Filter assemblies for surgical plume evacuation systems and surgical plume evacuation systems incorporating the same

Abstract

A filter assembly for a surgical plume evacuation console includes a filter housing and a filter. The filter housing defines an inlet, an inlet chamber in communication with the inlet, an outlet chamber, and an outlet in communication with the outlet chamber. The filter is disposed within the filter housing between the inlet chamber and the outlet chamber and is formed from a plurality of layers. A plume flow path of a surgical plume evacuated from a surgical site is defined from the inlet, through the inlet chamber, through the filter, through the outlet chamber, and out of the outlet. A surgical plume evacuation console includes the filter assembly, a console housing, a suction generator disposed within the console housing and coupled to the plume flow path, and an exhaust assembly disposed within the console housing and coupled to the suction generator.

Description

FILTER ASSEMBLIES FOR SURGICAL PLUME EVACUATION SYSTEMS AND SURGICAL PLUME EVACUATION SYSTEMS INCORPORATING THE SAMECROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 641,990, filed May 3, 2024, which is incorporated herein by reference in its entirety.FIELD

[0002] This disclosure relates to surgical systems. More specifically, this disclosure relates to filter assemblies for surgical plume evacuation systems and surgical plume evacuation systems incorporating the same.BACKGROUND

[0003] Various different energy-based surgical instruments generate a surgical plume, e.g., including surgical smoke, as a by-product of energy-based tissue treatment. One such energybased surgical instrument, for example, is a monopolar electrosurgical pencil. A monopolar electrosurgical pencil is typically connected to an electrosurgical generator that supplies high frequency electrosurgical energy, e.g., radio frequency (RF) alternating current, to the monopolar electrosurgical pencil for treating tissue. A return electrode, e.g., a return pad, may be utilized to complete the electrosurgical circuit from the electrosurgical pencil back to the electrosurgical generator. The electrosurgical generator may supply various different energy waveforms suitable for achieving various different surgical effects such as, for example, cutting, coagulating, blending, spraying, fulgurating, etc.

[0004] A surgical plume produced as a by-product of the application of electrosurgical energy from a monopolar electrosurgical pencil to tissue at a surgical site, may include air, smoke particulate, contaminants, debris, gaseous byproducts, and / or other matter that may be harmful to the patient and / or surgical staff, may decrease visibility at the surgical site, and / or may produce unpleasant odors. Thus, evacuation of the plume, including the smoke, from the surgical site may be desirable.SUMMARY

[0005] As used herein, the term “distal” refers to the portion that is being described which is farther from a suction generator, while the term “proximal” refers to the portion that is being described which is closer to the suction generator. Terms including “generally,” “about,” “substantially,” and the like, as utilized herein, are meant to encompass variations, e.g., manufacturing tolerances, material tolerances, use and environmental tolerances, measurement variations, design variations, and / or other tolerances and variations, up to and including plus or minus 10 percent. Further, to the extent consistent, any or all of the aspects detailed herein may be used in conjunction with any or all of the other aspects detailed herein.

[0006] Provided in accordance with aspects of this disclosure is a filter assembly for a surgical plume evacuation console. The filter assembly includes a filter housing and a filter. The filter housing defines an inlet, an inlet chamber in communication with the inlet, an outlet chamber, and an outlet in communication with the outlet chamber. The filter is disposed within the filter housing between the inlet chamber and the outlet chamber and is formed from a plurality of layers. A plume flow path of a surgical plume evacuated from a surgical site is defined from the inlet, through the inlet chamber, through the filter, through the outlet chamber, and out of the outlet.

[0007] In an aspect of this disclosure, the filter housing is arranged in a horizontal orientation relative to a direction of gravity. In such aspects, the plurality of layers of the filter may define a longitudinal axis extending substantially perpendicular to the direction of gravity and the inlet, inlet chamber, the plurality of layers, the outlet chamber, and the outlet may be disposed along the longitudinal axis.

[0008] In an aspect of this disclosure, the outlet chamber defines a duct to facilitate plume flow along the plume flow path from the outlet chamber to the outlet. In aspects, the duct may be tapered. In other aspects, the duct is not tapered. Alternatively or additionally, a tapered (or untampered) duct may be provided to facilitate plume flow along the plume flow path through the inlet and into the inlet chamber.

[0009] In another aspect of this disclosure, the filter housing is arranged in a vertical orientation relative to a direction of gravity. In such aspects, the plurality of layers of the filter defines a longitudinal axis extending substantially parallel to the direction of gravity with the inlet disposed below the filter and the outlet disposed above the filter. The inlet and outlet, in aspects, are disposed on opposite sides of the longitudinal axis.

[0010] In still another aspect of this disclosure, the inlet chamber and / or the outlet chamber includes an angled ramp configured to facilitate plume flow through the filter.

[0011] In yet another aspect of this disclosure, at least one moisture collection device is disposed within the inlet chamber of the filter housing.

[0012] In still yet another aspect of this disclosure, a liquid trap is disposed within the inlet chamber of the filter housing. Alternatively or additionally, a suction port is disposed through the filter housing and configured to connect to a suction source for suctioning fluid from the filter and / or the inlet chamber.

[0013] In another aspect of this disclosure, the filter housing is disposed within a casing defining an inflow port.

[0014] In another aspect of this disclosure, a dehumidifier is disposed within the casing between the inflow port and the filter housing.

[0015] In still another aspect of this disclosure, the plurality of layers of the filter includes at least one layer configured to remove gross particulate (also referred to herein as at least one gross particulate layer), a layer configured to remove Volatile Organic Compounds (VOCs) (also referred to herein as a VOC layer), and an Ultra-Low Particulate Air (ULPA) layer. In such aspects, a first gross particulate layer is disposed at an input side of the filter, the VOCs layer is disposed between the first gross particulate layer and a second gross particulate layer, and the ULPA layer is disposed at an output side of the filter. The VOC layer may be formed from, in aspects, a blended media to facilitate capture of a wide spectrum of VOCs.

[0016] A surgical plume evacuation console in accordance with this disclosure includes a console housing, a suction generator disposed within the console housing, an exhaust assembly disposed within the console housing, and a filter assembly configured to fluidly connect to the suction generator. The suction generator is configured to generate a flow of an evacuated surgical plume from a surgical site along an evacuation flow path and the exhaust assembly is configured to exhaust the evacuated plume from the evacuation flow path to an exterior of the console housing. The filter assembly may be configured similar to any of the aspects of the filter assembly detailed above or otherwise herein.

[0017] In an aspect of this disclosure, the surgical plume evacuation console further includes a controller disposed within the console housing and configured to control the suction generator in accordance with filter assembly information received from or about the filter assembly.

[0018] In another aspect of this disclosure, the filter assembly includes a casing retaining or defining the filter housing. The casing is configured to releasably engage the console housing.BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The above and other aspects and features of this disclosure will become more apparent in view of the following detailed description when taken in conjunction with the accompanying drawings wherein like reference numerals identify similar or identical elements.

[0020] FIG. 1 is a perspective view of a surgical plume evacuation system provided in accordance with aspects of the disclosure including a plume evacuation console having an energybased plume evacuation surgical instrument connected thereto;

[0021] FIG. 2 is a bottom, partially transparent view of the plume evacuation console of FIG. 1;

[0022] FIGS. 3 A and 3B are first and second side, cross-sectional views of the plume evacuation console of FIG. 1 ;

[0023] FIG. 4 is a schematic illustration of the plume evacuation console of FIG. 1 ;

[0024] FIG. 5 is a cross-sectional view illustrating a filter (e.g., including a plurality of filter layers) of a filter assembly of the plume evacuation console of FIG. 1 ;

[0025] FIG. 6 is a cross-sectional view illustrating a horizontally oriented configuration of the filter assembly of the plume evacuation console of FIG. 1;

[0026] FIG. 7 is a cross-sectional view illustrating a vertically oriented configuration of the filter assembly of the plume evacuation console of FIG. 1;

[0027] FIG. 8A is a cross-sectional view of the filter assembly of the plume evacuation console of FIG. 1 in the vertically oriented configuration including features to facilitate flow through the filter assembly;

[0028] FIGS. 8B-8E are cross-sectional views of the filter assembly of the plume evacuation console of FIG. 1 in the vertically oriented configuration including various features to facilitate moisture removal;

[0029] FIGS. 9A-9C are schematic illustrations of dehumidifier configurations for use with the filter assembly of the plume evacuation console of FIG. 1 ;

[0030] FIG. 10 is a schematic illustration of a fluid flow path through the surgical plume evacuation system of FIG. 1; and

[0031] FIG. 11 is a schematic illustration of an exemplary robotic surgical system configured for use with the surgical plume evacuation system of FIG. 1.DETAILED DESCRIPTION

[0032] This disclosure provides filter assemblies for surgical plume evacuation systems and surgical plume evacuation systems incorporating the same. Although detailed below with respect to surgical plume evacuation system 10 (including plume evacuation console 100 and electrosurgical pencil 200), the filter assemblies of this disclosure may also be utilized with any other suitable plume evacuation systems.

[0033] Referring to FIG. 1, a surgical plume evacuation system configured for use in accordance with aspects of the present disclosure is shown generally identified by reference numeral 10. Surgical plume evacuation system 10 includes a plume evacuation console 100 and one or more surgical devices which may include an energy-based surgical device (such as, for example, an electrosurgical pencil 200), a surgical evacuation tube, or any other suitable surgical device configured to fluidly connect to plume evacuation console 100. Although plume evacuation console 100 is shown and described herein in connection with electrosurgical pencil 200, it is contemplated that any suitable energy-based surgical devices, or any other suitable surgical devices including, as noted above, surgical evacuation tubes, may alternatively or additionally be utilized with plume evacuation console 100 such as, for example and without limitation, monopolar electrosurgical devices, bipolar electrosurgical devices, microwave electrosurgical devices, ultrasonic electrosurgical devices, surgical lasers and / or other optical-energy surgical devices, high-speed mechanical energy-based surgical devices (e.g., drills, burs, debrides, etc.), thermal energy-based surgical devices, etc. Further, although plume evacuation console 100 is shown configured as a stationary unit, e.g., for rack-mounted, pole-mounted use, or table-top use, it is also contemplated that plume evacuation console 100 may be configured as a portable console configured to attach to a user, surgical table, patient, or otherwise enable movement and selective placement of plume evacuation console 100. Thus, the term console as utilized herein is not limited to any particular physical size or configuration.

[0034] Electrosurgical pencil 200 includes a housing 210, an electrode 220 coupled to and extending from a distal end portion 212 of housing 210, a nozzle 230 coupled to and extendingdistally from distal end portion 212 of housing 210 adjacent to electrode 220, and flexible tubing 240 coupled to and extending from a proximal end portion 214 of housing 210.

[0035] Housing 210 may be configured as a handle to facilitate grasping and manipulation by a surgeon (FIG. 1) or may be configured to mount to an arm 1002, 1003 of a surgical robotic system 1000 for use in robotic surgery (see FIG. 11). In either configuration, housing 210 includes a fluid lumen 216 extending from distal end portion 212 of housing 210 to proximal end portion 214 of housing 210 to fluidly couple nozzle 230 with flexible tubing 240. Fluid lumen 216 may be at least partially defined by internal features of housing 210 and / or may include a separate tube(s) disposed on or within housing 210.

[0036] Electrode 220 of electrosurgical pencil 200 is at least partially formed from an electrically conductive material to enable the conduction of energy from electrode 220 to tissue in contact with or adjacent to electrode 220 for treating the tissue. Electrode 220 may define any suitable configuration including, for example and without limitation, a blade, a hook, a needle, etc. In aspects, electrode 220 is releasably engagable with housing 210 to enable replacement of electrode 220 with a similar or different electrode. A suitable electrical pathway, e.g., formed of electrically conductive structures, wires, etc., electrically connects electrode 220 with a cable (not shown) that, in turn, is configured to connect to a source of electrosurgical energy, e.g., an electrosurgical generator incorporated into plume evacuation console 100 or a separate electrosurgical generator (not shown), to enable the conduction of energy to electrode 220 for treating tissue therewith.

[0037] Continuing with reference to FIG. 1, nozzle 230, as noted above, is coupled to and extends distally from distal end portion 212 of housing 210 adjacent to electrode 220. Nozzle 230 defines at least one opening 232 configured to enable the suctioning of a surgical plume, e.g., containing surgical smoke, through nozzle 230, fluid lumen 216, and flexible tubing 240 to plume evacuation console 100. In aspects, nozzle 230 is releasably engagable with housing 210 to enable replacement of nozzle 230 with a new nozzle and / or nozzle of a different configuration, e.g., a different size, shape, number and / or arrangement of openings, etc. For example, a nozzle may be selected for use depending on the particular electrode configuration, surgical procedure to be performed, and / or power settings to be utilized.

[0038] In aspects, electrosurgical pencil 200 further includes one or more controls 250 disposed on housing 210 and configured to enable control of energy settings associated withelectrosurgical pencil 200, e.g., ON / OFF, power level, mode, etc. Controls 250 may electrically connect to the electrosurgical generator via the same cable as electrode 220 or in any other suitable manner.

[0039] Flexible tubing 240 may be corrugated or otherwise configured to facilitate flexion of flexible tubing 240 while minimizing kinking of flexible tubing 240. Further, flexible tubing 240 is coupled to housing 210 via a connector 260 which may be, for example and without limitation, a swivel connector enabling rotation and / or pivoting of flexible tubing 240 relative to housing 210 to further minimizing kinking of flexible 240. Flexible tubing 240 is configured to connect to an inlet port 120 of plume evacuation console 100 such that nozzle 230 is fluidly coupled to plume evacuation console 100 to enable plume evacuation console 100 to withdraw a surgical plume, e.g., including air, smoke, debris, other particulates, etc., from a surgical site through electrosurgical pencil 200.

[0040] Although electrosurgical pencil 200 is detailed above as incorporating a plume evacuation flow path, e.g., from nozzle 230, through fluid lumen 216, to flexible tubing 240, it is also contemplated that a standalone device, separate from electrosurgical pencil 200 or removably attachable to electrosurgical pencil 200, may define the plume evacuation flow path from the surgical site to plume evacuation console 100.

[0041] Referring also to FIGS. 2-4, plume evacuation console 100 includes a housing 110, an inlet port 120, a filter assembly 130, a suction generator 140, an exhaust chamber 150 (also referred to as an expansion chamber), a controller 160, and a user interface (UI) 170. Housing 110 supports the above-noted components of plume evacuation console 100 thereon or therein and further includes a plurality of exit vents 112 in communication with exhaust chamber 150 to enable the re-circulation of air evacuated into plume evacuation console 100, and filtered therein, back into the operating room or to another location, e.g., piped out of the operating room.

[0042] Inlet port 120 of plume evacuation console 100 enables connection of flexible tubing 240 of electrosurgical pencil 200 (see FIG. 1), or any other suitable component(s) defining a plume evacuation path from a surgical site, to plume evacuation console 100. Inlet port 120 fluidly communicates with filter assembly 130 such that a plume suctioned from flexible tubing 240 through inlet port 120 enters filter assembly 130.

[0043] Filter assembly 130 includes one or more filters that allow evacuated air to pass through the filter while trapping smoke particulate within the filter(s). One or more of the filters of filterassembly 130, or portions of a filter of filter assembly 130, may alternatively or additionally be configured to remove contaminants, debris, gaseous byproducts, and / or odors from the evacuated plume. Filter assembly 130 is described in greater detail below.

[0044] Suction generator 140 is disposed downstream of filter assembly 130 (although, in other aspects, suction generator 140 may be disposed upstream of filter assembly 130) and includes one or more blowers 142, e.g., fans, each driven by a motor 144, e.g., a brushless DC motor. In aspects, as shown in FIGS. 3 A and 4, two (or more) blowers 142 (each including a corresponding motor 144) are provided and arranged in series, although parallel configurations are also contemplated. Controller 160 controls motors 144 which, in turn, controls blowers 142 to regulate the flow of the evacuated plume through plume evacuation console 100. More specifically, the one or more blowers 142 establish negative gauge pressure upstream of suction generator 140 to thereby generate suction to draw the plume from the surgical site, through electrosurgical pencil 200 (FIG. 1), into inlet port 120 and through filter assembly 130, and into blowers 142. From blowers 142, the filtered plume, e.g., air, continues to exhaust chamber 150 and, ultimately, back into the operating room through exit vents 112 of housing 110.

[0045] Within housing 110 of plume evacuation console 100, the various components in the plume flow path may be connected to one another via any suitable conduit(s) and / or other fluid- tight components. For example, pipes, tubes, chambers, cavities, combinations thereof, any other any other suitable components may be utilized to define the various plume flow paths within plume evacuation console 100: flow path 146a between filter assembly 130 and first blower 142; flow path 146b between blowers 142 (e.g., between first and second blowers 142); flow path 146c from the last blower 142 to exhaust chamber 150; and flow path 146d from exhaust chamber 150 to exit vents 112. In aspects, a silencer 147 (see FIG. 3B) configured to reduce noise resulting from the air flow through flow path 146c is provided. Silencer 147, also referred to as muffler, defines at least a portion of flow path 146c and is disposed between the last blower 142 and exhaust chamber 150.

[0046] In aspects, as shown in FIG. 4, suction generator 140 further includes a bypass conduit 148, e.g., connected along flow path 146a, establishing a flow path from exhaust chamber 150 (which, in turn, is open to the external environment via flow path 146d and exit vents 112) to filter assembly 130 that bypasses blowers 142. Thus, in the event of an at least partial occlusion of theplume flow path, the one or more blowers 142 are still able to draw in air, thus inhibiting motor overheating and / or motor surge.

[0047] As an alternative to bypass conduit 148 connecting filter assembly 130 to exhaust chamber 150, an open conduit (not shown) may be connected along flow path 146a and open to the external environment, e.g., the operating room. Thus, in the event of an at least partial occlusion of the plume flow path, the one or more blowers 142 are still able to draw in air, thus inhibiting motor overheating and / or motor surge. In such aspects, a passive valve, e.g., a pressuresensitive valve, or a controlled valve, e.g. , a solenoid controlled by controller 160, may be provided along flow path 146a or the open conduit to inhibit drawing in air when there is no occlusion and / or minimal risk of motor overheating and / or motor surge.

[0048] With respect to both bypass conduit 148 and the open conduit, flow through blower(s) 142 is maintained in the event of an occlusion at electrosurgical pencil 200, inlet port 120, filter assembly 130, and / or elsewhere along the plume flow path. The arrows included in FIG. 4 illustrate the plume flow path through plume evacuation console 100, as well as the bypass flow path through bypass conduit 148. With respect to the open conduit, similar to bypass conduit 148, flow would be through the open conduit to flow path 146a.

[0049] Referring again to FIGS. 1-4, exhaust chamber 150 enables the expansion and pressure equalization of the evacuated, filtered air as the evacuated, filtered air flows from exhaust chamber 150 through exit vents 112 and back into the operating room. As noted above, silencer 147 (FIG. 3B), which may also be referred to as a muffler, may form at least a portion of flow path 146c and, in aspects, silencer 147 (FIG. 3B) extends into and terminates within exhaust chamber 150.

[0050] In aspects, one or more sensors such as, for example, pressure sensors, flow sensors, temperature sensors, and / or other suitable sensors may be disposed along the plume flow path of plume evacuation console 100. For example, one or more sensors may be disposed at inlet port 120, on or within filter assembly 130, along flow path 146a, at or within suction generator 140 (e.g., at or within one or more of blowers 142 and / or motors 144), along flow path 146b, along flow path 146c, at or within exhaust chamber 150, along flow path 146d, and / or at exit vents 112. These sensors may communicate with controller 160 to facilitate feedback-based control of plume evacuation console 100, to detect error conditions, to assess plume flow, and / or for other purposes. Additionally or alternatively, one or more sensors may be disposed on or within housing 110 and / or separate from plume evacuation console 100 and configured to communicate with controller 160,e.g., via a wired or wireless connection. Various sensors configured to facilitate feedback-based control of plume evacuation console 100 in accordance with the present disclosure are detailed below.

[0051] Controller 160 of plume evacuation console 100 includes a processor 162 and a memory 164. Instructions stored in memory 164 may be executed by processor 162, which may include one or more digital signal processors (DSPs), general-purpose microprocessors, application-specific integrated circuits (ASICs), field programmable logic arrays (FPGAs), or other equivalent integrated or discrete logic circuitry. Accordingly, the term “processor” as used herein may refer to any of the foregoing structures or any other physical structure suitable for implementation of the techniques described in accordance with this disclosure. These techniques could be fully implemented in one or more circuits or logic elements. In aspects, these techniques may be implemented in hardware, software, firmware, or any combination thereof. If implemented in software, the functions may be stored as one or more instructions or code in memory 164, which may include a computer-readable medium configured to be executed by a hardware-based processing unit, e.g., processor 162. Computer-readable media may include non-transitory computer-readable media, which corresponds to a tangible medium such as data storage media (e.g., RAM, ROM, EEPROM, flash memory, or any other medium that can be used to store desired program code in the form of instructions or data structures and that can be accessed by a computer).

[0052] Referring back to FIG. 1 , UI 170 of plume evacuation console 100 includes one or more displays 172 and one or more buttons 174. The one or more displays 172 may include a graphical user interface (GUI) and / or other suitable display(s) for providing information to a user and, in aspects, enabling the input of information by the user. Buttons 174 may include one or more virtual buttons, e.g., incorporated into a GUI, and / or physical buttons. Buttons 174 enable adjustment of settings, toggling of information, etc., as well as the input of information by the user.

[0053] Plume evacuation console 100 may further include or be connectable to a suitable power source (not shown). For example, the power source may include any one or more of a battery, a plurality of batteries, or a direct current high voltage power supply connected to an AC source (e.g., line voltage). Additionally or alternatively, the power source may be a conventional AC wall outlet wherein plume evacuation console 100 includes a suitable cable and plug (not shown) for electrically coupling to the AC wall outlet. Plume evacuation console 100 mayadditionally or alternatively be plugged into a power source (not shown) on another system in the operating room such as a robotic system or an electrosurgical generator.

[0054] Referring to FIGS. 1-4, filter assembly 130 is described in greater detail. Filter assembly 130, in aspects, is disposed within a casing 132 that is engaged with housing 110 of plume evacuation console 100. Casing 132 may define inlet port 120 of plume evacuation console 100. In aspects, casing 132 is releasably engagable with housing 110 of plume evacuation console 100 to enable removal or replacement of filter assembly 130. As an alternative or in addition to the releasable engagement of casing 132 with housing 110, the interior of casing 132 may be accessible (while engaged with housing 110 or disengaged therefrom) via, for example, a door of casing 132, removal of a cover panel of casing 132, etc., to enable removal or replacement of filter assembly 130.

[0055] Turning to FIGS. 5-7, filter assembly 130 includes a filter housing 510 defining a flow inlet 512 and a flow outlet 514 and a filter 520 disposed within filter housing 510. Filter housing 510 of filter assembly 130 may be disposed within casing 132 (see, e.g., FIGS. 9A-9C) or may be formed as at least a portion of casing 132, e.g., wherein casing 132 defines filter housing 510. In aspects, as shown in FIG. 6, filter assembly 130 is disposed in a horizontal orientation, wherein inlet 512, outlet 514, and the layers of filter 520 all extend along a longitudinal axis defined by the layers of filter 520 and disposed in a generally horizontal orientation relative to a direction of gravity. Alternatively, as shown in FIG. 7, filter assembly 130 may be disposed in a vertical orientation, wherein inlet 512 and outlet 514 are oriented horizontally relative to a direction of gravity and wherein the layers of filter 520 extend along a longitudinal axis defined by the layers of filter 520 in a generally vertical orientation relative to the direction of gravity. In such vertical orientation configurations, inlet 512 may be disposed on a lower side of filter 520 and outlet 514 may be disposed on an upper side of filter 520, with inlet 512 and outlet 514 disposed on opposite sides of the longitudinal axis.

[0056] Filter 520 may be configured as an Ultra-Low Particulate Air (ULPA) filter having efficiency, at the appropriate flow rate, of 99.9995% at the Most Penetrating Particle Size (MPPS). In the horizontal orientation, the vertical orientation, or any other suitable orientation, filter 520, as noted above, may include a plurality of layers. The layers of filter 520 of filter assembly 130 may include, in a direction of flow across filter 520 from an input side 521a of filter 520 to an output side 521b of filter 520, a first layer 522 configured to capture gross particulates, waterdroplets, and a significant portion of particulate material (in aspects, up to at least 99% of particulate material); a second layer 524 comprising a blended media (or other suitable configuration) for capturing Volatile Organic Compounds (VOCs); a third layer 526 configured to capture material from second layer 524 and to further capture particulate material passing through first and second layers 522, 524; and a fourth layer 528 for final filtration to capture the smallest particles.

[0057] Any suitable material(s) may be utilized for the various layers 522-528. For example, in aspects, the first layer 522 is formed from polypropylene. Regardless of the material, first layer 522 may have a Minimum Efficiency Reporting Value (MERV) rating of or of at least 13 and / or an EN779 classification of or of at least F7. The third layer 526 may be formed from the same material and / or include the same ratings / classifications as the first layer 522. The second layer 524 may be formed from blended media including, for example, Potassium Permanganate (KMnO4) and activated carbon. The fourth layer 528 may be a ULPA filter. Other suitable materials and / or layer configurations are also contemplated.

[0058] With reference to FIG. 6, as noted above, filter assembly 130 may be disposed in a horizontal orientation, wherein plume flows along the longitudinal axis defined by filter 520 and substantially perpendicular to the direction of gravity through inlet 512, through layers 522-528, and out of outlet 514, wherein the plume proceeds further along the flow path defined by suction evacuation console 100 (see FIG. 4). Turning to FIG. 7, as also noted above, filter assembly 130 may be disposed in a vertical orientation, wherein plume flows substantially perpendicular to the direction of gravity through inlet 512 and into filter housing 510 at a location below filter 520. From the location within filter housing 510 below filter 520, the plume is drawn upwardly (substantially opposite of the direction of gravity) through the layers 522-528 via the suction provided by suction generator 140 (FIG. 4) and, ultimately, through outlet 514 in a direction substantially perpendicular to the direction of gravity, wherein the plume proceeds further along the flow path defined by suction evacuation console 100 (see FIG. 4).

[0059] In aspects, whether in the horizontal orientation or the vertical orientation, filter housing 510 may define an inlet chamber 516 disposed between inlet 512 and filter 520 and / or an outlet chamber 518 disposed between filter 520 and outlet 514, thus facilitate uniform airflow at plume intake to filter assembly 130 and at plume exit from filter assembly 130, respectively. Further, in the horizontal orientation, as shown in FIG. 6, filter housing 510 may include a taperedduct 540 leading to outlet 514 to facilitate plume flow at plume exit from filter assembly 130. Alternatively or additionally, a tapered duct (not shown) may be provided leading to inlet 512 to facilitate plume flow through inlet 512 and into inlet chamber 516. In other aspects, inlet and / or outlet ducts may be provided without a taper. With respect to the vertical orientation, as shown in FIG. 8A, ramps 542, 544 may be provided within inlet chamber 516 and / or outlet chamber 518, respectively. Ramps 542, 544 are angled towards inlet 512 and outlet 514, respectively, to facilitate uniform airflowthrough filter 520 (e.g., to increase the cross-sectional area width of filter 520 that is utilized).

[0060] Referring generally to FIGS. 8B-9C, it has been found that moisture within the plume flow into filter assembly 130 may decrease the life of filter 520 and / or may make it more difficult to achieve plume capture (e.g., requiring greater operating speed or power). Accordingly, this disclosure provides various features to facilitate moisture removal prior to filter 520 of filter assembly 130, thus thereby helping to improve filter life and plume capture. Any or all of the features below may be utilized in any suitable combination with one another. Further, although shown with respect to the vertical orientation of filter assembly 130, it is also contemplated that any or all of the features detailed below may likewise be utilized in the horizontal orientation of filter assembly 130.

[0061] With particular reference to FIG. 8B, in aspects, one or more desiccants 550 is disposed within inlet chamber 516 of filter housing 510 to reduce moisture in the plume flow prior to filter 520. The one or more desiccants 550 may be removable (and replaceable) from filter housing 510 or may be integrated into filter assembly 130. FIG. 8C illustrates a demister 560 disposed within inlet chamber 516 of filter housing 510 to reduce moisture in the plume flow prior to filter 520. Demister 560 may be removable (and replaceable) or integrated. In addition or as an alternative to the one or more desiccants 550 (FIG. 8B) and / or demister 560, filter assembly 130 may include hydrophobic materials disposed within inlet chamber 516 such that moisture within plume flowing into filter 520 is repelled and / or hydrophilic materials disposed within inlet chamber 516 to attract moisture away from filter 520.

[0062] As shown in FIG. 8D, filter assembly 130 may include a liquid trap 570 disposed within inlet chamber 516 of filter housing 510 and configured to collect liquid removed from the plume flow entering the filter assembly 130. With respect to the vertical orientation of filter assembly 130, gravity facilitates the removal of (the relatively heavier) moisture from the plume flow (whilethe relatively lighter gas is suctioned upwardly). The separated moisture is collected as liquid within liquid trap 570. Liquid trap 570 may likewise be utilized in the horizontal orientation of filter assembly 130. Liquid trap 570 may be accessible via a door 580 (e.g., a hinged door) providing access through filter housing 510 to inlet chamber 516, thus enabling emptying and / or replacing liquid trap 570. In addition or as an alternative to liquid trap 570, a liquid removal port 590, as shown in FIG. 8E, may be disposed through filter housing 510 and in communication with inlet chamber 516. Liquid removal port 590 may include a Luer lock fitting or other suitable fitting configured to enable connection of a suction source (not shown) to liquid removal port 590 for suctioning liquid out of inlet chamber 516. More specifically, liquid may be suctioned out of filter 520 and / or inlet chamber 516 (and, in aspects where provided, liquid trap 570 (FIG. 8D)). Port 590 enables safe removal of liquid, e.g., minimizing user contact with the potentially contaminated liquid.

[0063] Referring to FIGS. 9A-9C, in addition or as an alternative to the above-detailed moisture reducing features disposed within filter housing 510 of filter assembly 130, moisture removal may be provided by a dehumidifier disposed upstream of filter housing 510 such as, for example, within casing 132 of filter assembly 130 between inlet port 120 of plume evacuation console 100 and filter housing 510 of filter assembly 130. With reference to FIG. 9A, in aspects, a cyclone separator dehumidifier 910 is disposed within casing 132 of filter assembly 130 between inlet port 120 of casing 132 and inlet 512 of filter housing 510. Cyclone separator dehumidifier 910 includes: one or more inverted conical bodies 912; an inlet 914 fluidly coupling inlet port 120 of casing 132 with body 912 at an upper, base end of body 912; an outlet 916 at the upper, base end of body 912 fluidly coupling body 912 with inlet 512 of filter housing 510; and a bottom port918 at a lower, apex upper end of body 912. Cyclone separator dehumidifier 910 is configured to receive plume flow through inlet 914 and to generate flow within body 912 in a cyclone-shaped configuration, thereby allowing heavier matter within the plume (e.g., liquid) to be thrown outward via centrifugal force and fall under the influence of gravity towards bottom port 918 while lighter matter within the plume (e.g., gas) flows out through outlet 916 and continues along the flow path of plume evacuation console 100 (FIG. 4). Bottom port 918 may be selectively openable to enable drainage of liquid at the lower, apex end of body 912 or may be open (or openable) to a liquid trap919 configured to collect liquid exiting bottom port 918.

[0064] FIG. 9B illustrates a vane deflector dehumidifier 920 disposed within casing 132 of filter assembly 130 between inlet port 120 of casing 132 and inlet 512 of filter housing 510. Vane deflector dehumidifier 920 includes a plurality of spaced vane plates 922 each having a plurality of angled panels 924. Although vane plates 922 are shown oriented substantially vertically for substantially horizontal plume flow therethrough, vane plates 922 may alternatively be oriented substantially horizontally for substantially vertical plume flow therethrough, or at an angle for angled plume flow therethrough. Angled panels 924 of vane plates 922 force plume flowing between vane plates 922 to change directions multiple times which, in turn, separates out heavier matter within the plume (e.g., liquid) from lighter matter within the plume (e.g., gas) due to the greater inertia of the heavier matter. As a result, the separated liquid can fall under gravity into a liquid trap 926 or for collection in any other suitable manner, while the lighter matter (e.g., gas) continues along the flow path of plume evacuation console 100 (FIG. 4) to inlet 512 of filter housing 510.

[0065] Referring to FIG. 9C, a Peltier dehumidifier 930 is shown disposed within casing 132 of filter assembly 130 between inlet port 120 of casing 132 and inlet 512 of filter housing 510. Peltier dehumidifier 930 includes a Peltier element 932 configured to be coupled between positive (+) and negative (-) terminals of an energy source (not shown) to energize Peltier element 932, thus defining a cool side 934 and a warm side 936. Plume inflow through inlet port 120 of casing 132 first encounters cool side 934 of Peltier element 932 whereby the moisture condenses out of the gas as it cools when it encounters cool side 934 of Peltier element 932, allowing the separated liquid to fall under gravity into a liquid trap 938 or for collection in any other suitable manner, while the remaining plume continues along warm side 936 of Peltier element 932, bringing the temperature of the remaining plume back up as it continues along the flow path of plume evacuation console 100 (FIG. 4) to inlet 512 of filter housing 510. In aspects, a fan 939 is provided to direct the remaining plume across warm side 936 of Peltier element 932 before the remaining plume continues to inlet 512 of filter housing 510. In other aspects, fan 939 is omitted as the above-detailed flow is provided by suction generator 140 (FIG. 4).

[0066] With reference to FIG. 10, in conjunction with FIG. 4, in aspects, controller 160 is configured to control console 100 and, more specifically, suction generator 140 thereof, to achieve capture of at least 90% (by volume) of a surgical plume generated at a surgical site. It has been found that this at least 90% capture can be achieved by controlling plume evacuation console 100to achieve and maintain, e.g., substantially constant, a flow that provides a minimum inlet plume velocity at plume collection, e.g., at opening 232 of nozzle 230 of electrosurgical pencil 200 (see FIG. 1), necessary to achieve at least 90% capture.

[0067] The inlet plume velocity at plume collection depends upon the flow through system 10 which, in turn, depends upon the configuration and operation of the various components of the plume evacuation system utilized. For example, with respect to system 10, the configuration and operation of the plume evacuation device at the surgical site, e.g., electrosurgical pencil 200, the configuration and operation of filter assembly 130, the configuration and operation of suction generator 140, the configuration and operation of the exhaust assembly 180, e.g., silencer 147 and / or exhaust chamber 150, and, in aspects where provided, the configuration and operation of any bypass, e.g., bypass conduit 148 (FIG. 4), all impact the flow provided and, thus, the inlet plume velocity at plume collection.

[0068] With respect to filter assembly 130 in particular, the pressure drop (also referred to as pressure loss or resistance) across filter assembly 130 impacts the flow provided and, thus, inlet plume velocity at plume collection. The pressure drop across filter assembly 130 is the difference between the pressure at the input to filter assembly 130, Pfii-in, and the pressure at the output from filter assembly 130 (which corresponds to the input to suction generator 140), Pai-out.

[0069] In aspects, a mathematical model, e.g., including a plurality of equations, takes into account the configurations and operations of the components of plume evacuation system 10, e.g., electrosurgical pencil 200, filter assembly 130, suction generator 140, and exhaust assembly 180, to enable control of suction generator 140 to establish a flow sufficient to achieve and maintain the minimum (or other target) inlet plume velocity at plume collection, thus enabling capture of at least 90% (by volume) of a surgical plume generated at a surgical site. Establishing and maintaining other suitable target volumetric flows are also contemplated.

[0070] The mathematical model, in aspects, includes a plurality of equations each including one or more coefficients corresponding to one or more of the components of the plume evacuation system 10, e.g., wherein the coefficient(s) at least partially represent the impact of the pressure drop across that component on flow. More specifically, in aspects, the one or more coefficients are set as constants based upon the particular configuration of the component, and may be determined empirically or in any other suitable manner.

[0071] With respect to filter assembly 130, which may be removable and replaceable from plume evacuation console 100 and / or may which include different features, the coefficients, e.g., constants, utilized for the mathematical model of equations, may be different depending upon the particular filter assembly 130 and / or features thereof. Further, as there may be variation from filter assembly 130 to filter assembly 130, even withing the same type and / or same featured filter assembly, the coefficients, e.g., constants, utilized for the mathematical model may be different from filter assembly 130 to filter assembly 130.

[0072] Thus, to enable the appropriate coefficients to be assigned to filter assembly 130, filter assembly information may first be obtained by controller 160. The filter assembly information may be obtained by communication with an RFID tag associated with filter assembly 130, accessing an EEPROM associated with filter assembly 130, evaluating a resistive or other information-conveying circuit associated with filter assembly 130, reading a barcode, QR code, or other optical code associated with filter assembly 130, by input or selection of filter assembly 130 by a user, e.g., at UI 170 (see FIG. 1), or in any other suitable manner. In aspects, the filter assembly information is detected during setup or initially during use, for example, by predicting the filter assembly utilized based upon flow characteristics, e.g., a determined resistance to flow through filter assembly 130.

[0073] Depending upon the filter assembly information provided, the coefficients may be model specific, lot specific, device specific, manufacturing date specific, etc. For example, the coefficients may be set for a given device model (or SKU) number, or may vary for the same model of device based upon, for example, lot number, manufacturing date, use information, and / or other device information. Further, in aspects, the coefficients are set based upon device serial number. As such, manufacturing variations, device-to-device variations, etc., may be accounted for in determining the appropriate coefficients. Such manufacturing variations, as they impact the appropriate coefficients, may be associated with the device during manufacturing (e.g., written to memory, associated with a barcode, etc.), thus enabling plume evacuation console 100 to obtain this information from filter assembly 130 (or packaging thereof, for example). Alternatively, this information may be provided to plume evacuation console 100 separately, e.g., via a system update indicating the latest filter assemblies, lots, etc. and corresponding coefficients. With respect to use variations, information representing changes in the coefficients over the course of use (e.g., use time) of filter assembly 130 may be provided such that the appropriate coefficients may beimplemented (or updated) based upon use tracking of filter assembly 130, which may also be accomplished by plume evacuation console 100. Thus, the term “constant,” as utilized herein, is not limited to a static value for the entire life of filter assembly 130; rather, a constant may be updated, for example, based upon use data (actual or predicted), filter assembly information, etc.

[0074] The coefficients may be determined from the filter assembly information such as, for example, by accessing a lookup table associating filter assembly information with corresponding coefficient valves (including formulae or values enabling calculation of the coefficient values), although other suitable manners of determining the coefficients directly or indirectly from the filter assembly information are also contemplated. Alternatively, the filter assembly information itself may include the coefficients. Regardless of the particular manner of obtaining these coefficients, these coefficients are established or predicted coefficients based upon the filter assembly information.

[0075] Continuing with reference to FIGS. 4 and 10, in aspects, controller 160 is configured to implement the above-detailed mathematical model, e.g., by solving some or all of the equations of the model using the coefficients, sensed input(s), and / or other input(s) to solve for one or more variables that are not otherwise determined. These solved variables provide the parameters that achieve the desired target. For example, the equations of the mathematical model may be solved to determine the variables that enable maintaining the minimum inlet plume velocity. In such aspects, these solved variables may include the input power to suction generator 140 or the rotation speed of blower(s) 142 such that control signals may be provided to motor(s) 144, e.g., to provide the input power and / or to drive blower(s) 142 at the speed, to maintain the minimum inlet plume velocity. Other suitable feedback-based control using the above-detailed mathematical model of equations is also contemplated.

[0076] In addition or as an alternative to enabling flow control to achieve a minimum inlet plume velocity, e.g., based upon filter assembly information associated with filter assembly 130, the above-detailed mathematical model of equations and, in particular, the coefficients thereof, may be utilized to monitor system components and / or function. For example, the established or predicted coefficients of filter assembly 130 (e.g., determined based on the filter assembly information) may be compared to calculated or actual coefficients of filter assembly 130 (determined by solving some or all of the equations of the model using sensed input(s), and / or other input(s)) to evaluate the status of filter assembly 130. More specifically, where a differencebetween the predicted and actual coefficients is outside a threshold range and / or where a rate of change of the actual coefficient(s) is outside a threshold range (e.g., indicating a sudden change in coefficient value), the presence of a clog or leak (depending upon whether the difference or rate of change is positive or negative) in filter assembly 130 can be detected.

[0077] Additionally or alternatively, the actual coefficients may be tracked to monitor a condition / remaining life of the filter of filter assembly 130. More specifically, during an initial period of use of filter assembly 130, the actual coefficient(s) may remain within a threshold of the predicted coefficient(s) or a coefficient curve, indicating that the of filter assembly 130 is sufficiently unrestricted and / or still has useful life. However, as restriction increases over use, the actual coefficient(s) may deviate from the predicted coefficient(s) or coefficient curve and exceed the threshold, thus indicating that the filter assembly 130 has become significantly restricted and / or has reached the end of its useful life.

[0078] The above-noted monitoring of filter assembly 130 may be performed by controller 160. In such aspects, controller 160 may output a suitable notification, e.g., for display on UI 170, indicating the condition of filter assembly 130, whether a clog or leak has been detected, whether the filter of filter assembly 130 has reached the end of its life (and, thus, to change the filter of filter assembly 130), etc. An audible alert, e.g., output from a speaker associated with plume evacuation console 100, is additionally or alternatively contemplated. Operation of suction generator 140 may additionally or alternatively be modified or stopped in response to detection of a clog, leak, or other adverse condition associated with filter assembly 130.

[0079] The plume evacuation consoles and systems provided in accordance with this disclosure may be utilized in any type of surgical procedure including, for example, open surgical procedures, laparoscopic surgical procedures, robotic surgical procedures, robotic-assisted surgical procedures, etc. While the particular surgical instrument(s) and connections thereto may vary depending upon the type of surgical procedure, the aspects and features of the plume evacuation consoles and systems detailed hereinabove remain applicable to each type of procedure and / or each different surgical instrument configured for use therewith energy devices.

[0080] Turning to FIG. 11, a robotic surgical system 1000 configured for use in accordance with this disclosure is shown. Aspects and features of robotic surgical system 1000 not germane to the understanding of this disclosure are omitted to avoid obscuring the aspects and features of this disclosure in unnecessary detail.

[0081] Robotic surgical system 1000 generally includes a plurality of robot arms 1002, 1003; a control device 1004; and an operating console 1005 coupled with control device 1004. Operating console 1005 may include a display device 1006, which may be set up in particular to display three-dimensional images; and manual input devices 1007, 1008, by means of which a clinician, e.g., a surgeon, may be able to telemanipulate robot arms 1002, 1003 in a first operating mode. Robotic surgical system 1000 may be configured for use on a patient 1013 lying on a patient table 1012 to be treated in a minimally invasive manner. Robotic surgical system 1000 may further include a database 1014, in particular coupled to control device 1004, in which are stored, for example, pre-operative data from patient 1013 and / or anatomical atlases.

[0082] Each of the robot arms 1002, 1003 may include a plurality of members, which are connected through joints, and a mounted device which may be, for example, a surgical tool “ST.” The surgical tools “ST” may include, for example, electrosurgical pencil 200 (FIG. 1). Electrosurgical pencil 200 (FIG. 1) may, in turn, be connected to plume evacuation console 100 (FIG. 1), which is mounted on the robot arm 1002, 1003, disposed on a surgical cart (not shown) associated with robotic surgical system 1000, or otherwise positioned as part of or separate from robotic surgical system 1000 to provide any of the above-detailed plume evacuation functionality for use with robotic surgical system 1000.

[0083] Robot arms 1002, 1003 may be driven by electric drives, e.g., motors, connected to control device 1004. The motors, for example, may be rotational drive motors configured to provide rotational inputs to accomplish a desired task or tasks. Control device 1004, e.g., a computer, may be configured to activate the motors, in particular by means of a computer program, in such a way that robot arms 1002, 1003, and, thus, their mounted surgical tools “ST” execute a desired movement and / or function according to a corresponding input from manual input devices 1007, 1008, respectively. Control device 1004 may also be configured in such a way that it regulates the movement of robot arms 1002, 1003 and / or of the motors.

[0084] Control device 1004, more specifically, may control one or more of the motors based on rotation, e.g., controlling to rotational position using a rotational position encoder (or Hall effect sensors or other suitable rotational position detectors) associated with the motor to determine a degree of rotation output from the motor and, thus, the degree of rotational input provided. Alternatively or additionally, control device 1004 may control one or more of the motors based on torque, current, or in any other suitable manner.

[0085] Aspects of this disclosure may be further described by reference to the following numbered paragraphs:

[0086] 1. A filter assembly for a surgical plume evacuation console, comprising: a filter housing defining an inlet, an inlet chamber in communication with the inlet, an outlet chamber, and an outlet in communication with the outlet chamber; and a filter disposed within the filter housing between the inlet chamber and the outlet chamber, the filter formed from a plurality of layers, wherein a plume flow path of a surgical plume evacuated from a surgical site is defined from the inlet, through the inlet chamber, through the filter, through the outlet chamber, and out of the outlet.

[0087] 2. The filter assembly according to paragraph 1, wherein the filter housing is arranged in a horizontal orientation relative to a direction of gravity, wherein the plurality of layers of the filter defines a longitudinal axis extending substantially perpendicular to the direction of gravity, and wherein the inlet, inlet chamber, the plurality of layers, the outlet chamber, and the outlet are disposed along the longitudinal axis.

[0088] 3. The filter assembly according to paragraph 2, wherein the outlet chamber defines a tapered duct to facilitate plume flow along the plume flow path from the outlet chamber to the outlet.

[0089] 4. The filter assembly according to paragraph 1, wherein the filter housing is arranged in a vertical orientation relative to a direction of gravity, wherein the plurality of layers of the filter defines a longitudinal axis extending substantially parallel to the direction of gravity, wherein the inlet is disposed below the filter, and wherein the outlet is disposed above the filter.

[0090] 5. The filter assembly according to paragraph 4, wherein the inlet and the outlet are disposed on opposite sides of the longitudinal axis.

[0091] 6. The filter assembly according to paragraph 4 or 5, wherein at least one of the inlet chamber or the outlet chamber includes an angled ramp configured to facilitate plume flowthrough the filter.

[0092] 7. The filter assembly according to any preceding paragraph, further comprising at least one moisture collection device disposed within the inlet chamber of the filter housing.

[0093] 8. The filter assembly according to any preceding paragraph, further comprising a liquid trap disposed within the inlet chamber of the filter housing.

[0094] 9. The filter assembly according to any preceding paragraph, further comprising a suction port disposed through the filter housing, wherein the suction port is configured to connect to a suction source for suctioning fluid from at least one of the filter or the inlet chamber.

[0095] 10. The filter assembly according to any preceding paragraph, wherein the filter housing is disposed within a casing defining an inflow port.

[0096] 11. The filter assembly according to paragraph 10, further comprising a dehumidifier disposed within the casing between the inflow port and the filter housing.

[0097] 12. The filter assembly according to any preceding paragraph, wherein the plurality of layers of the filter includes: at least one layer configured to capture gross particulate; a layer configured to capture Volatile Organic Compounds (VOCs); and an Ultra-Low Particulate Air (ULPA) layer.

[0098] 13. The filter assembly according to paragraph 12, wherein a first gross particulate layer is disposed at an input side of the filter, the VOCs layer is disposed between the first gross particulate layer and a second gross particulate layer of the at least one gross particulate layer, and the ULPA layer is disposed at an output side of the filter.

[0099] 14. The filter assembly according to paragraph 12 or 13, wherein the VOC layer is formed from a blended media.

[0100] 15. A surgical plume evacuation console, comprising: a console housing; a suction generator disposed within the console housing, the suction generator configured to generate a flow of a surgical plume evacuated from a surgical site along an evacuation flow path; an exhaust assembly disposed within the console housing, the exhaust assembly configured to exhaust the evacuated plume from the evacuation flow path to an exterior of the console housing; and a filter assembly configured to fluidly connect to the suction generator, the filter assembly including: a filter housing defining an inlet, an inlet chamber in communication with the inlet, an outlet chamber, and an outlet in communication with the outlet chamber; and a filter disposed within the filter housing between the inlet chamber and the outlet chamber, the filter formed from a plurality of layers, wherein the filter assembly defines a portion of the evacuation flow path the portion of the evacuation flow path defined from the inlet, through the inlet chamber, through the filter, through the outlet chamber, and out of the outlet.

[0101] 16. The surgical plume evacuation console according to paragraph 15, further comprising a controller disposed within the console housing, the controller configured to controlthe suction generator in accordance with filter assembly information received from or about the filter assembly.

[0102] 17. The surgical plume evacuation console according to paragraph 15 or 16, wherein the filter housing is arranged in a vertical orientation relative to a direction of gravity, wherein the plurality of layers of the filter define a longitudinal axis extending substantially parallel to the direction of gravity, wherein the inlet is disposed below the filter, and wherein the outlet is disposed above the filter.

[0103] 18. The surgical plume evacuation console according to any one of paragraphs 15-17, wherein the filter assembly further includes at least one of: at least one moisture collection device disposed within the inlet chamber of the filter housing, or a dehumidifier disposed upstream of and fluidly coupled to the filter housing.

[0104] 19. The surgical plume evacuation console according to any one of paragraphs 15-18, wherein the plurality of layers of the filter includes: at least one layer configured to capture gross particulate; a layer configured to capture Volatile Organic Compounds (VOCs); and an Ultra-Low Particulate Air (ULPA) layer.

[0105] 20. The surgical plume evacuation console according to paragraph 19, wherein a first gross particulate layer is disposed at an input side of the filter, the VOCs layer is disposed between the first gross particulate layer and a second gross particulate layer of the at least one gross particulate layer, and the ULPA layer is disposed at an output side of the filter.

[0106] 21. The surgical plume evacuation console according to paragraph 19 or 20, wherein the VOC layer is formed from a blended media.

[0107] 22. The surgical plume evacuation console according to any one of paragraphs 15-21, wherein the filter assembly includes a casing retaining or defining the filter housing, wherein the casing is configured to releasably engage the console housing.

[0108] While several aspects of the disclosure have been shown in the drawings, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular aspects. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.

Claims

WHAT IS CLAIMED IS:

1. A filter assembly for a surgical plume evacuation console, comprising: a filter housing defining an inlet, an inlet chamber in communication with the inlet, an outlet chamber, and an outlet in communication with the outlet chamber; and a filter disposed within the filter housing between the inlet chamber and the outlet chamber, the filter formed from a plurality of layers, wherein a plume flow path of a surgical plume evacuated from a surgical site is defined from the inlet, through the inlet chamber, through the filter, through the outlet chamber, and out of the outlet.

2. The filter assembly according to claim 1, wherein the filter housing is arranged in a horizontal orientation relative to a direction of gravity, wherein the plurality of layers of the filter defines a longitudinal axis extending substantially perpendicular to the direction of gravity, and wherein the inlet, inlet chamber, the plurality of layers, the outlet chamber, and the outlet are disposed along the longitudinal axis.

3. The filter assembly according to claim 2, wherein the outlet chamber defines a tapered duct to facilitate plume flow along the plume flow path from the outlet chamber to the outlet.

4. The filter assembly according to claim 1, wherein the filter housing is arranged in a vertical orientation relative to a direction of gravity, wherein the plurality of layers of the filter defines a longitudinal axis extending substantially parallel to the direction of gravity, wherein the inlet is disposed below the filter, and wherein the outlet is disposed above the filter.

5. The filter assembly according to claim 4, wherein the inlet and the outlet are disposed on opposite sides of the longitudinal axis.

6. The filter assembly according to claim 4, wherein at least one of the inlet chamber or the outlet chamber includes an angled ramp configured to facilitate plume flow through the filter.

7. The filter assembly according to claim 1, further comprising at least one moisture collection device disposed within the inlet chamber of the filter housing.

8. The filter assembly according to claim 1, further comprising a liquid trap disposed within the inlet chamber of the filter housing.

9. The filter assembly according to claim 1 , further comprising a suction port disposed through the filter housing, wherein the suction port is configured to connect to a suction source for suctioning fluid from at least one of the filter or the inlet chamber.

10. The filter assembly according to claim 1 , wherein the filter housing is disposed within a casing defining an inflow port.

11. The filter assembly according to claim 10, further comprising a dehumidifier disposed within the casing between the inflow port and the filter housing.

12. The filter assembly according to claim 1, wherein the plurality of layers of the filter includes: at least one layer configured to capture gross particulate; a layer configured to capture Volatile Organic Compounds (VOCs); and an Ultra-Low Particulate Air (ULPA) layer.

13. The filter assembly according to claim 12, wherein a first gross particulate layer is disposed at an input side of the filter, the VOCs layer is disposed between the first gross particulate layer and a second gross particulate layer of the at least one gross particulate layer, and the ULPA layer is disposed at an output side of the filter.

14. The filter assembly according to claim 12, wherein the VOC layer is formed from a blended media.

15. A surgical plume evacuation console, comprising: a console housing;a suction generator disposed within the console housing, the suction generator configured to generate a flow of a surgical plume evacuated from a surgical site along an evacuation flow path; an exhaust assembly disposed within the console housing, the exhaust assembly configured to exhaust the evacuated plume from the evacuation flow path to an exterior of the console housing; and a filter assembly configured to fluidly connect to the suction generator, the filter assembly including: a filter housing defining an inlet, an inlet chamber in communication with the inlet, an outlet chamber, and an outlet in communication with the outlet chamber; and a filter disposed within the filter housing between the inlet chamber and the outlet chamber, the filter formed from a plurality of layers, wherein the filter assembly defines a portion of the evacuation flow path the portion of the evacuation flow path defined from the inlet, through the inlet chamber, through the filter, through the outlet chamber, and out of the outlet.

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