Abstract:
A suction tool having a hollow handle and a probe extending from the handle near one end of the handle to define a lumen in fluid communication with the hollow handle and a fitting, formed to extend near the other end of the handle and shaped to receive a vacuum source drawing fluids through the probe, handle, and fitting. The handle also includes an aperture extending at an acute angle with respect to the axis of the handle.

Description:
RELATED APPLICATIONS 
       [0001]    This application: is a continuation of co-pending U.S. patent application Ser. No. 29/452,746 filed Apr. 22, 2013; and is a continuation of co-pending U.S. patent application Ser. No. 29/452,752 filed Apr. 22, 2013; both of which are hereby incorporated by reference. 
     
    
     BACKGROUND 
       [0002]    1. Field of the Invention 
         [0003]    This invention relates to surgical tools and, more particularly, to novel systems and methods for suction probe structures, manufacture, and use. 
         [0004]    2. Background Art 
         [0005]    Surgical procedures depend upon visibility. Accordingly, fluids that collect in interstitial bodily spaces, such as in an abdomen or other areas, require suctioning. Similarly, clearance of collected fluids, either from leakage, incisions, collection, washing, or the like is often required. 
         [0006]    To this end, various types of probes or suctioning apparatus have been developed. One such probe is referred to as a suction probe or Frazier tip. A Frazier tip operates to permit air to enter a handle, thus breaking the vacuum or the draw that would otherwise occur at the outermost tip or point of the probe. However, such a passage of air causes an annoying, and interfering, high-pitched, whistling noise. 
         [0007]    Theoretically, the opening available in the handle is supposed to provide control. A surgeon or assistant may place a thumb over the opening in order to close a handle to the passage of air. The result is an immediate draw at the tip, the only remaining open location in the probe. Upon release of the thumb over the opening, air is drawn in much more easily than liquid fluids, and the suctioning reduces substantially and may reduce entirely. That is, the tip of the probe is no longer effective, and will not tend to suction, nor to grab at other surfaces in the region. Thus, the probe may be left in place, and simply touched at the aperture periodically in order to perform a suctioning function. 
         [0008]    As a result of the annoying, even aggravating, high-pitched whistle, doctors frequently place tape over the aperture in the handle. This renders control of the Frazier tip ineffective. With the aperture sealed at all times, suction never ceases at the tip. Thus, as a practical matter, the Frazier tip operates as a constant-suction device, and fails in its supposed function as a controllable suction device. 
         [0009]    Alternatively, the leaving of a Frazier tip with the aperture open causes such a loud, constant, high-pitched whistling that conversation, instructions, and other communication in an operating room are seriously compromised. What is needed is some solution to the currently unacceptable trade off between constant suction or interference with procedures by ongoing noise. 
       BRIEF SUMMARY OF THE INVENTION 
       [0010]    In view of the foregoing, in accordance with the invention as embodied and broadly described herein, a method and apparatus are disclosed in one embodiment of the present invention as including a probe and manufacturing method for reducing the failure and providing a system without the whistling noise, yet still providing controllable suction in a Frazier tip. In certain embodiments, an aperture is molded into a handle of a probe to provide a minimization of acoustic disturbances. Angling the aperture, or the tubular passage from the exterior of the handle down into the interior cavity has been shown effective to eliminate the whistling noise. 
         [0011]    Angling the passageway to join the central cavity in the handle at an acute angle reduces sufficiently the disturbance and oscillations that heretofore have been known. 
         [0012]    An angle of from about 30 degrees to about 70 degrees appears to serve adequately. An angle of from about 30 degrees to about 60 degrees is preferable, and an angle from about 30 degrees to about 45 degrees is more preferable. Angles less than 30 degrees between the cavity or central passage of the handle, and the axis of the passage from the external aperture or thumb-hole passage work very well. However, such small acute angles are extremely difficult to form, and create other manufacturing problems. 
         [0013]    In certain embodiments, a handle for a Frazier tip may be molded in a two-piece mold in a variety of ways. Typically, core-pulls may be required, if the handle is to be manufactured in a single step, or in a single molding step, with no post-molding assembly of the handle. In other embodiments, the two halves of a handle may be each molded separately in a two-piece injection mold, and the handle halves may be glued together subsequently. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    The foregoing features of the present invention will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only typical embodiments of the invention and are, therefore, not to be considered limiting of its scope, the invention will be described with additional specificity and detail through use of the accompanying drawings in which: 
           [0015]      FIG. 1  is a perspective view of one embodiment of an apparatus in accordance with the invention; 
           [0016]      FIG. 2  is a top plan view thereof; 
           [0017]      FIG. 3  is a bottom plan view thereof; 
           [0018]      FIG. 4  is a right side elevation view thereof; 
           [0019]      FIG. 5  is a left side elevation view thereof; 
           [0020]      FIG. 6  is a back end elevation view thereof; 
           [0021]      FIG. 7  is a front end elevation view thereof; 
           [0022]      FIG. 8  is a right side, cross-sectional, elevation view thereof; 
           [0023]      FIG. 9  is a right side elevation view of one embodiment of a mold showing a mold cavity therein, as the top rectangular image, and the matching, left side elevation view, opened up as if hinged, is illustrated; 
           [0024]      FIG. 10  is a top plan view of the right mold piece, showing its cord portion; 
           [0025]      FIG. 11  is an end elevation view, in cross-section, of the mold of  FIG. 9 ; 
           [0026]      FIG. 12  is a side, elevation, cross-sectional view of a handle in accordance with the invention, manufactured in a single molding step; 
           [0027]      FIG. 13  is a side, elevation, cross-sectional view of a mold with cores for manufacturing the handle of  FIG. 12 ; 
           [0028]      FIG. 14  is a top plan view of the handle, showing various, possible shapes for the aperture; and 
           [0029]      FIG. 15  is an end elevation view, in cross-section, of the mold of  FIG. 13 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0030]    It will be readily understood that the components of the present invention, as generally described and illustrated in the drawings herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the system and method of the present invention, as represented in the drawings, is not intended to limit the scope of the invention, as claimed, but is merely representative of various embodiments of the invention. The illustrated embodiments of the invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. 
         [0031]    Referring to  FIG. 1 , while referring generally to  FIGS. 1-13 , a probe  10  or suction probe  10 , may be thought of as a system  10  for introducing a probe  12  or tube  12  controllable by use of a handle  14 . In general, the handle  14  may have multiple angles and surfaces to assist in manipulation. 
         [0032]    The receiver  18  may be formed at one end of the handle  14  and is sized to provide a fit and stoppage orientation for the probe  12 . For example, in one embodiment, the receiver  18  may be provided with a central bore that terminates at a shoulder. In this way, the probe  12  may be fitted into the channel or bore of the receiver  18 , up to the point that the probe  12  stops against the shoulder. In certain embodiments, the receiver  18  may be sized for an interference fit with the probe  12 . In fact, the probe  12  may be formed as a single, comparatively long, straight, tube  12 . A core, such as a flexible plastic rod may be threaded through the entire length of the probe  12 , and may actually remain visible at both ends of the probe  12 , and the handle  14 . In this way, a surgeon may actually curve, bend, or angle (without buckling) the probe  12 . The probe may thus be formed at any suitable angle, or at multiple suitable angles in order to fit around particular obstructions, and arrive at the proper path, orientation, and location, with respect to the handle  14 , for use. 
         [0033]    Typically, the receiver  18  may have an interference fit with its internal bore against the outer surface of the probe  12 , and may receive such in various ways. For example, the probe  12  may be heated and inserted hot into the receiver  18 . In other embodiments, the receiver  18  and handle  14  may actually be molded around the probe  12 , with the probe  12  acting as a mold insert  12 . In other embodiments, the interference fit may be sufficiently tight that a mechanical force acting axially along the length of the probe  12 , may secure the probe  12  in the receiver  18 . 
         [0034]    In certain embodiments, an aperture  20  may be provided, constituting a passage  20  from the outside environment into the interior of the handle  14 . Typically, the aperture  20  will be positioned to identify and distinguish the sides  24  from the top  26  of the handle  14 . For example, the sides  24  have no aperture  20 . However, the top  26  or top surface  26  has the aperture  20  formed therein, and easily accessible. 
         [0035]    Typically, the sides  24  and top  26  are at right angles or  90  degree angles with respect to one another in order to provide a firm grip for aiming, pointing, or otherwise positioning the probe  12 , and specifically the end  16  or tip  16  thereof. Likewise, the location of the aperture  20  in the top surface  26  provides a designation of orientation. 
         [0036]    Thus, to a certain extent, the probe  12  may be moved, even when not visible, with a degree of accuracy and predictability, due to the orientation of the aperture  20  indicating the location and orientation of the end  16  of the probe  12 . 
         [0037]    Typically, the end  16  of the probe  12  operates as the suctioning portion. An interface  22  at an opposite end of the handle  14  operates to connect to a pump or vacuum source. The interface  22  may be threaded, or simply have a fitting for securing to a hose, line, or the like drawing a continual flow, and thus supplying a reduced pressure or “vacuum” as it is conventionally called in lay terms. 
         [0038]    Referring to  FIGS. 1-7 , while continuing to refer generally to  FIGS. 1-13 , the probe  12  may proceed from the receiver  18  a distance, after which the probe  12  angles down and away from the top  26 . The rectangular cross-section along the axial direction of the handle  14  provides for an easy grip, particularly for rotating the probe  12  against the leverage advantage of the tip  16  or end  16  thereof. That is, the comparative length of the probe  12  provides substantial leverage advantage for the tip  16 , to resist rotation of the handle  14  by a surgeon. Accordingly, the square or rectangular cross-section of the handle  14  provides certainty of grip, as well as a designation of the orientation of the probe  12  with respect to the handle  14 . 
         [0039]    Referring to  FIG. 8 , while continuing to refer generally to  FIGS. 1-13 , a probe  12  may be hollow to provide a lumen  28  or channel  28  for drawing fluids through the probe  12  and the handle  14 . Accordingly, a cavity  30  exists likewise in the handle  14 . The cavity  30  may have a larger cross-sectional area, or larger effective diameter than that of the lumen  28  of the probe  12 . In other embodiments, the cavity  30  may have a circular diameter identical to that of the probe  12 . 
         [0040]    Referring to  FIGS. 9-11 , a mold for making a handle  14  in accordance with the invention may have two mold halves  40 ,  42  that assemble together or fold together along a parting surface  41  or parting line  41 . In the illustrated embodiment, the mold  43  may have one mold half  40  that includes a cavity  44  shaped to the outer configuration of the handle  14 . 
         [0041]    Opposite the mold half  40  is a mold half  42  that includes a core  46  that will actually fit inside the cavity  44  of the mold half  40 . One will note that the core  46  has a main portion  48  and a vent portion  50 . The main portion  48  sweeps out the cavity  30 , while the main cavity  44  of the mold half  40  receives a plastic, resin, or other material that will form the body of the handle  14 . 
         [0042]    The vent portion  50  actually contacts the surface of the cavity  44 , thus providing the aperture  20  in the handle  14 . In the illustrated embodiment, the mold halves  40 ,  42  assemble as illustrated in  FIG. 11 . The core  46 , and particularly the main portion  48  extends into the cavity  44  to leave open only the portion of the cavity  44  that will receive material for the handle  14 . 
         [0043]    Meanwhile, the main portion  48  extends substantially into the cavity  44 , to preclude filling that portion thereof with the polymeric resin, such as a suitable plastic material. Meanwhile, the vent portion  50  extends out up to contact the wall of the cavity  44 , thus precluding any material from entering therein. 
         [0044]    In the illustrated embodiment, a mirror-image of all components may be manufactured. For example, the cavity  44  molds a single half of the handle  14 . The opposite half of the handle  14  may be fabricated by a mirror-image of this particular half. The half illustrated is the left half, and the mirror-image would be a right half. After release from the mold  43 , each half of the handle  14  may then be assembled to its mirror-image half, and both be glued together. 
         [0045]    In yet another alternative embodiment, the mold  43  may be formed to inject in two halves that separate end-to-end from one another. In such an embodiment, long lengths and the typical requirement for draft would typically cause a tapered shape for the handle  14 . Thus, a mold in accordance with such an embodiment may actually form the entire handle  14  in a single, two-piece mold. However, such would require tapering of the outer surfaces  24 ,  26  of the handle  14 , as well as the internal walls of the cavity  30 . That is, draft requirements would require this. Meanwhile, the aperture  20  would require a core pull in order to leave a suitable passage  20  or aperture  20 . 
         [0046]    Referring to  FIGS. 12-13 , the handle  14  may be formed in a mold  43  of alternate design. For example, a mold  43  may have mold halves  40 ,  42 , meeting at a parting line  41  or parting surface  41 . In the illustrated embodiment, the handle  14  may be formed in a cavity  44 . In the illustrated embodiment, the cavity  44  receives the resin that will cure to become the plastic of the handle  14 . Typically, the cavity  30  will have suitable draft angles (be tapered) somewhat. However, it is sufficient if a mold release is used, and if all changes in cross-sectional area are monotonically decreasing from right to left in the illustrated embodiment. Similarly, monotonically decreasing sizes from left to right may also be used. However, interior changes in cross-section may be limited. 
         [0047]    For example, in the illustrated embodiment, the shaft  51  may be a powered ram  51  that draws a central core  52  from the handle  14  after molding. The central core  52  may operate as a core pull, and may have changes in cross-section, such as the shoulder portion  53 , that is smaller than the shaft  51 , but larger than the central cavity portion  58 . 
         [0048]    In the illustrated embodiment, a vent core  54  may also draw out of the handle  14  in the cavity portion  44 , prior to opening the mold  43  by separating the mold halves  40 ,  42  along the parting line  41  or surface  41 . Typically, a vent pin portion  56  will be sized and shaped to actually contact the central cavity portion  58 , in order to prevent flash or injection of any resin material there. 
         [0049]    Thus, the image of  FIG. 13  represents a cross-sectional view of the cavity of a mold  43  in its associated hardware required. Here, the configuration is that required for injection, all in a closed configuration. At this point, gated runners may feed into the cavity  44  the liquid resin that will harden or cure to become the handle  14 . 
         [0050]    Following cooling, which may require only a matter of seconds, the core  54  or vent core  54  must be withdrawn first. Thereafter, the core  52  may either be drawn, or may simply be removed, or even maintained in place while the core halves  40 ,  42  are separated. Ultimately, the core  52  must be withdrawn from the handle  14  remaining. Accordingly, it is typical that a core pull  54  or the core  54  is pulled, followed by pulling the core  52 , followed by opening of the mold  43  by the separation of the mold halves  40 ,  42 . 
         [0051]    Thus, the vent pin portion  56  is responsible for leaving the aperture  20 . The central cavity portion  58  of the core  52  is responsible for leaving the cavity  30  in the handle  14 . The shoulder portion  53  of the core  52  is responsible for leaving the internal bore of the receiver  18 , sized to receive the probe  12 . In this embodiment, the internal cavity  30  extends into the interface  22  or connector  22 , as formed. 
         [0052]    In yet another alternative embodiment, the handle may be molded by any suitable means. The aperture may then be drilled. 
         [0053]    The present invention may be embodied in other specific forms without departing from its purposes, functions, structures, or operational characteristics. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.