Surgical suction venting system

Abstract

To provide favorable filter systems and the like.SOLUTION: A filter system for use with a suction canister or suction bag is disclosed, where the filter system includes a first filter and a second filter for retention of particles, smoke aerosol, liquid, aerosolized viruses and aerosolized bacteria, while maintaining high airflow and liquid retention. The first filter and the second filter are each multi-layered for performance. In various examples, the first and second filters are configured to integrate directly with the vacuum port of a suction canister lid.SELECTED DRAWING: Figure 5C

Description

[Technical Field]

[0001] Field The present disclosure relates to filter systems, such as those used in medical devices, and in particular, various examples relate to filter systems for medical suction canisters. [Background technology]

[0002] background During medical procedures, including surgery, suction canister systems are used to collect fluids, including blood and other bodily fluids, and rinses such as saline or Ringer's solution. Such fluids can accumulate within the body during a medical procedure and must be removed, contained, and discarded after the procedure. A conventional canister system can include a cylindrical canister closed by a cover or lid. The cylindrical canister can include a liner, or the canister can be a flexible-sided container or bag with a cover or lid. The lid includes a vacuum port for operably coupling the canister to a vacuum to create subatmospheric pressure within the canister. A collection tube can also be coupled to the patient port of the lid, and a vacuum is formed at the lid end of the collection tube to create suction. Various attachment or connection elements can also be included in the canister system, including an outlet or "ortho" port with a wide riser portion, a large access port with a cap, or a float valve configured to prevent fluid from being drawn into the vacuum.

[0003] Often, the vacuum operably coupled to the canister is part of a vacuum system common to several areas of the corresponding facility. Therefore, minimizing the intrusion of foreign objects, particles, aerosols, surgical smoke, bacteria, viruses, and fluids into the vacuum system is important to avoid contaminating the rest of the system. In fluid collection systems, fluids and / or materials within the fluids can evaporate under the influence of the vacuum system and become airborne. To mitigate contamination, filter elements are sometimes used in the vacuum port of the canister system, collectively known as aerosol traps. Aerosol traps are traditionally assembled on the canister side of the vacuum port, all of which require individual handling of the filter assembly components. Conventional canisters are not configured to effectively filter the above-mentioned contaminants. Instead, such filtration is attempted using additional accessories connected between the canister and the vacuum pump. These additional accessories must be acquired, stored, selected, assembled, used, and then discarded. The level of detail required to properly assemble the filter assembly within the canister to achieve the appropriate level of filtration to prevent contamination of the vacuum system makes the assembly and disassembly processes time-consuming and labor-intensive. Summary of the Invention

[0004] Abstract In a first aspect of the present disclosure, a filter system is disclosed, the filter system including: a housing defining an internal chamber including a chamber opening and an outlet port disposed on a base opposite the chamber opening; a first support member coupled to the housing; a first filter disposed above the chamber opening of the housing; and a second filter disposed between the first support grid and the first filter, wherein a liquid reservoir is defined by the first filter and the second filter.

[0005] In a second aspect of the present disclosure, a filtering assembly is disclosed. The filtering assembly includes a lid defining a port and a filter system integrated into the port. The filter system includes a first filter defining a thickness of about 120 microns to about 2000 microns, and a liquid entry pressure of 75 kPa or greater for 10 minutes at a surface tension of 55.5 mN / m and a flow rate of 9.3 cm. 2 and a second filter that maintains an airflow of greater than 20 liters per minute at a pressure drop of 11.5 kPa over an effective area of ​​100 mm. The first filter includes a first layer and a second layer, the first layer including a different material than the second layer.

[0006] In a third aspect of the present disclosure, a filter system is disclosed. The filter system includes a housing. The housing includes a base, a port defining an outlet extending from a first side of the base, a first wall extending from a second side of the base, and a second wall extending from the second side of the base, the first wall and the second wall defining a groove. The filter system includes: a first support member including an upper sidewall, the first support member configured to be received in the groove of the housing to couple the support member to the housing; a splash guard defining an inlet and an outlet and coupled to the first support member; a first filter disposed at the outlet of the splash guard; a second support member disposed between the first filter and the first support member; and a second filter disposed between the first support member and the second support member.

[0007] In various embodiments of the present disclosure, the second filter has a liquid inlet pressure of 75 kPa or greater for 10 minutes at a surface tension of 55.5 mN / m and a flow rate of 9.3 cm 2maintains an airflow of greater than 20 liters / minute with a pressure drop of 11.5 kPa over an effective area of ​​100 mm. In various embodiments of the present disclosure, the liquid reservoir has a thickness of 0.04 millimeters to 2 millimeters. In various embodiments of the present disclosure, the liquid reservoir has a thickness of 2 millimeters to 15 millimeters. In various embodiments of the present disclosure, the liquid reservoir has a thickness of 15 millimeters to 80 millimeters. In various embodiments of the present disclosure, the first filter defines a thickness of about 120 microns to about 2000 microns. In various embodiments of the present disclosure, the liquid reservoir includes a third layer of the first filter. In various embodiments of the present disclosure, the liquid reservoir includes a second support member positioned between the first filter and the second filter such that the first filter and the second filter are spaced apart from one another. In various embodiments of the present disclosure, the filter assembly includes a splash guard coupled to the first support member and extending from the first support member in a direction away from the housing, the splash guard defining an inlet and an outlet. In various aspects of the present disclosure, the splash guard has a conical shape and the outlet of the splash guard is wider than the inlet of the splash guard.

[0008] In various embodiments of the present disclosure, the canister port is communicatively coupled to a vacuum configured to maintain airflow through the filter system. In various embodiments of the present disclosure, the suction canister includes a container having flexible sides. In various embodiments of the present disclosure, the suction canister includes a rigid container. In various embodiments of the present disclosure, the filter system is integrated into the port by ultrasonic welding. In various embodiments of the present disclosure, the filter system is heat welded to the lid so that the filter system covers the port. In various embodiments of the present disclosure, the second filter is hydrophobic. In various embodiments of the present disclosure, the first filter includes a second layer including polymer filaments less than 6 microns in diameter. In various embodiments of the present disclosure, the first filter includes a second layer including thermoplastic filaments. In various embodiments of the present disclosure, the first filter includes a second layer including polypropylene, polyethylene, polyethylene terephthalate, polyethylene terephthalate copolymer, or non-thermoplastic filaments. In various embodiments of the present disclosure, the first filter includes an oleophobic first layer. In various embodiments of the present disclosure, the first filter includes a 0.5 m 2 / g or greater than 2m 2 In various embodiments of the present disclosure, the second filter comprises a thermoplastic textile layer.

[0009] In various aspects of the present disclosure, the port of the housing is configured to couple to a vacuum port of the suction canister. In various aspects of the present disclosure, the splash guard has a conical shape, and the outlet of the splash guard is wider than the inlet of the splash guard. In various aspects of the present disclosure, the first filter includes multiple layers, and the first layer includes a different structure than the second layer.

[0010] The above-described embodiments are merely embodiments and should not be construed to limit or otherwise narrow the scope of the inventive concepts provided by the present disclosure. While multiple embodiments are disclosed, still other embodiments will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive. [Brief explanation of the drawings]

[0011] BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings are included to provide a further understanding of the disclosure, and are incorporated in and constitute a part of this specification, illustrate embodiments and, together with the description, serve to explain the principles of the disclosure.

[0012] [Figure 1] FIG. 1 shows an exploded view of one embodiment of a filter system including a first filter and a second filter, each including a membrane and a membrane support, according to at least one embodiment.

[0013] [Figure 2] FIG. 2 is a scanning electron micrograph (SEM) of a cross section of the second filter of FIG. 1 including a membrane and a membrane support, according to at least one embodiment.

[0014] [Figure 3] FIG. 3 is a scanning electron micrograph (SEM) of a cross section of the first filter of FIG. 1 , including the first, second, and third layers of the first filter, each defining a thickness according to at least one embodiment.

[0015] [Figure 4A] FIG. 4A is a top view of the filter system of FIG. 1 welded to an example suction canister lid.

[0016] [Figure 4B]4B is a perspective view of the filter system of FIG. 1 welded to a representative lid of a suction canister according to at least one embodiment.

[0017] [Figure 5A] FIG. 5A is a top perspective view of a filter system including a housing and a splash guard according to at least one embodiment.

[0018] [Figure 5B] FIG. 5B is a bottom perspective view of the filter system of FIG. 5A according to at least one embodiment.

[0019] [Figure 5C] FIG. 5C is a cross-sectional view of the filter system of FIG. 5A according to at least one embodiment.

[0020] [Figure 5D] FIG. 5D is an exploded cross-sectional view of the filter system of FIG. 5A according to at least one embodiment.

[0021] [Figure 5E] FIG. 5E is a top view of the first support member of the filter system of FIG. 5A according to at least one embodiment.

[0022] [Figure 5F] 5F is a bottom cross-sectional view of the filter system of FIG. 5A illustrating a second support member of the filter system of FIG. 5A according to at least one embodiment.

[0023] [Figure 5G] FIG. 5G is a top view of a second embodiment of a second support member of the filter system of FIG. 5A, according to at least one embodiment.

[0024] [Figure 5H] FIG. 5H is a top view of a third embodiment of the second support member of the filter system of FIG. 5A, according to at least one embodiment.

[0025] [Figure 6A] FIG. 6A is a cross-sectional view of an alternative embodiment of the filter system of FIG. 5A, according to at least one embodiment.

[0026] [Figure 6B] FIG. 6B is a cross-sectional view of a second alternative embodiment of the filter system of FIG. 5A, according to at least one embodiment.

[0027] [Figure 7] FIG. 7 is a schematic diagram of the coupling of the filter system of FIG. 5A with a suction canister lid, according to at least one embodiment.

[0028] [Figure 8] FIG. 8 is a schematic diagram of a test fixture for testing smoke particle retention of a filter system, according to at least one embodiment.

[0029] [Figure 9] FIG. 9 is a graphical representation of the smoke retention capacity of a filter system including a first filter as described herein, according to at least one embodiment, compared to a filter system not including a first filter, as measured by percentage of normalized airflow over time under constant smoke exposure.

[0030] [Figure 10A] FIG. 10A is a schematic diagram of the filter system of FIG. 1 coupled to a representative suction canister lid, according to at least one embodiment.

[0031] [Figure 10B] FIG. 10B is a photograph of the suction canister and filter system of FIG. 10A, where the suction canister is filled with deionized water, according to at least one embodiment.

[0032] [Figure 10C]FIG. 10C illustrates an inverted position of the suction canister of FIG. 10A, according to at least one embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0033] Detailed Description Those skilled in the art will readily appreciate that the various aspects of the present disclosure may be implemented by any number of methods and apparatus configured to perform the intended functions. It should also be noted that the accompanying drawings referred to herein are not necessarily drawn to scale and may be exaggerated to illustrate various aspects of the present disclosure, and in that regard, the drawings should not be construed as limiting.

[0034] Definitions and Terminology With respect to the term imprecision, the terms "about" and "approximately" may be used interchangeably to refer to a stated measurement, including any measurement that is reasonably close to the stated measurement. A measurement that is reasonably close to the stated measurement deviates from the stated measurement by a reasonably small amount, as would be understood and easily ascertained by one of ordinary skill in the relevant art. Such deviations may be due to measurement error, fine-tuning made to optimize performance, or the like. If it is determined that such a reasonably small difference would not be easily ascertainable by one of ordinary skill in the relevant art, the terms "about" and "approximately" may be understood to mean plus or minus 10% of the stated value.

[0035] This disclosure is not intended to be read in a restrictive manner. In other words, the terms used in this application should be read broadly in the context of the meanings ascribed to such terms by experts in the field.

[0036] Description of the Disclosed Embodiments FIG. 1 illustrates a layered filter system 100 for filtering contaminants, such as feces, in a medical procedure environment, including surgery. The layered filter system 100 includes a first filter 102 and a second filter 104. The second filter 104 may include a membrane 106 and a membrane support 108. The membrane 106 of the second filter 104 is configured to provide a barrier against bacteria and viruses contained in bodily fluids, rinse fluids, aerosolized fluids, or other fluids, as described further herein. The membrane support 108 provides strength and support to the second filter 104 and can be a weldable material, such as a polyester nonwoven material or a thermoplastic, to facilitate easy integration of the layered filter system 100 with a canister. In some embodiments, the layered filter system 100 may be integrated with or coupled to a suction canister lid.

[0037] The membrane 106 can be formed from expanded polytetrafluoroethylene (ePTFE), polyethylene, polyvinylidene difluoride, polyethersulfone, or electrospun polymer materials. The material forming the membrane 106 has hydrophobic and / or oleophobic properties that allow for high airflow and provide liquid barrier properties. The membrane 106 can be impermeable or relatively impermeable to the passage of liquids at a maximum operating pressure of up to 16 psi water entry pressure (WEP), while remaining highly permeable to the passage of gases and / or vapors. The membrane 106 can define a thickness of about 40 microns to about 150 microns, and the thickness can be about 40 microns to about 55 microns, about 55 microns to about 70 microns, about 70 microns to about 90 microns, about 90 microns to about 120 microns, or about 120 microns to about 150 microns.

[0038] The membrane support 108 includes a textile layer and can be formed, for example, from a thermoplastic textile (e.g., nonwoven polyester) or from polyethylene, polypropylene, polyvinyl chloride, or polyethylene terephthalate. The membrane support 108 can define a thickness of about 60 microns to about 600 microns, which can be about 60 microns to about 110 microns, about 110 microns to about 150 microns, 150 microns to about 190 microns, about 190 microns to about 230 microns, about 230 microns to about 280 microns, about 280 microns to about 330 microns, about 330 microns to about 400 microns, about 400 microns to about 500 microns, or about 500 microns to about 600 microns.

[0039] The second filter 104 can define a total thickness of about 100 microns to about 750 microns, and the second filter can have a thickness of about 100 microns to about 200 microns, about 200 microns to about 300 microns, about 400 microns to about 500 microns, about 500 microns to about 600 microns, or about 600 microns to about 750 microns. In various embodiments, the second filter 104 can maintain a liquid inlet pressure of 75 kPa or greater for at least 10 minutes at a surface tension of 55.5 mN / m and a flow rate of 9.3 cm. 2 configured to maintain an air flow of greater than 20 liters per minute with a pressure drop of 11.5 kPa over an effective area of ​​1.5 m.

[0040] In one embodiment, the second filter maintains high liquid retention (i.e., a bubble point of at least 8 psi) and exhibits increased bacterial filtration efficiency (BFE) and viral filtration efficiency (VFE), maintaining an airflow of about 12 liters / minute to about 8 liters / minute over one hour of continuous smoke, for example, during an electrosurgical procedure. In some embodiments, the bubble point can be at least 7.5 psi, at least 8 psi, at least 8.5 psi, or between 7 psi and 8.5 psi, 8 to 9.5 psi, or 8.5 to 10 psi.

[0041] 3 is a microscopic view of a cross section of the first filter 102. In various embodiments, the first filter 102 is approximately 0.5 mm thick. 2 / g ~ approx. 2m 2 The first filter 102 defines a specific surface area of ​​100 μm / g and includes three layers. The first layer 110 of the first filter 102 defines a thickness of about 40 microns to about 200 microns, and the first layer can have a thickness of about 40 microns to about 55 microns, about 55 microns to about 70 microns, about 70 microns to about 100 microns, about 100 microns to about 150 microns, or about 150 microns to about 200 microns. The first filter can be formed from filaments of polypropylene, polyethylene, polyethylene terephthalate, polyethylene terephthalate polyamide copolymer, polybutylene terephthalate, or combinations thereof. Each filament has a diameter of about 10 microns to about 30 microns. The first layer 110 can have oleophobic properties.

[0042] The second layer 112 defines a thickness of about 140 microns to about 1600 microns, and the second layer can have a thickness of about 140 microns to about 640 microns, about 640 microns to about 1140 microns, 1140 microns to about 1390 microns, or about 1390 microns to about 1600 microns. The second layer includes a plurality of filaments formed from polypropylene, polyethylene, polyethylene terephthalate, polyethylene terephthalate copolymer, polybutylene terephthalate, glass, a thermoplastic polymer, or a non-thermoplastic polymer. Each filament has a diameter of about 0.8 microns to about 8 microns, and each filament can have a diameter of about 0.8 microns to about 2 microns, about 2 microns to about 4 microns, or about 4 microns to about 6 microns.

[0043] The third layer 114, like the first layer 110, defines a thickness of about 40 microns to about 200 microns, and the first layer can have a thickness of about 40 microns to about 55 microns, about 55 microns to about 70 microns, about 70 microns to about 100 microns, about 100 microns to about 150 microns, or about 150 microns to about 200 microns. The first filter can be formed from filaments of polypropylene, polyethylene, polyethylene terephthalate, polyethylene terephthalate polyamide copolymer, polybutylene terephthalate, or combinations thereof. Each filament has a diameter of about 10 microns to about 30 microns.

[0044] The layered filter system 100, including the first filter 102 and second filter 104 described above, can be integrated into the vacuum port 116 of a conventional suction canister lid 118 by welding, as shown in Figures 4A and 4B. This integration method can include a two-step integration, where the second filter 104 (Figure 1) is heat-welded to the canister lid 118 in one step so as to cover the vacuum port 116 of the canister lid 118, and the first filter 102 is heat-welded to the canister lid 118 and the second filter 104 in a separate step. In other embodiments, the first filter 102 and the second filter 104 can each be welded to the canister lid 118 in a single step, with the second filter 104 positioned closest to the canister lid 118. Thus, in each embodiment, when suction is applied to the vacuum port 116, any media to be filtered first passes through the first filter 102, then through the second filter 104, and out the vacuum port 116. In some embodiments, the layered filter system 100 may be integrated with the vacuum port 116 by ultrasonic or heat welding. The suction canister lid 118 may accommodate a flexible-sided container or liner (FIGS. 10A-10C), a cup, a rigid container or other relatively resilient-walled container, or a typical suction canister that includes both a cup and a liner.

[0045] 5A-5F illustrate another embodiment of a filter system 200. The filter system 200 includes a housing 202 defining a port outlet 204, a first support member 236, a second support member 270, and a splash guard 210. The housing 202 includes a top portion 212 defining the port outlet 204. The port outlet 204 may be further defined by a port sidewall 214 extending from a top surface 216 of the top portion 212 in a direction opposite the splash guard 210, as described further herein. A housing sidewall 218 extends from a bottom surface 220 of the top portion 212 in a direction opposite the port sidewall 214. The housing sidewall 218 may be disposed relative to the top portion 212 such that the top portion 212 defines a flange 222 extending outwardly from the housing sidewall 218. Alternatively, the housing sidewall 218 may be positioned flush with the outer periphery 224 of the top 212 or may be positioned to form a larger or smaller flange 222 relative to the housing sidewall 218 .

[0046] 5C and 5D show various components of filter system 200 in longitudinal cross section. As shown in Figures 5C and 5D, housing 202 can include an inner wall 226 disposed substantially concentrically with housing sidewall 218. Inner wall 226 and inner surface 228 of housing sidewall 218 cooperate to define a coupling gap 230 for assembly of filter system 200, as described further herein. A sidewall step 232 can be disposed on an upper portion of inner surface 228 of housing sidewall 218, and one or more inner wall steps 234 can be disposed on one or both sides of an upper portion of inner wall 226 of housing 202.

[0047] A first support grid or first support member 236 is coupled to the housing 202 via a coupling gap 230, as described further herein. The first support member 236 includes an upper sidewall 238 and a lower sidewall 240, each shaped to facilitate assembly of the filter system 200. The upper sidewall 238 is shaped to substantially match the coupling gap 230 formed by the housing 202. In some embodiments, the thickness of the upper sidewall 238 matches the general thickness of the coupling gap 230. The upper sidewall 238 may also include a ledge 242 to facilitate a snug or interference fit with at least one of the sidewall step 232 and the inner wall step 234. As shown in FIGS. 5C and 5D , the upper sidewall 238 may not include a ledge corresponding to both the sidewall step 232 and the inner wall step 234. In other embodiments, the upper sidewall 238 may not include a ledge 242. In yet other embodiments, the first support member 236 may be coupled to the housing 202 by welding or threading. In embodiments in which the first support member 236 is coupled to the housing 202 by threading or an interference fit, a flexible seal, such as a rubber seal or O-ring, may be disposed between the first support member 236 and the housing 202 to facilitate a fluid-tight seal, where liquids and / or gases cannot pass between the first support member 236 and the housing 202.

[0048] As shown, the outer surface 252 of the upper sidewall 238 defines an outer diameter 250 sized so that the outer surface 252 contacts the inner surface 228 of the housing sidewall 218 when the first support member 236 is coupled to the housing 202. The inner surface 254 of the upper sidewall 238 defines an inner diameter 256 and an inner perimeter 257, and the grid portion 259 of the first support member 236 spans the area defined by the inner perimeter 257. As shown in FIGS. 5C-5E , the grid portion 259 includes a first arm 260 and a second arm 261 that intersect perpendicularly near the center of the first support member 236. In other embodiments, the grid portion 259 can include more arms to form a checkerboard pattern, a spoke pattern, a Y-shape, or another arrangement or pattern spanning the area defined by the inner perimeter 257. In yet other embodiments, the grid portion 259 can include only a single arm spanning the area defined by the inner perimeter 257. The arms 260, 261 of the grid portion 259 define a plurality of openings 255 within an area defined by the inner periphery 257 of the first support member 236. The plurality of openings 255 constitutes at least 60%, at least 70%, at least 80%, or at least 90% of the area defined by the inner periphery 257 of the first support member 236.

[0049] 5D , a housing groove 244 is defined on an outer surface 246 of the lower wall 240 of the first support member 236. The groove 244 corresponds to a ridge 248 located on the lower portion of the inner surface 228 of the housing sidewall 218. When coupled, the ridge 248 of the housing 202 is received within the groove 244 of the first support member 236. A rim 258 extends from the outer surface 246 of the lower sidewall 240 along the lower edge of the lower sidewall 240. When coupled, the rim 258 contacts a bottom edge 262 of the housing sidewall 218 to provide additional support to the filter system 200.

[0050] A second groove 264 is defined in an inner surface 266 of lower sidewall 240 to facilitate assembly of the remaining portions of filter system 200, as described further herein. Inner surface 266 of lower sidewall 240 defines a lower diameter 268 for receiving additional components of filter system 200, as described further herein. As shown in FIG. 5C , lower diameter 268 can be larger than inner diameter 256. In other embodiments, lower diameter 268 can be smaller than or substantially the same as inner diameter 256, so long as the remaining components, as described further herein, can be adequately received by lower sidewall 240.

[0051] The second filter 104 is positioned below the grid portion 259 within the lower sidewall 240 of the first support member 236. As shown, the second filter 104 is shaped and sized to fit closely against the inner surface 266 of the lower sidewall 240 and can be in contact with the inner surface 266 of the lower sidewall 240. Thus, the second filter 104 can be larger than, or at least substantially the same size as, the inner diameter 256 of the upper sidewall 238. Preferably, the second filter 104 covers the opening in the first support member 236 defined by the grid portion 259 of the first support member 236 so that airflow through the second filter 104 is not significantly impeded by the grid portion 259 of the first support member 236. The second filter 104 inserted into the filter system 200 does not need to include a membrane support 108 ( FIG. 1 ).

[0052] 5F, a second support grid or support member 270 is inserted beneath the second filter 104. The second support member 270 includes a boundary 271 that defines an outer periphery 275 and an inner periphery 277 of the second support member 270, and the second support member 270 further includes a second grid portion 273 that spans the area defined by the inner periphery 277 of the second support member 270. The second grid portion 273 includes a first arm 279 and a second arm 281 that intersect perpendicularly near the center of the second support member 270. In other embodiments, the second grid portion 273 can include more arms, forming a checkerboard pattern as shown in FIG. 5G (which can also be applied to the first support member 236 described above), a spoke pattern, or another arrangement or pattern that spans the area defined by the inner periphery 277 of the second support member 270. In yet other embodiments, second grid portion 273 may include only a single arm spanning the area defined by inner perimeter 277. Arms 279, 281 of second grid portion 273 define a plurality of openings 272 within the area defined by inner perimeter 277 of second support member 270. The plurality of openings may make up at least 60%, at least 70%, at least 80%, or at least 90% of the area defined by inner perimeter 277. In still other embodiments, such as those shown in FIG. 6A and further described herein, third layer 114 of first filter 102 may provide the functionality provided by second support member 270 as described herein and shown in FIG. 5H.

[0053] 5C and 5D , the second support member 270 can be shaped and sized to fit closely against the inner surface 266 of the lower sidewall 240, similar to the second filter 104, such that the second filter 104 substantially covers the second support member 270 and at least covers the opening 272 defined by the second support member 270. The first filter 102 is disposed below the second support member 270. As shown, the first filter 102 can be slightly smaller than or substantially the same size as the second support member 270, such that the first filter 102 covers the opening 272 defined by the second support member 270.

[0054] The first filter 102 and the second filter 104 are separated by a second support member 270. In other words, the thickness of the second support member 270 provides a distance between the second filter 104 and the first filter 102 so that the second filter 104 and the first filter 102 do not contact each other. The openings 272 defined by the second support member 270 form a liquid reservoir to capture any liquid that may pass through the first filter 102 and retain said liquid to mitigate saturation of the second filter 104 and leakage of liquid into the vacuum system. As described above, the second filter 104 is formed from a hydrophobic and / or oleophobic material, coating, or surface treatment to prevent the passage of liquid into or through the second filter 104.

[0055] Splash guard 210 includes an upper rim 274 configured to be received in second groove 264 to couple splash guard 210 to first support grid 236. Splash guard 210 supports first filter 102 such that first filter 102 covers base opening 276 defined by splash guard upper rim 274, and first filter 102 is effectively sandwiched between splash guard 210 and second support grid 270. As described above, first filter 102 supports second support member 270 and second filter 104. In other words, splash guard 210 cooperates with first support member 236 to sandwich first filter 102, second support member 270, and second filter 104 therebetween, holding first filter 102, second support member 270, and second filter 104 in place within filter system 200.

[0056] As shown, splash guard 210 can have a frusto-conical or other shape configured to protect the interior of filter system 200 from liquid in the suction canister. In other words, splash guard 210 can be shaped to mitigate the ingress of unwanted materials into filter system 200 while continuing to promote a high volume of airflow through filter system 200. Filter system opening 278 is located at the apex of splash guard 210, thereby allowing the ingress of air and materials drawn into filter system 200 via vacuum, as described above. As shown in FIGS. 5A and 5B , the only components accessible on the outside of filter system 200 include housing 202, rim 258 of first support member 236, and splash guard 210. Filter system 200 is generally circular to accommodate the vacuum port with which filter system 200 is integrated, as described further herein. In other embodiments, filter system 200 may be other shapes, including oval, square, rectangular, or other shapes, as needed to integrate with the vacuum port.

[0057] 6A and 6B, additional optional embodiments of the filter system are shown. In some embodiments, as shown in FIG. 6A, the filter system 300 may not include the second support member 270. In such embodiments, the second filter 104 and the first filter 102 may be stacked directly together and sandwiched between the splash guard 210 and the first support member 336. The third layer of the first filter 102, as described above, may serve a similar spacing or gap function to the second support member 270 in forming the liquid reservoir when the filter system does not include the second support member 270. In various embodiments of the filter system, whether formed by the third layer or otherwise by the second support member 270, the liquid reservoir may have a thickness of, for example, 0.04 mm to 80 mm, although various dimensions are contemplated.

[0058] In some embodiments, the thickness of second support member 270 can vary (e.g., to create a reservoir having a varying thickness). In some embodiments, such as filter system 400, second support member 270 is replaced with second support member 470, which defines a much greater thickness compared to second support member 270 shown in FIG. 5D . Second support member 470 forms a relatively thick reservoir. As shown in FIGS. 6A and 6B , in the variation of FIGS. 6A and 6B , the thickness of lower sidewall 440 of first support member 436 directly corresponds to the thickness of second support member 470, such that first filter 102, second filter 104, and second support member 470 can be snugly sandwiched between first support member 436 and splash guard 210.

[0059] 5C, 6A, and 6B, it can be seen that, as discussed above, the structure of first support member 236 can be modified to accommodate variations in system components and the sizes of the included components. In some embodiments, the coupling mechanism described above for coupling first support member 236 to housing 202 remains generally consistent among the described filter systems 200, 300, and 400, but the coupling structure of first support member 236 can be modified to accommodate the described variations. In some embodiments, the coupling structure of first support member 236 as shown in FIGS. 5C-5D includes a single upper sidewall 238 that corresponds to coupling gap 230 defined by housing 202, as discussed above.

[0060] 6A , the first support member 336 can include an upper sidewall 338 having an inner wall 382 configured to contact the inner wall 226 of the housing 202 and an outer wall 384 having a lip 386 configured to engage the ridge 248 of the housing 202. The inner wall 382 and the outer wall 384 of the upper sidewall 338 are spaced apart to fill the coupling gap 230 defined by the housing 202. The first support member 336 further includes a lower sidewall 340 as described above with respect to the first support member 236; however, instead of a rim 358 extending from the outer surface 346 of the lower sidewall 340, the rim 358 extends outwardly from the first support member 336 at a location intermediate the upper and lower sidewalls 338 and 340, such that the lower sidewall 340 extends below the rim 358 on the exterior of the housing 202. The remaining structure of the lower sidewall 340 is consistent with the first support member 236 described in connection with the filter system 200, particularly in view of the coupling mechanism with the splash guard 210.

[0061] 6B , upper sidewall 438 has an inverted L-shape with longitudinal portion 488 contacting inner surface 228 of housing sidewall 218 and extending into coupling gap 230, longitudinal portion 488 defining groove 490 that engages ridge 248 of housing 202, as described above in connection with first support member 236. Transverse portion 492 extends inwardly from longitudinal portion 488 and fits beneath inner wall 226 of housing 202 while facilitating sandwiching of second support member 470, first filter 102, and second filter 104 with splash guard 210. The extension 494 extends upward from the lateral portion 492 to contact the inner wall 226 such that the upper sidewall 438 spans the coupling gap 230 via the combination of the extension 494 and the longitudinal portion 488 of the upper sidewall 438 .

[0062] Similar to first support member 336 of filter system 300, in filter system 400, first support member 436 further includes a lower sidewall 340 similar to first support member 236. However, instead of a rim 458 extending from an outer surface 446 of lower sidewall 440, rim 458 extends outwardly from first support member 436 at a location intermediate upper sidewall 438 and lower sidewall 440, such that lower sidewall 440 extends below rim 458 on the exterior of housing 202. The remaining structure of lower sidewall 440 is consistent with first support member 236 associated with filter system 200, at least with respect to the coupling mechanism with splash guard 210.

[0063] Other modifications beyond those described herein may be made to filter system 200 depending on the environment in which the filter system resides and the vacuum system and / or suction canister utilized so that the filter system can be configured to meet various needs or goals for each situation. In particular, the thickness of second support member 270 may vary as described above. Additionally, a splash guard may or may not be included in the filter system. In addition to variations in design components, assembly methods may also vary. In some embodiments, filter system components may be manufactured by injection molding, additive manufacturing, or other known manufacturing methods.

[0064] FIG. 7 illustrates a canister lid 500. The canister lid 500 represents a generic canister lid that may encompass several variations of canister lids and suction canisters. The canister lid 500 includes a patient port 502 configured to fluidly couple the lid 500 to a patient via medical tubing (not shown). The canister lid 500 further includes a vacuum port 504 configured to fluidly couple the lid 500 to a vacuum system, as described above. As shown in FIG. 7 , the port sidewall 214 of the filter system 200 is configured to be received by the vacuum port 504 such that, during operation, the port outlet 204 is in fluid communication with the vacuum port 504 and the vacuum system. The port sidewall 214 illustratively defines a shape and size similar to the vacuum port 504, such that the port sidewall 214 forms an interference or otherwise snug fit within the vacuum port 504, such that airflow generated by the vacuum system must pass through the filter system 200 before exiting the lid 500 and entering the vacuum system. [Example]

[0065] Test Method Bubble Point Pressure Bubble point pressure was measured according to ASTM F31 6-02 using a capillary flow porometer (Model 3Gzh, Quantachrome Instruments, Boynton Beach, FL). The sample membrane was placed in the sample chamber and allowed to wet with Silwick Silicone Fluid (available from Porous Materials Inc.), which has a surface tension of 20.1 dynes / cm. The bottom clamp of the sample chamber was 2.54 cm in diameter and had a porous metal disc insert defining a thickness of 0.159 cm to support the membrane (Quantachrome Part No. 75461 Stainless Steel Filter).

[0066] smoke retention Smoke retention while maintaining high airflow under continuous aerosol loading was tested using an experimental setup 600 illustrated by the schematic shown in Figure 8. The experimental setup 600 included an aerosol generator 602 with an inlet connected to a compressed air source 604 via a first pressure regulator 601. The outlet of the aerosol generator 602 was 7 cm 2 The aerosol generator 602 was connected to a filter system 606 to be tested, having an active filter area of ​​1.8 μm to 2.0 μm. The aerosol generator 602 was set to 60 psi using pressure regulator 1. The aerosol generator 602 generated mineral oil aerosols in the range of 1.8 μm to 2.0 μm depending on the positive pressure of the system, as shown in Table 1, which contains data generated by Mesa Laboratories Inc., 10 Park Place, Butler, NJ 07405, USA. [Table 1]

[0067] The venturi nozzle 608 was connected to the test filter system 606 via a pressure sensor 612, a water trap 614, and a bidirectional airflow sensor 616. The venturi nozzle 608 was pressurized with compressed air from a second compressed air source 610, thereby generating a vacuum. A second pressure regulator 618 was used to set the vacuum pressure to -50 kPa. The aerosol generated by the aerosol generator 602 was pulled through the test filter system 606 by the vacuum generated by the venturi nozzle 608. The test filter system 606 was subjected to the vacuum pressure and aerosol treatment for 60 minutes. The airflow through the test filter system 606 was measured using the bidirectional airflow sensor 616, while the pressure sensor 612 was used to monitor the vacuum pressure and the pressure exiting the test filter system 606.

[0068] Virus filtration efficiency Viral filtration efficiency ("VFE") studies were performed using the MS-2 coliphage virus. The MS-2 coliphage has a diameter of approximately 23 nm and a molecular weight of 3.6 x 10 6 It is a non-enveloped single-stranded RNA model virus of 100 sq. d. Notably, MS-2 coliphage virions are relatively smaller in size than dicavirions, SARS-CoV-2 virions, HIV virions, T4 bacteriophage virions, and Mimivirus virions. The VFE test uses a 1x10 virion to promote cell viability throughout the test. 8 The experiment was conducted at a load exceeding plaque-forming units and a relative humidity of 90% or greater. The MS-2 coliphage suspension was aerosolized and introduced into a filter system having a first filter and a second filter as disclosed herein. The concentration of MS-2 coliphage in the aerosolized solution was measured and compared before and after passing through the filter system.

[0069] Bacterial Filtration Efficiency Bacterial filtration efficiency ("BFE") testing was performed using Brevundimonas diminuta bacteria, a gram-negative bacterium with a diameter of 0.4 μm to 1.0 μm. Brevundimonas diminuta bacteria are relatively smaller in size than Bacillus bacteria, PM2.5 bacteria, red blood cells, and PM10 bacteria. BFE testing was performed using a 1x10 cell count to promote cell viability throughout the test. 8 The test was carried out at a load exceeding colony-forming units and a relative humidity of 90% or higher. A Brevundimonas diminuta suspension was aerosolized and introduced into a filter system having a first filter and a second filter as disclosed herein. The concentration of Brevundimonas diminuta in the aerosolized solution was measured and compared before and after passing through the filter system.

[0070] The efficiency of the above filter system in the VFE and BFE tests was measured according to the following formula:

number

[0071] Water intrusion pressure To measure water intrusion through membrane layers as defined herein, a water intrusion pressure test was performed using a Mullen R™ tester (serial number: 8240+92+2949, manufactured by BF Perkins, Chicopee, Massachusetts, USA). A membrane layer test sample was clamped between a pair of test fixtures made of a square Plexiglas sheet measuring 1.27 cm thick and defining a side length of 10.16 cm. The lower fixture had the ability to pressurize a portion of the sample with water. A piece of pH paper was placed on top of the sample to serve as an indicator of evidence of water intrusion. The sample was pressurized by applying pressure in small increments until the color of the pH paper changed. The corresponding breakthrough or intrusion pressure was recorded as the water intrusion pressure, and the average of the three measurements was also recorded.

[0072] example Example 1 The membranes 106 of the layered filter systems 100, 200 were subjected to bubble point testing as described above. Conventional filters, designated "Sintered PE1," "Sintered PE2," and "Sintered PE3" in Table 2 below, were also tested. As shown in Table 2, the bubble points of the conventional filters were below the detection limit of the testing equipment and were therefore recorded as <1 psi. The membrane 106 recorded a bubble point of 8.5 psi. [Table 2]

[0073] A successful bubble point test indicates that the filter systems 100, 200 as described herein are configured to retain surgical waste, including blood and rinsing fluid, within the surgical canister, facilitating protection of surgical instruments, hospital personnel, the hospital environment, and patients from contamination during procedures in which such surgical canisters are used.

[0074] Example 2 Referring now to Figure 109, the smoke retention of various filter systems was tested as described above according to the specifications provided in Figure 9. A vacuum pressure of -50 kPa was applied to the filter systems for 1 hour, causing the vacuum pressure to cause interaction of the aerosol particles with the filter system.

[0075] As shown in FIG. 9 , line 902 indicates that the membrane-only embodiment 106 was able to prevent the passage of surgical smoke particles, but the airflow rate significantly decreased from approximately 15.5 liters / minute to less than 1 liter / minute during the first six minutes of the test window until continuous surgical suction was no longer possible. Line 900 illustrates the performance of a filter system including the membrane 106 of the present disclosure and the first filter 102. As shown, the decrease in airflow under continuous aerosol loading was significantly reduced with the addition of the first filter. The airflow rate decreased from approximately 15.5 liters / minute to approximately 12.3 liters / minute during the first 15 minutes of the test period, to approximately 11.2 liters / minute during the first 30 minutes of the test period, to approximately 10.5 liters / minute during the first 45 minutes, and to approximately 10.2 liters / minute at the end of the test period.

[0076] Line 904 shows the performance of a filter system including two layers of the membrane 106 and primary filter 102 of the present disclosure. The reduction in airflow under continuous aerosol loading was significantly reduced with the addition of a second primary filter. Airflow decreased from approximately 15.5 liters / minute to approximately 14.8 liters / minute in the first 15 minutes of the test period, to approximately 14.7 liters / minute in the first 30 minutes of the test period, to approximately 12.8 liters / minute in the first 45 minutes of the test period, and reached approximately 13.7 liters / minute at the end of the test period.

[0077] Conventional filters (e.g., sintered polyethylene filters) were also tested and found to be unable to retain surgical smoke particles. After a continuous one-hour aerosol challenge as described above, a thin film of oil was detected at the outlet of the sintered polyethylene filter and on top of the corresponding bacterial filter, indicating that aerosols could pass through the conventional filters. Because aerosols can easily pass through the conventional filters, the filters do not become clogged or their original air volume is reduced. This oil film was not observed at the outlet of the filter system including the membrane 106 or first filter 102 described above. The success of the smoke retention test indicates that a filter system including a first filter as disclosed herein can be used in a surgical smoke environment for at least one hour while maintaining a significant portion of the maximum possible airflow rate.

[0078] Example 3 The VFE test described above provided results of up to 99.99999% minimum viral filtration efficiency, or a log reduction of 7. This demonstrates improved filtration capabilities over conventional filters that may only provide results of up to 99.99% minimum viral filtration efficiency, or a log reduction of 4, as claimed by surgical suction container manufacturers, whereas some tests have shown conventional filters to provide results of up to 98% minimum viral filtration efficiency.

[0079] Example 4 The BFE tests described above provided results of up to 99.99999% minimum bacterial filtration efficiency, or a log reduction of 7. This demonstrates improved filtration capabilities over conventional filters that may only provide results of up to 99.99% minimum bacterial filtration efficiency, or a log reduction of 4, as claimed by surgical suction container manufacturers, whereas some tests have shown conventional filters to provide results of up to 98% minimum viral filtration efficiency.

[0080] Example 5 A layered filter system 100 as described above was welded to a suction canister lid to cover the vacuum port of the suction canister lid, the suction canister lid was coupled with a liner to create a lid and liner assembly as shown in Figure 10A, and the lid and liner assembly was filled with deionized water as shown in Figure 10B. Referring again briefly to Figures 1-3, the filter system 100 includes a first filter 102 and a second filter 104, the first filter 102 having a 0.5 mm 2 / g or greater than 2m 2 The second filter 104 defines a specific surface area of ​​less than 1 / g and includes three layers, the second filter 104 including a membrane 106, such as an ePTFE membrane or a membrane including an electrospun polymer, and a textile membrane support 108, which may be formed from a thermoplastic textile. The second filter 104 defines a total thickness of 230 microns, maintains a liquid entry pressure of 75 kPa or greater for at least 10 minutes at a surface tension of 55.5 mN / m, and has a resistance of 9.3 cm 2 configured to maintain an air flow rate of greater than 20 liters per minute with a pressure drop of 11.5 kPa over an effective area of ​​1.5 m.

[0081] The first layer 110 of the first filter 102 has oleophobic properties, defines a thickness of about 80 microns to about 200 microns, and includes a plurality of filaments, each filament having a diameter of about 17 microns to about 25 microns. The second layer 112 defines a thickness of about 320 microns and includes a plurality of filaments, each filament having a diameter of about 3 microns to about 6 microns. The second layer 112 can include thermoplastic filaments, polypropylene, polyethylene, polyethylene terephthalate, polyethylene terephthalate copolymer, or non-thermoplastic filaments. The third layer is similar to the first layer in thickness and composition.

[0082] Referring again to Figures 10A-10C, the lid and liner assembly was placed in a rigid container and connected to a vacuum pump (Medela Pumps "Dominant Flex"), which was operated at its maximum operating setting of -88 kPa for 11 minutes. No liquid leakage was observed after 11 minutes of continued liquid contact with the filter system. In a similar experiment, the lid and liner assembly was inverted overnight in the position shown in Figure 10C. In a separate experiment, the lid and liner assembly was subjected to another liquid inversion test over an 8-hour period, and the lid and liner assembly was subjected to a prolonged water intrusion pressure test at a differential pressure of 10 kPa. No liquid leakage was observed in either of these experiments.

[0083] While the exemplary embodiment includes a filter system for use with a suction canister or suction bag, in other embodiments, the filter system described above can be utilized in other applications where such filtration is required, such as manufacturing masks or filtering environmental systems. In other words, the invention of this application has been described above both generically and with reference to specific embodiments. It will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments without departing from the scope of the present disclosure. Accordingly, the embodiments are intended to cover the modifications and variations of the present invention provided they come within the scope of the appended claims and their equivalents.

Claims

1. a housing defining an internal chamber including a chamber opening and an exit port disposed on the base opposite the chamber opening; a first support member coupled to the housing; a first filter disposed over the chamber opening of the housing; and a second filter disposed between the first support grid and the first filter, wherein a liquid reservoir is defined by the first filter and the second filter; a filter system.

2. The second filter has a liquid entry pressure of 75 kPa or greater for 10 minutes at a surface tension of 55.5 mN / m and a liquid penetration pressure of 9.3 cm ２ 10. The filter system of claim 1, wherein the filter system maintains an air flow rate of greater than 20 liters / minute with a pressure drop of 11.5 kPa over an effective area of ​​100 sq. m.

3. The filter system of claim 1 , wherein the liquid reservoir is between 0.04 millimeters and 2 millimeters thick.

4. The filter system of claim 1 , wherein the liquid reservoir is between 2 millimeters and 15 millimeters thick.

5. The filter system of claim 1 , wherein the liquid reservoir is between 15 millimeters and 80 millimeters thick.

6. The filter system of claim 1 , wherein the first filter defines a thickness of about 120 microns to about 2000 microns.

7. The filter system of claim 1 , wherein the liquid reservoir comprises a third layer of the first filter.

8. 2. The filter system of claim 1, wherein the liquid reservoir includes a second support member disposed between the first filter and the second filter such that the first filter and the second filter are spaced apart from each other.

9. 10. The filter system of claim 1, further comprising a splash guard coupled to the first support member and extending from the first support member away from the housing, the splash guard defining an inlet and an outlet.

10. 10. The filter system of claim 9, wherein the splash guard has a conical shape and the outlet of the splash guard is wider than the inlet of the splash guard.

11. a lid defining a port; and a filter system integrated into said port, said filter system comprising: a first filter defining a thickness of about 120 microns to about 2000 microns, wherein the first filter comprises a first layer and a second layer, the first layer comprising a different material than the second layer; and A liquid penetration pressure of 75 kPa or more for 10 minutes at a surface tension of 55.5 mN / m and a pressure of 9.3 cm ２ a second filter that maintains an air flow of greater than 20 liters / minute with a pressure drop of 11.5 kPa over an effective area of , including a filtering assembly.

12. 12. The filtering assembly of claim 11, wherein the canister port is communicatively coupled to a vacuum configured to maintain airflow through the filter system.

13. The filtering assembly of claim 11 , wherein the suction canister comprises a container with flexible sides.

14. The filtering assembly of claim 11 , wherein the suction canister comprises a rigid container.

15. The filtering assembly of claim 11 , wherein the filter system is integrated into the port by ultrasonic welding.

16. The filtering assembly of claim 11 , wherein the filter system is heat welded to the lid so that the filter system covers the port.

17. The filtering assembly of claim 11 , wherein the second filter is hydrophobic.

18. 12. The filter system of claim 11, wherein the first filter comprises a second layer comprising polymer filaments less than 6 microns in diameter.

19. 12. The filter system of claim 11, wherein the first filter includes a second layer comprising thermoplastic filaments.

20. 12. The filter system of claim 11, wherein the first filter comprises a second layer comprising polypropylene, polyethylene, polyethylene terephthalate, polyethylene terephthalate copolymer, or non-thermoplastic filaments.

21. The filter system of claim 11 , wherein the first filter includes an oleophobic first layer.

22. The first filter is 0.5 m ２ / g or greater than 2m ２ 12. The filter system of claim 11, defining a specific surface area of ​​less than 1 / g.

23. 12. The filter system of claim 11, wherein the second filter comprises a thermoplastic textile layer.

24. a housing including a base, a port extending from a first side of the base and defining an outlet, a first wall extending from a second side of the base, and a second wall extending from the second side of the base, wherein the first wall and the second wall define a groove; a first support member including an upper sidewall, the first support member configured to be received within the groove of the housing to couple the support member to the housing; a splash guard coupled to the first support member, the splash guard defining an inlet and an outlet; a first filter disposed at an outlet of the splash guard; a second support member disposed between the first filter and the first support member; and a second filter disposed between the first support member and the second support member; a filter system.

25. 26. The filter system of claim 25, wherein the port of the housing is configured to be coupled to a vacuum port of a suction canister.

26. 26. The filter system of claim 25, wherein the splash guard has a conical shape and the outlet of the splash guard is wider than the inlet of the splash guard.

27. 26. The filter system of claim 25, wherein the first filter comprises multiple layers, a first layer comprising a different structure than a second layer.

Images