Fluid separators for surgical plume evacuation systems

Abstract

A fluid separator includes a body having an inlet, an outlet, and a chamber. The inlet communicates with an outer ring portion of the chamber at a tangential location and the outlet communicates with an inner chamber portion of the chamber at an axial location. The chamber further includes a funnel chamber portion extending from the outer chamber portion to a funnel drain.

Description

FLUID SEPARATORS FOR SURGICAL PLUME EVACUATION SYSTEMSCROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 677,666, filed July 31 , 2024, which is incorporated herein by reference in its entirety.FIELD

[0002] This disclosure relates to surgical devices and systems and, more specifically, to fluid separators for surgical plume evacuation systems and surgical plume evacuation systems incorporating the same to facilitate removal of surgical plume from a surgical site.BACKGROUND

[0003] Various different energy-based surgical instruments generate a surgical plume as a byproduct of energy-based tissue treatment. Surgical plume, e.g., produced as a by-product of the application of energy from an energy-based surgical instrument (for example, a monopolar electrosurgical pencil) to tissue at a surgical site, may include 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. In order to facilitate evacuation of surgical plume from the surgical site, surgical plume evacuation systems have been developed that suction surgical plume from the surgical site, through tubing, to a console for filtering the surgical plume and, ultimately, recirculating the filtered surgical plume into the operating room or expelling the filtered surgical plume from the operating room.

[0004] However, liquid suctioned into the console with surgical plume can damage and / or reduce the efficiency of the surgical plume evacuation system.SUMMARY

[0005] As used herein, the term “distal” refers to the portion that is being described which is farther from a suction generating device, while the term “proximal” refers to the portion that is being described which is closer to the suction generating device. 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 orminus 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 fluid separator including a body having an inlet, an outlet, and a chamber. The chamber has an inner chamber portion disposed about a longitudinal axis, an outer chamber portion disposed about the inner chamber portion, and a funnel chamber portion extending from the outer chamber portion to a funnel drain. The inlet communicates with the outer chamber portion at a tangential location and the outlet communicates with the inner chamber portion at an axial location.

[0007] In an aspect of this disclosure, the chamber and the position of the inlet and outlet relative to the chamber facilitate inflow from the inlet, through the outer chamber portion and along the funnel chamber portion in a vortical manner to enable liquid to fall through the funnel drain while gas flows upwardly from at or near the funnel drain axially along the longitudinal axis through the inner chamber portion to the outlet.

[0008] In an aspect of this disclosure, the chamber is a cyclonic chamber.

[0009] In an aspect of this disclosure, the inner chamber portion defines a cylindrical configuration, and the outer chamber portion defines a ring configuration.

[0010] In an aspect of this disclosure, the inlet defines an inlet passage having a height “a” along the longitudinal axis, the outer chamber portion of the chamber defines a diameter “D”, and a ratio of “a” to “D” is 0.42 plus or minus 20 percent.

[0011] In another aspect of this disclosure, the inner chamber portion of the chamber defines a height “S” along the longitudinal axis, the outer chamber portion of the chamber defines a diameter “D”, and a ratio of “S” to “D” is 0.65 plus or minus 20 percent.

[0012] In still another aspect of this disclosure, the chamber defines a height “H” along the longitudinal axis, the outer chamber portion of the chamber defines a diameter “D”, and a ratio of “H” to “D” is 1.45 plus or minus 20 percent.

[0013] In yet another aspect of this disclosure, the inner chamber portion of the chamber defines a height “S” along the longitudinal axis, the outer chamber portion of the chamber defines a height “h” along the longitudinal axis, and a ratio of “S” to “h” is 1.00 plus or minus 20 percent.

[0014] In still yet another aspect of this disclosure, the fluid separator further includes a reservoir configured to releasably engage the body. The reservoir defines a collection chamberdisposed in fluid communication with the funnel drain when the reservoir is engaged with the body.

[0015] In an aspect of this disclosure, the reservoir is releasably connected to the body via a bayonet coupling.

[0016] In an aspect of this disclosure, the bayonet coupling includes at least one protrusion disposed on at least one of the body or the reservoir and at least one slot defined within at least one of the body or the reservoir. The at least one protrusion is configured for receipt within the at least one slot to releasably connect the reservoir and the body with one another.

[0017] In another aspect of this disclosure, the reservoir further includes a baffle disposed within the collection chamber and configured to inhibit the suctioning of liquid from the collection chamber into the body.

[0018] In still another aspect of this disclosure, the reservoir includes a stopper configured to substantially occlude the funnel drain when a level of liquid within the collection chamber reaches a maximum fill limit.

[0019] In yet another aspect of this disclosure, the reservoir includes a stopper configured to substantially occlude the inner chamber portion of the chamber when a level of liquid within the collection chamber reaches a maximum fill limit.

[0020] A system provided in accordance with this disclosure includes a first tubing section configured for positioning at a surgical site, a second tubing section configured to connect to a surgical plume evacuation console, and the fluid separator according to any of the aspects detailed above or otherwise herein. The inlet of the fluid separator is configured to couple to the first tubing section and the outlet of the fluid separator is configured to couple to the second tubing section.

[0021] Another system provided in accordance with this disclosure includes a first tubing section configured for connecting to a surgical instrument, a second tubing section configured to connect to a surgical plume evacuation console, and the fluid separator according to any of the aspects detailed above or otherwise herein. The inlet of the fluid separator is configured to couple to the first tubing section and the outlet of the fluid separator is configured to couple to the second tubing section.

[0022] Still another system provided in accordance with this disclosure includes a tubing section configured for positioning at a surgical site, and the fluid separator according to any of the aspects detailed above or otherwise herein. The inlet of the fluid separator is configured to coupleto the tubing section and the outlet of the fluid separator is connected to a surgical plume evacuation console.

[0023] Yet another system provided in accordance with this disclosure includes tubing section configured for connecting to a surgical instrument, and the fluid separator according to any of the aspects detailed above or otherwise herein. The inlet of the fluid separator is configured to couple to the tubing section and the outlet of the fluid separator is connected to a surgical plume evacuation console.

[0024] In aspects of this disclosure, the outlet of the fluid separator is configured for receipt within an inlet port of the surgical plume evacuation console to couple the fluid separator with the surgical plume evacuation console. Alternatively, the outlet of the fluid separator is configured for positioning about the inlet port of the surgical plume evacuation console to couple the fluid separator with the surgical plume evacuation console.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] 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.

[0026] FIG. 1 A is a perspective view of a surgical plume evacuation system including a plume evacuation console having a surgical instrument connected thereto via tubing and a fluid separator provided in accordance with this disclosure disposed in-line along the tubing between the surgical instrument and the plume evacuation console;

[0027] FIG. IB is a perspective view illustrating coupling of the fluid separator of FIG. 1A directly to the plume evacuation console without intervening tubing;

[0028] FIG. 2A is an enlarged, perspective view of the area of detail indicated as “2A” in FIG.1 illustrating the fluid separator of the system of FIG. 1 A;

[0029] FIG. 2B is an exploded, perspective view of the fluid separator of FIG. 2A;

[0030] FIG. 3 is a cross-sectional view of the fluid separator of FIG. 2A;

[0031] FIGS. 4 A and 4B are schematic illustrations defining various dimensions of the fluid separator of FIG. 2A;

[0032] FIG. 5 is side view of the fluid separator of FIG. 2A including a baffle to inhibit the suctioning of liquid from the liquid reservoir;

[0033] FIGS. 6A and 6B are side views of the fluid separator of FIG. 2 A including an overflow prevention mechanism in open and closed positions, respectively;

[0034] FIGS. 7A and 7B are side views of the fluid separator of FIG. 2A including another overflow prevention mechanism in open and closed positions, respectively;

[0035] FIG. 8 is side, perspective, partial see-through view of another fluid separator configured for use with the system of FIG. 1A or any other suitable system;

[0036] FIGS. 9 and 10 are cross-sectional views of still other fluid separators configured for use with the system of FIG. 1A or any other suitable system;

[0037] FIG. 11 is a chart comparing the average tangential flow speeds, diameters, and heights of the fluid separators of FIGS. 2A and 8-10;

[0038] FIGS. 12A and 12C are heat maps illustrating tangential flow velocity and axial flow velocity, respectively, through the fluid separator of FIG. 8;

[0039] FIGS. 12B and 12D are graphs illustrating tangential flow velocity and axial flow velocity, respectively, through the fluid separator of FIG. 8 across the internal diameter of the fluid separator;

[0040] FIGS. 13A and 13C are heat maps illustrating tangential flow velocity and axial flow velocity, respectively, through the fluid separator of FIG. 2A;

[0041] FIGS. 13B and 13D are graphs illustrating tangential flow velocity and axial flow velocity, respectively, through the fluid separator of FIG. 2A across the internal diameter of the fluid separator;

[0042] FIGS. 14 and 15 are vector maps of flow velocity magnitude through the fluid separators of FIGS. 8 and 2A, respectively; and

[0043] FIG. 16 is a chart comparing dimensions and dimensional ratios of the fluid separators of FIGS. 2A and 8-10.DETAILED DESCRIPTION

[0044] Referring to FIG. 1A, 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, a surgical instrument, which may be an energy-based surgical instrument (such as, for example, an electrosurgical pencil 200), tubing 300 configured to fluidly couple electrosurgical pencil 200 toplume evacuation console 100 to enable evacuation of a surgical plume from a surgical site, and a fluid separator 400 disposed along tubing 300 (e.g., at a proximal end of tubing 300 or between distal and proximal tubing sections 310, 320, respectively) between electrosurgical pencil 200 and plume evacuation console 100 to facilitate the removal of liquid from the surgical plume and, thus, inhibit the suctioning of liquid into plume evacuation console 100.

[0045] Although system 10 is shown and described herein in connection with electrosurgical pencil 200, it is contemplated that any suitable energy-based surgical instrument may alternatively or additionally be utilized with system 10 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. In other aspects, tubing 300 functions as a stand-alone surgical instrument to remove a surgical plume from the surgical site with fluid separator 400 disposed between the stand-alone tubing 300 and plume evacuation console 100. Further, although plume evacuation console 100 is shown configured as a stationary unit, e.g., for rack-mounted, polemounted, or table-top use, it is also contemplated that plume evacuation console 100 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. In addition, while fluid separator 400 is shown disposed along tubing 300 with tubing 300 extending both proximally and distally of fluid separator 400, it is also contemplated that fluid separator 400 may mount directly to plume evacuation console 100, the surgical instrument, or that fluid separator 400 be disposed at any other suitable location in-line along the fluid flow path.

[0046] Continuing with reference to FIG. 1A, electrosurgical pencil 200 includes a housing 210, an electrode 220 coupled to and extending from a distal end portion 212 of housing 210, and a nozzle 230 coupled to and extending distally from distal end portion 212 of housing 210 adjacent to electrode 220. Tubing 300 is coupled to and extends from a proximal end portion 214 of housing 210.

[0047] Housing 210 may be configured as a handle to facilitate grasping and manipulation by a surgeon (FIG. 1A) or may be configured to mount to an arm of a surgical robotic system (not shown) for use in robotic surgery. In either configuration, housing 210 includes a fluid lumen 216extending from distal end portion 212 of housing 210 to proximal end portion 214 of housing 210 to fluidly couple nozzle 230 with tubing 300. 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.

[0048] 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 engageable 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.

[0049] Referring still to FIG. 1 A, 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 through nozzle 230, fluid lumen 216, tubing 300, fluid separator 400 and, ultimately, to plume evacuation console 100. In aspects, nozzle 230 is releasably engageable 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.

[0050] 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 with electrosurgical 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.

[0051] Tubing 300 may be corrugated or otherwise configured to facilitate flexion of tubing 300 while minimizing kinking of tubing 300. Further, tubing 300 is coupled to housing 210 via aconnector 260 which may be, for example and without limitation, a swivel connector enabling rotation and / or pivoting of tubing 300 relative to housing 210 to further minimizing kinking of tubing 300. Tubing 300 includes a distal section 310 configured to connect electrosurgical pencil 200 to an inlet 426 (FIG. 2 A) of fluid separator 400 and a proximal section 320 configured to connect an outlet 430 (FIG. 2A) of fluid separator 400 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, tubing 300, and fluid separator 400. In other aspects of this disclosure, as noted above, proximal section 320 of tubing 300 is omitted and outlet 430 of fluid separator 400 is configured to connect directly to inlet port 120 of plume evacuation console 100, as shown in FIG. IB. More specifically, outlet 430 of fluid separator may be received within inlet port 120 or positioned about inlet port 120 in friction- fit engagement to connect outlet 430 and inlet portion 120 with one another, although other suitable connections are also contemplated such as, for example, bayonet connections, threaded connections, snap-fit connections, etc.

[0052] Although electrosurgical pencil 200 is detailed above as incorporating a plume evacuation flow path, e.g., from nozzle 230, through fluid lumen 216, to tubing 300, it is also contemplated that a standalone device (available in various different sizes, depending upon the desired evacuation flow), separate from electrosurgical pencil 200 or removably attachable to electrosurgical pencil 200, may define the plume evacuation flow path from the surgical site, through fluid separator 400, to plume evacuation console 100.

[0053] 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 and includes one or more outlets (not shown) 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 external of smoke evacuation console 100 (e.g., piped out of the operating room).

[0054] Inlet port 120 of plume evacuation console 100 enables connection of tubing 300 to plume evacuation console 100 and fluidly communicates with filter assembly 130 such that a surgical plume suctioned from tubing 300 through inlet port 120 enters filter assembly 130.

[0055] Filter assembly 130 includes one or more filters that allow the evacuated plume to pass through the filter while trapping smoke particulate (and other matter) within the filter(s). One or more of the filters of filter assembly 130, or portions of a filter of filter assembly 130, may alternatively or additionally be configured to remove contaminants, debris, gaseous byproducts (e.g., Volatile Organic Compounds (VOCs)), and / or odors from the evacuated plume.

[0056] Suction generator 140 is disposed downstream of filter assembly 130 and is configured to generate suction to draw the plume from the surgical site, through electrosurgical pencil 200, tubing 300, fluid separator 400, into inlet port 120 and through filter assembly 130.

[0057] Exhaust chamber 150 enables the expansion and pressure equalization of the evacuated, filtered surgical plume as the evacuated, filtered surgical plume flows from exhaust chamber 150 back into the operating room or to another location outside the operating room.

[0058] With continued reference to FIG. 1, 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).

[0059] 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 morevirtual 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.

[0060] 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 may additionally 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.

[0061] Referring to FIGS. 2A-4B, in conjunction with FIG. 1 , fluid separator 400 is configured for connection along tubing 300 and, more specifically between distal section 310 of tubing 300, which extends between electrosurgical pencil 200 and fluid separator 400, and proximal section 320 of tubing 300, which extends between fluid separator 400 and plume evacuation console 100. Fluid separator 400 is configured to separate liquid, e.g., saline, blood, moisture droplets, etc., within the surgical plume or otherwise suctioned through distal section 310 of tubing 300 from the remainder of the surgical plume to inhibit the suctioning of liquid (including droplets suspending in the surgical plume as moisture) through proximal section 320 of tubing 300 and into plume evacuation console 100.

[0062] Fluid separator 400 includes a body 410 and a reservoir 440 releasably engageable with body 410, although it is also contemplated that reservoir 440 be integral with body 410 or that reservoir 440 be omitted in favor of collection tubing connecting body 410 to a remote collection reservoir. Body 410 of fluid separator 400 extends along a longitudinal axis “X-X” and defines a chamber 412. Body 410, more specifically, includes an inner portion 414 defining an inner chamber portion 416 of chamber 412, an outer portion 418 that cooperates with inner portion 414 to define an outer chamber portion 420 of chamber 412, and a funnel 422 that extends from outer portion 418 along longitudinal axis “X-X” to define a funnel chamber portion 424 of chamber 412. Body 410 also includes an inlet 426 defining an inlet passage 428 and an outlet 430 defining an outlet passage 432. In aspects, chamber 412 is configured as a cyclonic chamber; inner portion 414 is configured as an inner cylinder; inner chamber portion 416 is configured as an inner cylindrical chamber portion; outer portion 418 is configured as an outer cylinder; and / or outerchamber portion 420 is configured as an outer ring chamber portion. In other aspects, chamber 412, inner portion 414, inner chamber portion 416, outer portion 418, and / or outer chamber portion 420 define different configurations. Thus, although reference hereinbelow is made to cyclonic chamber 412, inner cylinder portion 414, inner cylindrical chamber portion 416, outer cylinder portion 418, and outer ring chamber portion 420, other suitable configurations of chamber 412, portions 414, 416 and / or chamber portions 418, 420 are also contemplated.

[0063] Inlet 426 of body 410 of fluid separator 400 is configured to connect to distal section 310 of tubing 300 to thereby connect the internal passage defined through distal section 310 of tubing 300 with outer ring chamber portion 420 of cyclonic chamber 412 via inlet passage 428. Inlet 426 meets outer cylinder 418 in substantially tangential relation relative thereto such that a surgical plume drawn through distal section 310 of tubing 300 and inlet 426 enters outer ring chamber portion 420 in a substantially tangential direction, thereby promoting helical or vortical fluid flow therein.

[0064] Outlet 430 of body 410 of fluid separator 400 is configured to connect to proximal section 320 of tubing 300 to thereby connect the internal passage defined through proximal section 320 of tubing 300 with inner cylindrical chamber portion 416 of cyclonic chamber 412 via outlet passage 432. Outlet 430 extends from inner cylinder 414 at a location substantially coaxial with inner cylinder 414 and longitudinal axis “X-X.” Outlet 430 may extend form inner cylinder 414 and define a bend of approximately 90 degrees or, in aspects, from about 60 degrees to about 120 degrees, to facilitate connection to proximal section 320 of tubing 300, e.g., wherein the free ends of outlet 430 and inlet 426 connect to proximal and distal sections 320, 310, respectively, of tubing 300 in substantially parallel relation relative to one another.

[0065] Funnel 422 defines a frustoconical configuration and is oriented such that flattened apex 425 thereof extends away from outer cylinder 418. Funnel 422 defines a drain passage 434 at flattened apex 425 thereof that is configured to connect funnel chamber portion 424 of cyclonic chamber 412 with a collection chamber 442 of reservoir 440 when reservoir 440 is engaged with body 410.

[0066] Continuing with reference to FIGS. 2A-4B, body 410 of fluid separator 400 defines a plurality of dimensions including: an overall height “H” of cyclonic chamber 412 measured along longitudinal axis “X-X” from the top of outer cylinder 418 to flattened apex 425 of funnel 422; a height “h” of outer ring chamber portion 420 of cyclonic chamber 412 measured along longitudinalaxis “X-X”; a height “S” of inner cylindrical chamber portion 416 of cyclonic chamber 412 measured along longitudinal axis “X-X”; a height “a” of inlet passage 428 measured along longitudinal axis “X-X”; a width “b” of inlet passage 428 measured transverse to longitudinal axis “X-X” and the height “a”; a diameter “B” of drain passage 434; a diameter “D” of outer ring chamber portion 420 of cyclonic chamber 412; and a diameter “De” of inner cylindrical chamber portion 416 of cyclonic chamber 412.

[0067] Referring again to FIGS. 1 and 2A-4B, when plume evacuation console 100 is activated to establish suction at inlet port 120 and, thus, through proximal section 320 of tubing 300, fluid separator 400, distal section 310 of tubing 300, and electrosurgical pencil 200 to suction a surgical plume and / or other fluid from a surgical site, the above- detailed configuration of body 410 of fluid separator 400 establishes a fluid flow vortex within body 410 from inlet 426 to outlet 430 with significantly more efficient liquid removal, less flow velocity reduction, and less pressure drop (thereby minimizing suction capacity loss) compared to conventional fluid separator systems that employ wall barriers to define a tortuous path or labyrinth for fluid flow through the fluid separator.

[0068] More specifically, the configuration of cyclonic chamber 412 of body 410 enables fluid to enter outer ring chamber portion 420 of cyclonic chamber 412 via inlet passage 428 and flow in a vortical or helical pattern within cyclonic chamber 412 from outer ring chamber portion 420 downwardly into and through funnel chamber portion 424 to or near flattened apex 425. This vortical flow and the narrowing of funnel chamber portion 424 in the downward direction generates centrifugal forces that are orders of magnitude higher on the larger particles, e.g., liquid molecules, as compared to the smaller particles, e.g., gas molecules, such that the larger particles migrate toward the wall of body 410, down the wall of body 410, and through drain passage 434 for collection within reservoir 440, while the smaller particles, under the suction force provided by plume evacuation console 100, return upwardly from or near flattened apex 425 along an inner axial flow path centered about longitudinal axis “X-X” to outlet passage 432 and, ultimately, to proximal tubing 320 and through inlet port 120 of plume evacuation console 100 into plume evacuation console 100.

[0069] As described in greater detail below, the efficiency of fluid separator 400 may be enhanced by selecting the appropriate dimensions and / or ratios of dimensions for cyclonic chamber 412 of body 410 of fluid separator 400, e.g., to achieve efficient liquid removal, less flow velocity reduction, and less pressure drop (thereby minimizing suction capacity loss).

[0070] Referring back to FIGS. 2A and 2B, as noted above, reservoir 440 of fluid separator 400 may be configured to releasably engage body 410 of fluid separator 400. The releasable engagement may be made via one or more bayonet couplings 444 including one or more protrusions disposed on body 410 and / or reservoir 440 and one or more slots defined within body 410 and / or reservoir 440 such that relative rotation between body 410 and reservoir 440 engages the protrusion(s) within the slot(s) to thereby releasably connect body 410 and reservoir 440 with one another. However, other suitable engagements, e.g., via threads, snap-fits, latches, etc. are also contemplated. With additional reference to FIG. 5, collection chamber 442 of reservoir 440 is configured to collect the liquid that flows down funnel 422 through drain passage 434. In aspects, reservoir includes a baffle 500 longitudinally spaced from drain passage 434 but extending radially across at least a portion of the diameter of drain passage 434 and, in aspects, across substantially an entire diameter of drain passage 434. Baffle 500 enables the liquid that flows through drain passage 434 to flow over and / or around baffle 500 and into collection chamber 442 while defining a tortuous path to inhibit the suctioning of liquid from within collection chamber 442 back into body 410 of fluid separator 400.

[0071] Turning to FIGS. 6A and 6B, in aspects, reservoir 440 of fluid separator 400 includes an overflow prevention mechanism 600 including a float 610 slidably mounted on a vertical track 620 and a stopper 630 engaged to float 610, although in aspects stopper 630 and float 610 may be a single component. In use, without liquid within collection chamber 442 of reservoir 440, float 610 and, thus, stopper 630, are disposed at the lower end of vertical track 620 longitudinally spaced from drain passage 434 (see FIG. 6A). As liquid is collected within collection chamber 442 of reservoir 440, the rising liquid level urges float 610 and, thus, stopper 630, along vertical track 620 towards drain passage 434. As the liquid level within collection chamber 442 of reservoir 440 approaches a maximum fill limit, float 610 and, thus, stopper 630, are urged farther along vertical track 620 towards drain passage 434 until, at the maximum fill limit, stopper 630 substantially occludes drain passage 434, thus inhibiting further liquid collection (see FIG. 6B). By closing reservoir 440 in this manner, the risk of overflow and / or spillage of potentially hazardous liquid, e.g., containing blood, tissue, bacteria, etc.) is reduced. Once full (or prior thereto), reservoir 440 can be removed, drained, and reattached for further use.

[0072] Referring to FIGS. 7A and 7B, fluid separator 400 is shown including another overflow prevention mechanism 700 similar to overflow prevention mechanism 600 (FIGS. 6A and 6B)except that stopper 730 is mounted on an extension 740 that extends from float 710 (within collection clamber 442 of reservoir 440) through drain passage 434 and into cyclonic chamber 412 of body 410. In use, without liquid within collection chamber 442 of reservoir 440, float 710 is disposed at the lower end of vertical track 720 such that stopper 730 is longitudinally spaced from inner cylindrical chamber portion 416 of cyclonic chamber 412 (see FIG. 7A). As liquid is collected within collection chamber 442 of reservoir 440, the rising liquid level urges float 710 along vertical track 720 towards drain passage 434, thereby urging stopper 730 towards inner cylindrical chamber portion 416 of cyclonic chamber 412. As the liquid level within collection chamber 442 of reservoir 440 approaches a maximum fill limit, float 710 is urged farther along vertical track 720 and stopper 730 is urged farther towards inner cylindrical chamber portion 416 of cyclonic chamber 412 until, at the maximum fill limit, stopper 730 substantially occludes inner cylindrical chamber portion 416 of cyclonic chamber 412, thus inhibiting further function of fluid separator 400 (see FIG. 7B) and reducing the risk of overflow as noted above. At this point, reservoir 440 must be removed, drained, and reattached to enable further use.

[0073] Turning to FIGS. 8-10, various other bodies 810, 910, 1010 of fluid separators 800, 900, 1000, respectively, in accordance with this disclosure are shown defining cyclonic chambers 812, 912, 1012. Bodies 810, 910, 1010 of fluid separators 800, 900, 1000, respectively, define different dimensions and / or ratios of dimensions compared to body 410 of fluid separator 400 (FIGS. 2A-4B) and one another.

[0074] FIG. 11 illustrates computational fluid dynamics simulation test results measuring average tangential fluid flow speed or velocity for each of bodies 410, 810, 910, 1010 and corresponding body diameters (dimension “D” (FIG. 4A)) and body heights (dimension “H” (FIG. 4A)) for each of bodies 410, 810, 910, 1010. Tangential fluid flow speed has been found to be an indicator of a well-formed fluid flow vortex within the cyclonic chamber with the inflow fluid moving tangentially from the inlet through the outer ring chamber portion downwardly along the funnel chamber portion, while the outflow fluid moves axially upwardly along the longitudinal axis (within the vortex) through the funnel chamber portion to the inner cylindrical chamber portion and, ultimately to the outlet. A well-formed vortex, in turn has been found to be indicative of efficient liquid removal, less flow velocity reduction, and less pressure drop (thereby minimizing suction capacity loss).

[0075] Turning to FIGS. 12A-12D and 13A-13D, computational fluid dynamics simulation test results for body 810 and body 410, respectively, are provided. As shown, body 410 enables greater tangential and axial flow velocities and a better-formed vortex compared to body 810. Referring also to FIGS. 14 and 15, as indicated at location “SC”, body 810 may be prone to some leakage wherein fluid is able to short circuit the cyclonic chamber and flow directly from the outer ring chamber portion to the inner cylindrical chamber portion rather than traveling downwardly through the funnel chamber portion to or towards the flattened apex of the funnel. This shortcircuiting decreases flow velocity and, thus, efficiency. In contrast, body 410 enables a well- formed vortex without short-circuited fluid flow.

[0076] With reference to FIG. 16, the various dimensions and select dimension ratios of bodies 410, 810, 910, 1010 are shown. Bodies 410, 810, 910, 1010 have different dimensional ratios and provide different performance levels, including flow velocities. As described above, the efficiency of fluid separator 400 may be enhanced by selecting the appropriate dimensions and / or ratios of dimensions for cyclonic chamber 412 of body 410 of fluid separator 400, e.g., to achieve a well- formed vortex, and in turn (and efficient liquid removal), less flow velocity reduction, and less pressure drop (thereby minimizing suction capacity loss). More specifically, referring also to FIG. 11, body 410 provides the highest flow velocity of the group, body 1010 provided a flow velocity slightly higher flow velocity than body 810 but not as high as body 410, and body 910 provides the lowest flow velocity of the group.

[0077] In accordance with this disclosure, various dimensional ratios for a fluid separator are contemplated such as, for example, the ratios of body 410 provided in FIG. 16, wherein dimensional ratio “a / D” equals 0.42, dimensional ratio “S / D” equals 0.65, dimensional ratio “H / D” equals 1.45, and / or dimensional ratio “S / h” equals 1.00. In aspects, dimensional ratio ranges in accordance with this disclosure are providing utilizing the above ratios plus or minus 20 percent; in other aspects, plus or minus 15 percent; in still other aspects, plus or minus 10 percent; or in yet other aspects, plus or minus 5 percent.

[0078] Additionally or alternatively, various dimensional ratio ranges for a fluid separator are contemplated such as, for example: a dimensional ratio “a / D” of less than about 0.49, less than about 0.45, or less than about 0.43; a dimensional ratio “S / D” of greater than about 0.57, greater than about 0.61, or, greater than about 0.64; a dimensional ratio “H / D” between about 1.00 and 2.00; between about 1.25 and 1.75, or between about 1.40 and 1.50; and / or a dimensional ratio“S / h” between about 0.90 and 1.20, between about 0.93 and 1.12, or between about 0.95 and 1.05. Other suitable dimensional ratios and / or ranges thereof are also contemplated.

[0079] 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 fluid separator, comprising: a body including an inlet, an outlet, and a chamber having an inner chamber portion disposed about a longitudinal axis, an outer chamber portion disposed about the inner chamber portion, and a funnel chamber portion extending from the outer chamber portion to a funnel drain, wherein the inlet communicates with the outer chamber portion at a tangential location and the outlet communicates with the inner chamber portion at an axial location.

2. The fluid separator according to claim 1 , wherein the chamber and the position of the inlet and outlet relative to the chamber facilitate inflow from the inlet, through the outer chamber portion and along the funnel chamber portion in a vortical manner to enable liquid to fall through the funnel drain while gas flows upwardly from at or near the funnel drain axially along the longitudinal axis through the inner chamber portion to the outlet.

3. The fluid separator according to claim 1, wherein the chamber is a cyclonic chamber.

4. The fluid separator according to claim 1 , wherein the inner chamber portion defines a cylindrical configuration and wherein the outer chamber portion defines a ring configuration.

5. The fluid separator according to claim 1, wherein the inlet defines an inlet passage having a height “a” along the longitudinal axis, wherein the outer chamber portion defines a diameter “D”, and wherein a ratio of “a” to “D” is 0.42 plus or minus 20 percent.

6. The fluid separator according to claim 1 , wherein the inner chamber portion defines a height “S” along the longitudinal axis, wherein the outer chamber portion defines a diameter “D”, and wherein a ratio of “S” to “D” is 0.65 plus or minus 20 percent.

7. The fluid separator according to claim 1 , wherein the chamber defines a height “H” along the longitudinal axis, wherein the outer chamber portion defines a diameter “D”, and wherein a ratio of “H” to “D” is 1.45 plus or minus 20 percent.

8. The fluid separator according to claim 1, wherein the inner chamber portion defines a height “S” along the longitudinal axis, wherein the outer chamber portion defines a height “h” along the longitudinal axis, and wherein a ratio of “S” to “h” is 1.00 plus or minus 20 percent.

9. The fluid separator according to claim 1, further comprising a reservoir releasably connected to the body, the reservoir defining a collection chamber disposed in fluid communication with the funnel drain when the reservoir is connected with the body.

10. The fluid separator according to claim 9, wherein the reservoir is releasably connected to the body via a bayonet coupling.

11. The fluid separator according to claim 19, wherein the bayonet coupling includes at least one protrusion disposed on at least one of the body or the reservoir and at least one slot defined within at least one of the body or the reservoir, the at least one protrusion configured for receipt within the at least one slot to releasably connect the reservoir and the body with one another.

12. The fluid separator according to claim 9, wherein the reservoir further includes a baffle disposed within the collection chamber and configured to inhibit the suctioning of liquid from the collection chamber into the body.

13. The fluid separator according to claim 9, wherein the reservoir includes a stopper configured to substantially occlude the funnel drain when a level of liquid within the collection chamber reaches a maximum fill limit.

14. The fluid separator according to claim 9, wherein the reservoir includes a stopper configured to substantially occlude the inner chamber portion when a level of liquid within the collection chamber reaches a maximum fill limit.

15. A system, comprising: a first tubing section configured for positioning at a surgical site; a second tubing section configured to connect to a surgical plume evacuation console; andthe fluid separator according to claim 1, wherein the inlet of the fluid separator is configured to couple to the first tubing section and wherein the outlet of the fluid separator is configured to couple to the second tubing section.

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