Abstract:
A seal system may include: an annular shaped resilient seal, the resilient seal having an outer portion, an inner portion, a distal end, and a proximal end; a conical portion located in the inner portion of the resilient seal, the conical portion converging toward the distal end, the conical portion defining a hole at the distal end; an anti-friction ring; flexible fingers defining at least part of the anti-friction ring; and an end feature located at a distal part of the flexible fingers, the end feature having at least a partial spherical cross-sectional shape, wherein the anti-friction ring is dimensioned to fit, at least partially, in the conical portion of the inner portion of the resilient seal. A method of making a seal system may also be provided.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of provisional application titled, SEAL ASSEMBLY HAVING AN ANTI-FRICTION RING AND METHOD OF ASSEMBLY, having application No. 61/901,174, filed on Nov. 7, 2013. The above mentioned application is incorporated by reference in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates generally to a seal assembly having an anti-friction ring. More particularly, the present invention relates to a surgical port having a seal assembly configured to form a seal with instruments extending through the surgical port where the seal assembly includes an anti-friction ring. 
       BACKGROUND OF THE INVENTION 
       [0003]    Surgical ports are used in laparoscopic surgeries. A surgical port may include a trocar having a cannula. An obturator may be inserted through the cannula to assist in creating a hole or incision in the subject. Once the hole or incision is made in a subject, the cannula is inserted through the hole or incision into the subject. The trocar is removed and a variety of medical instruments may be inserted into the subject via the cannula. It may be desirable to form a seal around various elongated medical instruments that are inserted into the surgical port and cannula. 
         [0004]    Resilient seals may be used for this purpose. In some instances, the resilient seals may include an orifice through which the elongated instruments are inserted. Insertion of the instrument may result in the stretching of the orifice. In some instances, moving an elongated instrument through the orifice of the seal may result in friction. The friction may result from two sources. First, the friction may result from the moving of the elongated instrument through the seal and second, the stretching of the orifice. Relatively high amounts of friction may be undesirable as the friction may be a hindrance to a surgeon moving instruments through the surgical port. 
         [0005]    In addition to relatively high amounts of friction, another problem that may be associated with some current designs is that the insertion of the elongated instrument may damage or compromise the sealing ability of the seal. In some instances, the elongated instruments may not be aligned with the orifice. In such situations, the elongated instruments may tend to poke the resilient seal until the elongated instrument finds the orifice and moves through it. This poking or jabbing of a resilient seal may result in damage to the seal or may compromise its sealing capabilities. 
         [0006]    Accordingly, it is desirable to provide a sealing system that can, in some embodiments, form a seal around an instrument that is inserted into a surgical port. In some embodiments, it may be desirable for a sealing system that may alleviate at least one of the conditions described above. 
       SUMMARY OF THE INVENTION 
       [0007]    The foregoing needs are met, to a great extent, by the present invention, wherein in one aspect an apparatus is provided that in some embodiments forms a seal around an instrument that is inserted into a surgical port. In some embodiments, a sealing system may protect the seal from being damaged by an end of an instrument and may reduce friction between the seal and an instrument. 
         [0008]    In accordance with one embodiment of the present invention, A seal system may be provided. The seal system may include: an annular shaped resilient seal, the resilient seal having an outer portion, an inner portion, a distal end, and a proximal end; a conical portion located in the inner portion of the resilient seal, the conical portion converging toward the distal end, the conical portion defining a hole at the distal end; an anti-friction ring; flexible fingers defining at least part of the anti-friction ring; and an end feature located at a distal part of the flexible fingers, the end feature having at least a partial spherical cross-sectional shape, wherein the anti-friction ring is dimensioned to fit, at least partially, in the conical portion of the inner portion of the resilient seal. 
         [0009]    In accordance with another embodiment of the present invention, a method of making a seal system may be provided. The method may include: providing an annular shaped resilient seal, the resilient seal having an outer portion, an inner portion, a distal end, and a proximal end; locating a conical portion in the inner portion of the resilient seal, the conical portion converging toward the distal end, the conical portion defining a hole at the distal end; inserting an anti-friction ring in the conical portion of the seal, the anti-friction ring having flexible fingers defining at least part of the anti-friction ring; and forming an end feature located at a distal part of the flexible fingers, the end feature having only rounded outer surfaces. 
         [0010]    In accordance with yet another embodiment of the present invention, a seal system may be provided. The system may include: means for sealing having an outer portion, an inner portion, a distal end, and a proximal end; a conical portion located in the inner portion of the means for sealing, the conical portion converging toward the a distal end, the conical portion defining a hole at the distal end; a means for reducing friction; flexible fingers defining at least part of the means for reducing friction, the flexible fingers and dimensioned to not contact each other and have a flexible hinge portion that connects the flexible finger to the remainder of the anti-friction ring that is as wide as the width of the flexible finger adjacent to the hinge portion; and means for contacting the means for sealing located on a distal part of the flexible fingers, wherein the means for reducing friction is dimensioned to fit, at least partially, in the conical portion of the inner portion of the means for sealing. 
         [0011]    There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto. 
         [0012]    In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting. 
         [0013]    As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]      FIG. 1  is assembled perspective view of a surgical port or trocar in accordance with an embodiment described herein. 
           [0015]      FIG. 2  is an exploded, perspective view of the surgical port or trocar shown in  FIG. 1 . 
           [0016]      FIG. 3  is a side view of a seal used in accordance with this disclosure. 
           [0017]      FIG. 4  is a cross-sectional view of the seal shown in  FIG. 3  taken along the line  4 - 4 . 
           [0018]      FIG. 5  is a top view of two anti-friction rings in accordance with an embodiment of the disclosure. 
           [0019]      FIG. 6  is a side view of the two anti-friction rings shown in  FIG. 5 . 
           [0020]      FIG. 7  is a cross-sectional view of one of the anti-friction rings shown in  FIGS. 5 and 6 . 
           [0021]      FIG. 8  is an enlarged, partial, detail view of the cross-sectional view taken about detail  8  in  FIG. 7 . 
           [0022]      FIG. 9  is a cross-sectional view of one of the anti-friction rings shown in  FIGS. 5 and 6 . 
           [0023]      FIG. 10  is an enlarged, partial, detail view of the cross-sectional view taken about detail  10  in  FIG. 9 . 
           [0024]      FIG. 11  is a partial cross-sectional view of an end of an instrument entering the anti-friction ring and seal. 
           [0025]      FIG. 12  is a partial cross-sectional view of an instrument where the end has passed through the anti-friction ring and seal and a seal is formed round the instrument and the hole in the seal. 
       
    
    
     DETAILED DESCRIPTION 
       [0026]    The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. An embodiment in accordance with the present invention provides a surgical port having an internal seal system to create a seal around an elongated instrument inserted into the surgical port. The seal system includes a resilient seal and anti-friction ring. In some embodiments, the anti-friction ring helps to open an orifice associated with the resilient seal as an instrument is inserted into the surgical port so that by the time the instrument contacts the orifice, the anti-friction ring is already partially enlarged the orifice. 
         [0027]    The term “distal” refers to the direction toward the bottom of the surgical port  20  as oriented in  FIGS. 1 and 2 . The term “proximal” refers to the direction toward the top of the surgical port  20  as oriented in  FIGS. 1 and 2 . 
         [0028]    An embodiment of a surgical port  20  in accordance with the present disclosure is shown in  FIGS. 1 and 2 .  FIG. 1  is an assembled view of the surgical port  20 .  FIG. 2  is an exploded view. The surgical port  20  may also be referred to as a trocar  20 . The surgical port  20  includes a cap assembly  22  attached on top of a cannula  24 . The cannula  24  is a long hollow member that may be inserted into a subject. The obturator  27  may be placed through the cap assembly  22  and cannula  24  such that the tip  26  extends below the cannula  24 . The tip end  26  may be sharp or dimensioned so that it a can assist in cutting or moving flesh and tissue while positioning the surgical port  20 . 
         [0029]    The obturator  27  includes a shaft  28  and an obturator cap  30 . The obturator cap  30  has a hole  32  so that instruments may be inserted into the obturator  27 . An example of an instrument that may be inserted into the obturator cap  30  is a camera that may be extended into the tip  26  which, in some instances may be clear. This will allow the user to position the surgical port  20  in a subject at a desired location. 
         [0030]    The cap assembly  22  includes a floating seal cap  34 . The floating seal cap  34  may have a conical top  36 . The conical top  36  may assist a user in placing the obturator  27  into the hole  38  in the floating seal cap  34  by having the conical portions sloped toward the hole  38  in the floating seal cap  34 . The cap assembly  22  also includes a caged seal cap  40 . The caged seal cap  40  helps to contain the anti-friction ring  42  and seal  44  in the seal housing  46 . The seal housing  46  helps contain and/or secure the duckbill seal  48 . The seal housing  46  is mounted to the cannula  24 . In some embodiments in accordance with the present disclosure, the anti-friction ring  42  and the seal  44  may be contacted by an elongated instrument that is inserted into the entry port  20 . For example, if the obturator  27  is inserted into the entry port  20  as contemplated in  FIG. 2 , the shaft  28  of the obturator  27  will contact the anti-friction ring  42 . The seal  44  will form a seal between the shaft  28  and the seal  44 . Further discussion regarding how this sealing will be accomplished will be provided later below. 
         [0031]    At the proximal end of the cannula  24  is a wider portion forming a duckbill seal housing  54 . The caged seal housing  46  attaches to the duckbill seal housing  54 . This provides at least two advantages. First, the duckbill seal  48  is trapped between the duckbill seal housing  54  and the caged seal housing  46 . Second, this connection also allows the cap assembly  22  to be connected to the cannula  24 . The cannula  24  may include a stopcock handle  50  that may be rotated between an on and off or open and closed position. The cannula  24  may also include ribs  52 . 
         [0032]    The description contained herein of the entry port/trocar  20 , the cannula  24 , and obturator  27  are primarily designed to provide context for the following discussion of the anti-friction ring  42 , seal  44  and how they reside within the caged seal housing  46 . Further detailed discussion of the entry port/trocar  20 , cannula  24  and obturator  27  is not relevant and will be foregone in favor of additional description of features found in various embodiments of the anti-friction ring  42  and seal  44 . This additional description will be made with reference to  FIGS. 3-12 . 
         [0033]      FIG. 3  is a side view of a seal  44  in accordance of the present disclosure.  FIG. 4  is a cross-sectional view of the seal shown in  FIG. 3 . The following discussion will be made with reference to both  FIGS. 3 and 4 .  FIGS. 3 and 4  show a resilient seal  44 . In some embodiments, the seal  44  may be referred to as a floating or caged seal  44  because it is not fixed within the seal housing  46 , but rather may slide radially within the housing  46 . In other embodiments, the seal  44  may be fixed within the seal housing  46 . The seal  44  includes a seal body  56 . The seal body  56  has a proximal end  58  which includes a proximal lip  60 . In some embodiments, a groove  62  may be located adjacent to the proximal lip  60 . The seal body  56  may also define one or more ribs  64  and  66 . The ribs  64  and  66  may be annularly shaped and extend around the seal body  56 . The seal body  56  may also include a distal groove  68  located adjacent to a distal lip  70 . 
         [0034]    In some embodiments, the proximal lip  60  and distal lip  70  may be slightly compressed thereby making the proximal groove  62  and distal groove  68  smaller when the seal  44  is located within the seal housing  46 . However, in some embodiments the proximal lip  60  and the distal lip  70  are not so compressed as to eliminate the ability of the seal  44  to move radially within the seal housing  46 . 
         [0035]    As shown in  FIG. 4 , the seal  44  has an large diameter hole  71 . The seal  44  also includes a transitional area  72  that may be tapered as shown. The seal  44  may also include a vertical wall section  74  and a conically shaped portion  76 . The transitional area  72 , the vertical wall section  74 , and the conically shaped portion  76  may be dimensioned to receive the anti-friction ring  42 . The conically shaped portion  76  may be terminated by a hole  77  (which may also be referred to as an orifice). In some embodiments, it is the conically shaped portion  76  near the hole or orifice  77  that engages an elongated tool being inserted through the entry port  20 . For example, in instances where the obturator  27  is inserted into the entry port  20 , the shaft  28  of the obturator  27  may be dimensioned to have a slightly larger diameter than the hole  77 . As result, when the shaft  28  moves through the hole  77 , the hole  77  will stretch to accommodate the outer diameter of the shaft  28 . In some embodiments, the conical portion  76  near the hole  77  of the seal  44  will seal to the shaft  28  of the obturator  27 . It is to be understood that while an obturator  27  has been described to be inserted into the entry port  20  and sealed to the seal  44 , this is been described by way of example only. Those of ordinary skill the art reviewing this disclosure will understand that a variety of tools or instruments having various diameters can be inserted into the surgical port  20  and seal to the seal  44  in such a manner as described above with respect to the obturator  27 . 
         [0036]      FIG. 5-10  are various views of two embodiments of anti-friction rings  42  that may be used with the seal  44  illustrated in  FIGS. 2-4 .  FIGS. 5 and 6  are top and side views respectively. The anti-friction ring  42  on the left illustrates and a first embodiment  78  anti-friction ring  78  and the anti-friction ring  42  on the right illustrates a second embodiment  80  anti-friction ring  80 . Both embodiments and of anti-friction rings  78  and  80  are similar. The similar features will be described together and the differences between the two embodiments  70  and  80  will be described separately further below. 
         [0037]    The anti-friction rings  78 ,  80  include bowl shaped portions  81 . The bowl shaped portion  81  has flexible fingers  82  attached to the distal portion of the bowl shaped portion  81 . The fingers  82  are separated by slits  84 . The bowl shaped portion  81  fits into the transition area  72  in the seal  44 . The fingers  82  have straight portions  85  which fit in against the vertical wall section  74  of the seal  44 . The fingers  82  are biased to a conical shape as shown in  FIGS. 6-10 . When set in the seal  44 , the fingers  82  may rest against the conic portion  76  of the seal  44  or slightly spaced apart from the conic section  76  of the seal  44  depending upon the embodiment. 
         [0038]    The fingers  82  are terminated at their distal ends with end features  86 . Different geometry of the end features  86  are the characterizing differences between the anti-friction ring  42  of the first embodiment  78  and the anti-friction ring  42  of those second embodiment  80 . The fingers  82  may attach to the bowl portion  81  of the anti-friction rings  42  via an attaching portion  88 . The anti-friction rings  42  have distal openings  92  and proximal openings  94  which together form a through hole which permit an instrument to pass through the anti-friction ring  42 . 
         [0039]    In some embodiments, the anti-friction rings  42  have eight fingers  82 . In other embodiments, greater or fewer fingers  82  may be used. The flexible fingers  82  are attached to the bowl portion  81  via the attaching portions  88 . In some embodiments, the attaching portions  88  are approximately the same width as the portion of the fingers  82  where the fingers  82  connect to the connecting portion  88 . The fingers  82  may decrease in width toward the distal end as the slits  84  converge moving towards the distal end as shown. The connecting portion  88  is separated by the slits  84  and may be considered a part of the fingers  82 . 
         [0040]    In some embodiments, the anti-friction rings  42  may be manufactured or molded together as a pair. In such embodiments, the anti-friction rings  42  may be connected to each other by a connector  90  as shown in  FIGS. 5 and 6 . However the connector  90  is merely an artifact of manufacturing and is removed prior to the anti-friction ring  42  being inserted into a seal  44 . 
         [0041]      FIGS. 7 and 8  are cross-sectional views of the first embodiment  78  of the anti-friction ring  42 .  FIG. 8  shows an enlarged section of  FIG. 7 . In the first embodiment  78  of the anti-friction ring  42 , the attachment portion  88  is shown attaching the fingers  82  to the anti-friction ring  42 . The fingers  82  are separated by slits  84 . The end features  86  at the distal end of the fingers  82  are generally spherical in shape. The end features  86  comprise a shape slightly larger than a hemisphere and not quite as large as a sphere as shown. When combined with the fingers  82  the features  86  may form a full sphere. In other embodiments, other shapes for the end features  86  may be used. 
         [0042]      FIGS. 9 and 10  are cross-sectional views of the second embodiment  80  of the anti-friction ring  42 .  FIG. 10  shows an enlarged section of  FIG. 9 . In the second embodiment  80  of the anti-friction ring  42 , the attachment portion  88  is shown attaching the fingers  82  to the anti-friction ring  42 . The fingers  82  are separated by slits  84 . The end features  86  at the distal end of the fingers  82  are generally spherical in shape. The end features comprise a rounded shape that, in cross-section, is similar in size to the end features  86  of embodiment one  78 . However, the rounded end features  86  of embodiment two  80  is not as spherical as shown. In other embodiments, other shapes for the end features  86  may be used. 
         [0043]    In some embodiments, an elongated instrument  96  is inserted into the assembled surgical port  20 .  FIGS. 11 and 12  show a seal  44  including the anti-friction ring  42 . An instrument  96  is partially engaged with the anti-friction ring  42  and seal  44 . The fingers  82  will flex radially outwardly to accommodate the relatively large diameter instrument  96 . In some embodiments, much of the flexing of the fingers  82  will occur along the attaching portion  88 . In other embodiments, flexture of the fingers  82  will occur along various locations the fingers  82  and not be confined to the attaching portion  88 . 
         [0044]    As shown in  FIG. 11 , the elongated instrument  96  (for example a tip  26  of the obturator  27  will initially contact the anti-friction ring  42  rather than the seal  44 . This may help protect the resilient seal  44  from damage resulting from contact from the tip  26 . As the tip  26  (or end of any other instrument) continues to move distally, the fingers  82  will flex radially outwardly causing the end features  86  and, in some embodiments, the actual fingers themselves  82  to contact the conical portion  76  of the seal  44 . Continued distal movement of the tip  26  (or end of another instrument) will cause the end features  86  and or fingers  82  to move the conical portion  76  radially outwardly thereby enlarging the hole or orifice  77 . 
         [0045]    Enlarging the hole or orifice  77  will allow the tip  26  (or end of another instrument) to move through the hole  77  with reduced friction. In some embodiments, the hole  77 , even when enlarged due to the action of the fingers  82  and or end features  86 , will be dimensioned to be smaller than the diameter of the shaft  28  of the obturator  27  (or another instrument  96 ) so that the conical portion  76  of the seal  44  will stretch at the hole  77  to allow the instrument  96  to pass through. One of features of the stretching will be that a seal will be formed between the seal  44  and the instrument  96 . 
         [0046]      FIG. 12  shows an embodiment where the instrument  96  has fully extended through the seal  44 . The fingers  82  have flexed at the attaching portions  88 . In some embodiments, the fingers  82  may flex along their length. The end features  86  have engaged both the instrument  96  and the conical section  76  of the seal  44 . The hole  77  has become enlarged to permit the instrument  96  to pass through the conical section  76 . The hole  77  has formed a seal with the instrument  96 . 
         [0047]    The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.