fluid trap, such as the fluid trap reaching a maximum fill state.

In an embodiment, a filter includes (i) a filter body, (ii) a front cap associated with a first end of the filter body and coupled to and receiving smoke from a vacuum hose, (iii) a back cap associated with a second end of the filter body and having a filter exhaust sized and shaped to associate with and communicate suction from a smoke evacuation system, (iv) a compressed carbon reservoir disposed within the filter body between the front cap and the back cap, and (v) a flexible porous barrier disposed on at least a first side of the compressed carbon reservoir.

In an embodiment, a replaceable filter for processing smoke derived from electrosurgery includes (i) a filter body, (ii) a front cap associated with a first end of the filter body, (iii) a back cap associated with a second end of the filter body and configured to receive suction, (iv) one or more particulate filters disposed within the filter body between the front cap and the back cap, (v) a compressed carbon reservoir disposed within the filter body between the one or more particulate filters and the back cap, and (vi) a flexible porous barrier disposed on at least a first side of the compressed carbon reservoir.

In an embodiment, a three-stage filter for processing smoke derived from electrosurgery includes a first stage for removing one or more fluids from the smoke, a second stage for removing particulates, and a third stage having a compressed carbon reservoir. The first stage can include a fluid trap having a fluid trap inlet port and a fluid trap exhaust port. The fluid trap inlet port extends into an interior chamber of the fluid trap and couples to and receives smoke from a vacuum hose. The fluid trap exhaust port is positioned opposite and above the fluid trap inlet port and defines an open channel between an interior chamber of the fluid trap, where one or more fluids extracted from the smoke are retained, and the second stage of the three-stage filter. In some embodiments, the second-stage removes particulates using one or more particulate filters, such as a coarse media filter and an ultra-low penetration air (ULPA) filter in series. In some embodiments, the third stage can be under a compressive bias by a flexible porous barrier. The flexible porous barrier can transition from a flexed state to a partially relaxed state in response to the compressed carbon reservoir reducing in volume, which in some embodiments is caused by settling of the compressed carbon reservoir or pressure from suction applied to the compressed carbon reservoir.

In an embodiment, an RF current sensor is configured to operate in at least two modes—a first mode and a second mode—and includes (i) a sensor body having at least a cable interfacing sidewall and a retaining member, the cable interfacing sidewall and the retaining member defining a retention pocket configured to receive a cable communicating RF current, (ii) a sensor element for detecting RF current in the cable, and (iii) a sensor cable in electrical communication with the sensor element, the sensor cable communicating one or more of an activation signal or a current signal derived from the detected RF current to the smoke evacuation device.

The RF sensor can operate in the first mode when the sensor element identifies a single RF current in the cable. The single RF current in the cable can be communicated between a signal generator and an active electrode of a monopolar electrosurgical instrument or between a return electrode and the signal generator, and the activation signal and/or the current signal are derived from the single RF current when the RF current sensor operates in the first mode. The RF sensor can operate in the second mode when the sensor element identifies two RF currents—a first RF current flowing in an opposite direction as a second RF current—in the cable. Operating in the second mode causes the RF current sensor to detect the first RF current with respect to the second RF current and to derive the activation signal and/or the current signal from the first RF current.

In an embodiment, a method for remote activation of a smoke evacuation device includes (i) generating an RF current at a signal generator, (ii) communicating the RF current through a source cable to an electrosurgical instrument, (iii) detecting an activation of RF current with an RF current sensor communicatively coupled to a smoke evacuation device, (iv) communicating an activation signal from the RF current sensor to the smoke evacuation device in response to detecting the activation of RF current, (v) receiving the activation signal at the smoke evacuation device, and (vi) activating a vacuum source for one or more of a defined period of time or to generate a defined smoke evacuation flow rate in response to receiving the activation signal.

In some embodiments, the method for remote activation of a smoke evacuation device can additionally include (i) detecting the RF current with the RF current sensor subsequent to detecting the activation of RF current, (ii) periodically or continuously communicating a current signal from the RF current sensor to the smoke evacuation device in response to detecting the RF current, the signal current including data associated with the RF current, (iii) receiving the current signal at the smoke evacuation device, and (iv) in response to receiving the current signal, adjusting the defined period of time and/or the defined smoke evacuation flow rate of the vacuum source.

In some embodiments, the method for remote activation of a smoke evacuation device can additionally include deriving a treatment power based on the activation signal and/or the current signal and calculating an estimated smoke production based on the treatment power, and the defined period of time and/or the defined smoke evacuation flow rate can be based on the estimated smoke production.

In an embodiment, an electrosurgical system includes (i) a signal generator producing an RF current, (ii) a source cable electrically coupled to the signal generator and to an electrosurgical instrument, the source cable communicating the RF current from the signal generator to the electrosurgical instrument, (iii) a smoke evacuation device that includes a vacuum hose positioned proximate the electrosurgical instrument and configured to evacuate smoke generated by the electrosurgical instrument, and (iv) an RF current sensor communicatively coupled to the smoke evacuation device, the RF current sensor activating the smoke evacuation device in response to identifying the RF current.

In some embodiments, the RF current sensor is removably coupled to the source cable or the return cable and detects RF current flowing therethrough. In some embodiments, the RF current sensor is integrally formed within the return electrode or within the smoke evacuation device.

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

Additional features and advantages of the disclosed embodiments will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of the disclosure. These and other features will become more fully apparent from the following description and appended claims, or may be learned by the practice of the present disclosure.

