Illuminated suction device

An illuminated medical device comprising an outer housing, and an illumination assembly comprising at least one direct light source oriented to emit light radially away from a central axis of the medical device and at least one reflector configured to reflect light from the at least one direct light source toward a target area external to the outer housing.

FIELD OF THE INVENTION

Embodiments described herein relate to a surgical instrument with a compact illumination assembly for improved lighting and heat dissipation features. The surgical instrument described in the illustrative embodiments herein is especially well suited for the removal of body fluids such as blood from a surgical wound and for simultaneously illuminating an area of the wound so that the same can be visualized by a surgeon.

INTRODUCTION

It is often necessary during the course of a surgical procedure for body fluids, such as blood, to be removed from the area of the surgical wound in order that the same may be visualized by the surgeon. The arrangements hitherto provided for the removal of such fluids from and for the illumination of surgical wounds have left much to be desired.

It is often necessary to maintain a surgical suction device in place in the wound in order to permit the surgeon to visualize the point at which the bleeding has occurred. Particularly when such a suction device is in place, it is extremely difficult and often impossible to prevent the suction device from interfering with the desired visualization and illumination.

Hand-held suction devices are routinely used during surgical procedures. These devices are typically connected to a standard suction source in the operating room, enabling the physician to dynamically and efficiently remove blood, bone fragments, or fluid previously irrigated into the surgical site. These suction devices are sometimes also used to provide low force retraction of fat, muscle, or other structures during the procedure. The surgeon holds the suction device from its proximal end, manipulating the distal portion of the suction device during the surgical procedure in order to provide suction at the desired location. Hand-held suction devices are widely available in a variety of distal tip configurations suited to various surgical applications.

A Yankauer suction device is a medical instrument that provides suction to a wound or other surgical incision to remove fluids from the area. Conventional Yankauer suction devices come in a metal version and a plastic version, which is usually a sterile, single-use suction tool used to remove mucus from the mouth, primarily from the throat. A tail end of the Yankauer suction device is connected to a tubing (which provides the suction) that can work with suction machine devices, and a tip end is inserted into the area to be evacuated. The devices may come with several style tips. Some have a hole at the tip end and some have additional holes on the sides.

Illuminated Yankauer suction devices available for surgical use fall into two categories: first, a suction device with illumination supplied by a fiber-optic light guide connected to the device, with light guided through the light guide to an aperture near the distal end of the suction device, from which the light is directed toward the surgical field; and second, illumination supplied by an LED installed on the instrument and powered by batteries, with unmodified luminance from the LED being aimed toward the surgical field. U.S. patent application Ser. No. 15/646,372, assigned to the same assignee herein and incorporated herein by reference, is an example of an illuminated suction device falling into the second category.

The first category of suction devices is constrained by the need for its umbilical cord, i.e., light guide, tethering it to a large, heavy, expensive, relatively non-portable, AC-powered light source. The limited flexibility of the light guide tends to hamper the use of the tool by the surgeon. The second category of suction devices have an LED coupled to the top, i.e., 12 o'clock, position on the tube of the suction device and relies on the native luminance pattern of the LED to project an acceptable pattern of illuminance onto the target surgical field. The target surgical field or target area (target surface) is typically defined as a relatively flat surface in contact with, and substantially perpendicular to, the tip of the suction tube. In addition, the luminance pattern is constrained by the limited shapes of the LEDs and the limited space available on the suction tube for attaching the LED in a way that would avoid blocking the view of the surgical field during use and avoid increasing the size of the suction tube.

With both categories of existing illuminated suction tube surgical instruments, the illuminance pattern at the target surface is the most intense at the center, with a radial decline in illuminance when measuring away from the center. In addition, the illuminance pattern at the target surface displays a darker shaded portion just under the tip of the suction tube. This is because typically illuminated suction tools have their light-emitting aperture located above the suction tube, i.e., at 12 o'clock when the tube is viewed as a clock face. Therefore, typically the suction tube itself casts a shadow at a 6 o'clock position on the target surface.

SUMMARY OF THE INVENTION

The present invention provides an improved illuminated medical device, such as a Yankauer suction device, which provides a uniform illuminance pattern over a circular target area and eliminates formation of a shadow from the medical device in the illuminated target area. The target area (target surface) is a surface in contact with or near the distal tip of the suction tube and substantially perpendicular to the distal tip of the suction tube.

Moreover, the illuminated medical device of the present invention provides bright illumination, without increasing the bulk of the device so that the device can be inserted into small spaces and so that the illumination assembly does not obscure the surgeon's field of view. Specifically, the illuminated medical device of the present invention achieves an improved level of illuminance for a sufficient time duration, while keeping the size and weight of the onboard energy source (typically batteries) reasonably small for a hand-held tool. In addition, the device of the present invention includes heat dissipation features that prevent the illumination assembly from heating the device and avoid potential injury to patient tissues. Other features of the illuminated medical device of the present invention are described in the detailed description.

In accordance with the present invention, an illuminated medical device comprises an outer housing, and an illumination assembly comprising at least one direct light source oriented to emit light radially away from a central axis of the medical device and at least one reflector configured to reflect light from the at least one direct light source toward a target area external to the outer housing. The illumination assembly does not include a waveguide. The medical device includes a proximal end and a distal end, and wherein the target area is adjacent the distal end of the medical device.

In certain embodiments, the at least one reflector is a concave reflector, and may be a multi-faceted reflector, and wherein the direct light source is positioned within a concavity of the at least one reflector. In some embodiments, the illumination assembly further includes at least one lens for refracting light reflected from the at least one reflector toward the target area. In some illustrative embodiments, the at least one direct light source includes a first direct light source oriented to emit light radially away from the central axis of the medical device in a first direction and a second direct light source oriented to emit light radially away from the central axis of the medical device in a second direction different from the first direction, and wherein the at least one reflector reflects light emitted from the first direct light source and light emitted from the second direct light source toward the same target area. The first direction may be opposite to the second direction.

In some embodiments, the illuminated medical device is a suction device further comprising a suction tube extending from the outer housing and wherein the target area is adjacent to a distal end of the suction tube.

The present invention is also directed to an illuminated suction device comprising an outer housing having a suction tube extending therethrough, and an illumination assembly including a plurality of direct light sources and a built-in power source for supplying power to the plurality of direct light sources, said power source being housed within the outer housing. In some embodiments, each of the plurality of direct light sources is provided at a different location around the suction tube. In certain embodiments, the plurality of direct light sources include a first direct light source provided adjacent to one side of the suction tube and a second direct light source provided adjacent to another side of the suction tube. In certain embodiments, the illumination assembly further includes one or more optical elements including one or more of a reflector and a lens.

In some arrangements of the illumination assembly, each of the plurality of direct light sources emits light radially away from the suction tube and the one or more optical elements are configured to direct light emitted from the plurality of direct light sources toward a target area adjacent to a distal tip of the suction tube. The one or more optical elements include at least one concave reflector configured to reflect light emitted from the at least one direct light source toward the target area.

In some embodiments, the outer housing includes a proximal end and a distal end, the suction tube extends from the proximal end of the outer housing and beyond the distal end of the outer housing, and the built-in power source is provided adjacent the proximal end of the outer housing.

In some embodiments, the illuminated suction device further comprises a heat sinking assembly for dissipating heat generated by the plurality of direct light sources, the heat sinking assembly comprising one or more heat sinking members thermally connected to the direct light sources. The heat sinking assembly may include a plurality of heat sinking members, each said heat sinking member being thermally connected with a direct light source and each said heat sinking member comprising a metallic plate having a high thermal conductivity.

The present invention is also directed to an illuminated suction device comprising an outer housing having a suction tube extending therefrom, and an illumination assembly including one or more direct light sources and one or more optical elements, said illumination assembly being configured to provide substantially shadowless, substantially uniform light to a target area adjacent a distal end of the suction tube. In some embodiments, the one or more optical elements include one or more of a reflector and a lens. In some embodiments, the illumination assembly includes a plurality of direct light sources and the one or more optical elements includes at least one concave reflector for reflecting light emitted from the plurality of direct light sources toward the target area, with the plurality of direct light sources being positioned within a concavity of the at least one concave reflector. Each of the direct light sources is oriented so as to emit light radially in a direction away from a central axis of the suction tube. In one arrangement, the plurality of direct light sources include a first light source positioned adjacent a first side of the suction tube and a second light source positioned adjacent a second side of the suction tube opposite of the first side. The one or more optical elements may further include at least one lens for refracting light reflected from the at least one concave reflector.

Applicant's invention is also directed to an illuminated medical device comprising: an outer housing, an illumination assembly at least partially enclosed by the outer housing and including a plurality of direct light sources for providing illumination from the outer housing, and a heat sinking assembly comprising a plurality of heat sinking members, each heat sinking member being thermally coupled with at least one of the direct light sources.

In some embodiments, each heat sinking member comprises a metallic plate member including one or more through openings, each of said through openings being configured to accommodate one of the direct light sources. In some embodiments, the plurality of direct light sources are mounted on one or more flexible circuits and each flexible circuit is thermally coupled to a corresponding heat sinking member using adhesive thermal tape. In some arrangements, each heat sinking member extends along a substantial portion of a length of the outer housing. In some arrangements, each heat sinking member extends along a substantial portion of the length of the outer housing and at its proximal end expands a really to effect a relatively large amount of thermal transfer to the outer housing.

In some embodiments, the medical device is a suction device including a suction tube extending from the outer housing. The suction tube extends within the outer housing and along at least a substantial portion of a length of the outer housing, and the outer housing includes projections therein for maintaining an air gap between the suction tube and the plurality of heat sinking members.

Other arrangements and features of the invention are contemplated and described herein below.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Drawings have been used herein to depict select exemplary embodiments. For the sake of clear illustration, many practical details are explained together in the description below. However, it should be appreciated that those details should not be used to limit the scope of any claims that issue in connection with this application. In some embodiments, certain details are not essential.

Moreover, for the sake of drawing simplification, some customary structures and elements in the drawings have been shown in a simplified way. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts.

The present invention is directed to a medical device, which can be a suction device, such as a Yankauer suction device. The exemplary embodiments described below are directed to an illuminated suction device that has an improved illumination assembly and other features, such as heat dissipation, lens sealing, etc. It is understood that the features described below with respect to the illuminated suction device may also be applied to other medical devices. For example, the illumination assembly and heat dissipation features described below may be used in other medical devices, such as retractors, laryngoscopes, electrocautery devices, speculums, and other medical devices that use illumination and/or that have components that produce heat.

The illuminated suction device of the present invention provides a reasonably uniform field of illuminance over a 40-mm-diameter area on a target surface approximately normal to a surgical suction tube and with said target surface in contact with or nearby the distal tip of said suction tube. In some embodiments described below, the illuminated suction device has an illumination assembly that provides the reasonably uniform field of illuminance by means of one or more LED light sources mounted adjacent to the suction tube, along with optical elements designed to shape and distribute the visible light emitted from the LED light sources, with the optical elements also being mounted adjacent to said suction tube. Flow control assemblies that may be used in the suction device or other medical devices incorporating suction are also described below.

The suction device described below includes a suction tube having a proximal end configured to be connected via flexible tubing to a source of suction (for example, a vacuum pump) and a distal end fitted with any of a variety of tips designed to provide suitable suction action during a surgical procedure. The suction device may also include a suitable controller for controlling the suction flow and/or suction pressure.

The suction device described below further includes a source of electrical energy, typically one or more primary storage batteries, along with an electrical circuit designed to make use of the stored electrical energy to operate the one or more LED light sources, with a suitable switch/control member to control the on-off condition of, as well as the relative brightness of, the LED light source(s). The electrical circuit is typically designed to provide from two to five hours of operational time of the LED light source(s) from the energy stored in said batteries, but may be modified to provide longer or shorter operational times.

In the present invention, the aforementioned optical elements, to be described in more detail below, form an important aspect of this invention due to their role in efficiently shaping and directing the light emitted from the LED light source(s) so as to maximize the illumination level within the 40-mm-diameter area on the target surface for a given level of LED power consumption.

Another important aspect of this invention involves the size, shape, and locations of the optical elements' emitting apertures. These details of the apertures have been designed to minimize shadows cast by the suction tube, while also minimizing obscuration of the surgeon's field of view. In certain embodiments described below, this goal is achieved by locating these apertures somewhere other than at the top of the suction tube, i.e., somewhere other than at the 12 o'clock position, and keeping them within a reasonable diameter circular area, while maximizing the portion of emitted light that is transmitted through the outermost zones of the apertures. In other embodiments described below, some of the apertures may be located at locations other than the top of the suction tube, while having one of the apertures present at the top of the suction tube.

At the same time, the present invention burdens its optical design with the goal of producing a reasonably uniform field of illuminance at the target surface, with a diameter of approximately 40 millimeters. In one exemplary configuration, the suction device described below makes use of one or more optical elements, including a faceted concave reflector and/or a lens, with the one or more optical elements being so disposed as to shape the emitted light from an LED light source. In one exemplary configuration, the suction device uses both the faceted concave reflector and a lens for directing and shaping the light from each LED light source, while in other exemplary configurations, the suction device may use either the lens or the reflector for shaping and directing the light from each LED light source. In one exemplary configuration described below, the device includes two symmetrical light source channels, each including a light source, e.g., an LED, a faceted concave reflector, and a lens, with the two light source channels being symmetric about the vertical medial plane of the suction tube.

As mentioned above and described in more detail below, the present invention further includes heat dissipation features which allow for use of multiple light sources having improved brightness for longer periods of operating time without heating the device. These heat dissipation features improve patient safety and avoid the possibility of damaging patient tissues by heat generated by the illumination assembly.

The above and other features of the invention are described in more detail below.

FIGS. 1A-1Gshow different views of an illustrative embodiment of the suction device100of the present invention. The suction device includes an outer housing, comprising a body1, a spine2, a battery door10and a rear cap6, a suction tube13extending within the outer housing and having a distal end extending outside of the outer housing, and an illumination assembly comprising one or more direct light sources (not visible) and one or more optical elements.

The body1of the outer housing forms a partial enclosure of the suction device, and in this illustrative embodiment, the body1includes an open proximal end1a, which is covered by the rear cap6, an open distal1bend which accommodates the illumination assembly and through which the suction tube13extends, and an open top, which is covered by the spine2and the battery door10. In certain embodiments, the body1, the spine2, the battery door10and the rear cap6interlock with one another, and/or are welded to one another, so as to provide fluid-tight construction. In other embodiments, the spine and one or more optical elements, such as the lens, are coupled with one another so as to provide fluid-tight construction, especially at the distal end of the body1. As shown inFIGS. 1A-1G, the rear cap6includes a suction port6awhich can be connected to a vacuum source to provide suction. In some embodiments, the body1, the spine2, the battery door10and the rear cap6of the outer housing are formed from plastic or polymer materials, such as cyclic olefin copolymers (COC), aliphatic polyamides (PA, e.g., Nylon), polycarbonates (PC, e.g., Lexan), polymethyl methacrylate (PMMA aka Acrylic), acrylonitrile butadiene styrene (ABS), or polystyrene (PS). In other embodiments, other materials, including metallic materials, may be used for the outer housing components. The configuration of the outer housing inFIGS. 1A-1Gis illustrative and is configured to allow for easy assembly of the internal components of the suction device100. However, in other embodiments, the outer housing may be formed as a single piece or may combine some of the components of the outer housing in the present embodiment.

The suction tube13extends through the entire length of the body1and a distal portion of the suction tube13extends outwardly from the distal end1bof the body1. A proximal end (not visible) of the suction tube13is fluidly coupled to the vacuum port6ain the rear cap6. The distal end of the suction tube13is adapted to have one or more suction tips13battach thereto and the suction tips may be interchangeable. In certain embodiments, the suction tube13is formed from a metallic material, such as stainless steel, while in other embodiments, the suction tube13may be made from plastic or polymer materials, such as cyclic olefin copolymers (COC), aliphatic polyamides (PA, e.g., Nylon), polycarbonates (PC, e.g., Lexan), polymethyl methacrylate (PMMA aka Acrylic), acrylonitrile butadiene styrene (ABS), or polystyrene (PS).

As mentioned herein above, the suction device100includes the illumination assembly for providing illumination to the target surface. The illumination assembly includes one or more direct light sources (not visible inFIGS. 1A-1G), such as LEDs, one or more power sources housed within the outer housing and one or more optical elements for directing and/or shaping light emitted from the one or more direct light sources. As shown inFIG. 1A-1G, the one or more light sources and one or more optical elements of the illumination assembly are offset from the distal tip of the suction tube13by a predetermined distance. This predetermined distance may vary, but in some embodiments, the distance is around 2.0-2.5 inches from the distal tip of the suction tube13. In the illustrative embodiment ofFIGS. 1A-1G, the one or more power sources are located adjacent the battery door10near the proximal end of the outer housing and can be removed from the outer housing by opening the battery door10. The battery door10also includes an opening for inserting a push-tab14of a push-tab assembly, which is used to control whether or not the illumination assembly can be turned ON by electrically disconnecting the power source(s) from circuitry of the illumination assembly in a “storage” configuration and by electrically connecting the power source(s) to the circuitry of the illumination assembly to close the circuit in a “use” configuration. The push-tab assembly also assists in removing the one or more power sources from the outer housing without requiring physical contact of the user with the one or more power sources by hooking around a portion of the one or more power sources, or otherwise physically engaging with the power source(s), when the one or more power sources are housed in the outer housing and causing the one or more power sources to be removed from the outer housing when the battery cover10is opened. The details of the push-tab14and of the push-tab assembly and how it interacts with the electrical components of the illumination assembly and the power source(s) are described in U.S. Pat. No. 10,512,519, assigned to the same assignee herein and incorporated herein by reference.

In the present illustrative embodiment, the optical elements include one or more concave reflectors4(not visible inFIGS. 1A-1Gbut shown inFIG. 2BandFIGS. 2F-2H) and one or more lenses3, and these optical elements are used for directing and shaping the light emitted from the direct light sources. As described in more detail below, in one illustrative configuration, each light source is located adjacent to the side of the suction tube13, with exemplary positions being at a 3 o'clock position and a 9 o'clock position with the top of the suction tube13being a 12 o'clock position. In addition, the light sources emit light radially with respect to the central axis of the suction tube, i.e., in a direction away from the suction tube13. In this configuration, the concave reflectors direct the light emitted from the light sources toward the lenses3, which shape the light so as to provide a uniform field of illuminance over a predetermined area, e.g., an area of 40 mm, on the target surface.

As described in more detail below, in some embodiments, the optical elements may include only the reflectors or only the lenses. In addition, in some embodiments, particularly the embodiments without reflectors, the light sources are oriented so as to emit light in a direction toward the distal tip of the suction tube13. Exemplary configurations of such embodiments will be described in more detail below.

As described in more detail below, the interface between the suction tube13and the lenses3may be sealed using a sealing assembly. As shown inFIGS. 1A and 1E, a gasket5is used for sealing the space or interface between the suction tube13and the lenses3. The sealing provides a fluid tight environment within the distal end of the outer housing and within the illumination assembly and prevents fluids from entering behind the lens and from entering the reflector4.

The illumination assembly also includes a switch11or a similar operating member for controlling the ON/OFF state of the illumination assembly and in some embodiments, for also controlling the brightness and/or color of the light source(s). In the illustrative embodiment ofFIGS. 1A-1G, the switch11is a button lever provided within a recess11ain the spine2. In other embodiments, the switch11is a slider, which moves or slides within the recess11afrom an OFF position at one end of the recess11ato an ON position and the brightness of the light source(s) is controlled to increase as the lever slides in a direction of the other end of the recess. Other types of switches, such as a potentiometer switch described in U.S. Pat. No. 10,512,519, may be used for the illumination assembly of the present invention. As shown inFIGS. 1A-1G, the switch is provided in the spine2of the outer housing. However, the position of the switch11is not limited to the one shown and may instead be provided in other areas of the outer housing, including in the body1or in the rear cap6.

The configurations of the illumination assembly described in more detail below are aimed at providing illumination with uniform brightness to the target area, while eliminating shadows. The configurations of the illumination assembly described below also aim to achieve this improved illumination without a significant increase in the size of the suction device so that the device itself and its illumination assembly do not obscure the user's view of the operating site and so that the suction device can be inserted into small incisions.FIGS. 1C-1Eshow exemplary dimensions of the suction device100of the present invention. As shown inFIG. 1D, the exemplary length of the suction device100is around 329 mm from the tip of the suction tube to the end of the port6a, and the exemplary height of the outer housing at the proximal end1aof the body1is about 37 mm. As shown inFIG. 1E, the exemplary width of the body1at the distal end1bwhere the light source(s) and optical elements are housed is about 21.3 mm. Although not shown, the suction tube has an exemplary inside diameter of about 4.5 mm to minimize clogs and an outer diameter of about 5.5 mm. In certain embodiments, the inner and outer diameter of the suction tube13remains substantially uniform throughout its length, while in other embodiments, the diameter may change, such as to accommodate a flow control assembly or to provide sealing to the lens. The LEDs in this illustrative example are about 1.6 mm wide. However, smaller or larger LEDs may be used depending on the size restrictions of the suction device.

FIGS. 2A-2DandFIGS. 2E-2Ishow in more detail the configurations of the distal end1bof the body and the optical elements of the illumination assembly in the suction device. InFIGS. 2E-2I, the configuration of the illumination assembly of the suction device ofFIGS. 1A-1Gis shown, while inFIGS. 2A-2D, a modified configuration of the illumination assembly is shown. Similar numbering is used for the same or similar components of the illumination assembly.

FIGS. 2A and 2Eshow the distal end1bof the body1in an assembled state,FIGS. 2B, 2F and 2Gshow the distal end1bwith the spine2taken off to expose an internal assembled configuration of the distal end1b, andFIGS. 2C and 2Hshows an exploded view of the optical elements, i.e., the reflector4and the lens3in the distal end1bof the body1.FIG. 2Dshows an additional view of the distal end1bof the body with the spine2removed to expose the internal assembled configuration with a heat sinking assembly andFIG. 2Ishows an additional view ofFIG. 2Hwith the heat sinking assembly removed from the illumination assembly. As shown inFIGS. 2A-2DandFIGS. 2E-2I, the suction tube13extends through the length of the body1and passes through the lens3or between multiple lenses3of the illumination assembly to extend from the distal end1bof the body1.

In the illustrative embodiment ofFIGS. 2A-2D, the illumination assembly includes a pair of light sources (not visible), such as LEDs, each of which is positioned adjacent to a side of the suction tube13, with a top of the suction tube13being covered by the spine2. The light sources are arranged so that each light source emits light radially relative to the central axis of the suction tube13, i.e., in a direction away from the surface of the suction tube13. In other embodiments, multiple light sources instead of a single light source may be used at each location adjacent to the suction tube13. As shown inFIGS. 2B-2D, the optical elements of the illumination assembly include a reflector4and a lens3that includes lens portions corresponding to each light source or to each set of light sources, with the lens portions being coupled to one another via a bridge.

The reflector4is a concave multi-faceted reflector with a reflective surface on its concave surface. The reflector4is positioned so as to partially surround the light sources adjacent to the sides of the suction tube13and to reflect light emitted from the light sources toward the corresponding lens portions of the lens3. The reflector4may be a portion of a paraboloid, a segmented approximation of a portion of a paraboloid, or a collection of specifically determined facets whose geometry has been optimized to maximally and uniformly illuminate the desired area of the target surface. In the illustrative embodiment ofFIG. 2C, the reflector has an elongated, substantially ovular or rectangular shape, and includes a recess or cutout4atherein for positioning the reflector4over and around the suction tube13. When the reflector4is positioned over and around the suction tube13, the suction tube13passes through the cutout4a, and each light source is partially enclosed within the concave space of the reflector so that light emitted from the light sources is directed toward the reflector4.

FIGS. 5A-5Dshow more detailed views of the reflector4ofFIGS. 2A-2D, including a top view (FIG. 5A), a perspective front view (FIG. 5B), a front view (FIG. 5C) and a side view (FIG. 5D). As shown inFIGS. 5A-5D, the reflector includes a flattened top wall4b, concave sidewalls4con each side so as to enclose the light sources, a partial flattened bottom wall4dand a partial concave back wall4e. The reflector4has the recess or a cutout4ain the bottom4dand back4ewalls, with the recess or cutout4abeing shaped and sized so that the reflector4can be easily positioned over and around the suction tube13without affecting its reflecting characteristics. As shown inFIGS. 5A-5D, the walls4b-4eof the reflector each have multiple facets, particularly the side walls4cand the back wall4e, which have reflecting angles and characteristics customized so as to direct the light beams emitted from the light sources toward the corresponding lens portions of the lens3and to shape the light beams in order to achieve uniform illumination in the target area.

As will be recognized by one skilled in the art, the detailed geometric design of the reflective surface(s) of an optical reflector (hereinafter referred to as “the reflector design”) such as this may be optimized, by itself or in conjunction with a lens (such as lens3in FIG.2D), in order to maximize two important characteristics of the overall illumination assembly: 1) the uniformity of illuminance falling upon the target area; and 2) the total luminous flux falling within the target area. The target area is defined, as above, as a 40 mm diameter circular area on a planar surface in contact with or nearby the distal tip of suction tube13and approximately normal to the axis of the tube where it passes through the reflector.

In some embodiments, the reflector design is optimized using commercially available optical design software, such as Zemax OpticStudio. Such software allows the user to define the geometry of the reflector and then to trace a large number of rays from a light source to a target surface, following which the uniformity of illuminance and total luminous flux within the target area may be evaluated. By making changes to said geometry, re-running a ray trace, and then re-evaluating the uniformity and total flux, the user can gradually improve the theoretical performance of the geometry until satisfactory results are achieved.

In some embodiments the reflector design approximates a paraboloid, which has the inherent property that rays emanating from a single point (the focus of the paraboloid) emerge collimated after reflection. In some embodiments it is desirable to approximate a paraboloid by means of multiple flat facets for the purpose of “homogenizing” the light, meaning to combine or overlap multiple sets of rays, each of which sets may produce a non-uniform illuminance pattern at the target, such that the combined total illuminance is more uniform.

In some embodiments the initial reflector design is arrived at via the following logic:

1. Start with a point light source located at the center of the emitting surface of the LED15(FIG. 12D) or other light source, with emission characteristics defined to approximate the measured or specified luminous intensity of the light source as a function of ray angle from the axis of the light source (note that generally the luminous intensity of an LED is not variable with polar angle; i.e., an LED's luminous intensity pattern is circularly symmetric).FIGS. 12E and 12Fshow a typical small high-intensity LED and a graph of its luminous intensity as a function of emittance angle. If the light source is other than an LED, its particular emittance characteristics should be used.

2. Define a paraboloidal surface such that the focus of the paraboloid is at said point light source, and such that the focal length of the paraboloid is chosen as follows:

2.1. Choose the portion of the full solid angle of emission of the light source that will be intercepted by the reflector. As shown inFIG. 12F, capturing emission within an emittance angle range of 0° to 60°, for example, will make use of a major portion of the total emission from an LED, as the luminous intensity is substantially decreased beyond 60°.

2.2. Truncate the paraboloidal surface to that portion that intercepts the selected portion of the light source's emission solid angle.

2.3. Measure the distance from the device axis (i.e., the axis of the suction tube13where it passes through the reflector) to the farthest point on the truncated paraboloidal surface.

2.4. Vary the paraboloid focal length until said measured distance is the desired maximum radial size of the device aperture. In this embodiment, the radial size of the aperture was limited to about 9 mm in order to limit the device package width to around 22 mm. This relationship will vary, of course, depending on the design details of any housing surrounding the reflector aperture.

3. Replace said defined paraboloidal surface with a set of planar facets that lie approximately on the paraboloidal surface, i.e., each facet being tangent to said surface at a point near the center of the facet. Define the extents of said facets as follows:

3.1. Set a minimum bound for the facet dimensions based on the manufacturing technology to be employed. For example, practical injection molding tooling is often limited to features larger than 1 mm in extent.

3.2. Set a minimum bound for the total number of facets based on the desire for effective homogenization as well as the allowable angular deviation of any given facet from the theoretical underlying paraboloidal surface. For example, having too few facets will fail to provide adequate homogenization of the light source's emission; and having facets that are too large will reflect some light rays at an angle that deviates excessively from the angle that would be reflected by the ideal paraboloid.

3.3. Arrange the facets and their extents so that the solid angle subtended by the light rays intercepted by each facet is roughly equal for all facets. This implies facets located farther away from the point source should be larger than facets located closer to the point source.

4. Finally, fine-tune the tilt angles of the facets in order to produce acceptable results in terms of illuminance uniformity and total luminous flux across the target area.

It will be understood by one skilled in the art that there is interaction between all the design parameter choices listed in the logical steps1to4above. For example, limiting the radial extent of the device, and hence of the reflector aperture, will result in a larger fraction of the rays emitted by the reflector to be blocked by the suction tube. Also, setting a larger angular range to capture a larger fraction of the light source's emission will tend to decrease the resulting focal length of the paraboloid, leading again to more blocked rays.

In following the design logic for some embodiments, the point source defined in step1above may be replaced by a finite source object with dimensions approximating the actual emitting surface of the chosen light source. Similarly, in some embodiments, the design process using optical software may make use of actual measured emittance data from a light source manufacturer, which can be specified as a database of rays to be launched from the source object position during a ray trace.

It should be emphasized that in some embodiments the reflector design may not begin with or approximate a paraboloid. Indeed, any free-form collection of planar or non-planar facets, which combine to form a reflector that intercepts a significant fraction of the light source's emission, may be employed as a starting point for the reflector design. Similarly, any method, whether using simulation software on a computer or using physical trial and error, may be employed to vary the reflector design and to arrive at a satisfactory design solution.

In some embodiments, the presence of lens3adds another set of variables into the overall optical design, such that the total optical design of reflector plus lens may be optimized using optical ray tracing software or other methods.

Referring back toFIGS. 2A-2D, the lens3is disposed adjacent the distal edge of the body1and is positioned so as to cover the opening in the distal end1bof the body and adjacent the front open end of the reflector4. In some embodiments, the lens3may be positioned so as to cover the front open concave end of the reflector4, while in other embodiments, the reflector4may be positioned further away from the lens3. As shown, the lens3in the present illustrative embodiment includes two lens portions3a,3b, each of which corresponds to the respective light source or set of light sources, and the lens portions3a,3bare connected to one another by a bridge3cso as to form a single lens unit. The lens3also includes a through opening3din the bridge3cthat accommodates the suction tube13extending from the body1of the suction device. This configuration of the lens3contributes to the fluid tight configuration of the outer housing and eliminates the need for additional lens holding members. In other embodiments, however, a separate lens may be used for each light source or set of light sources and in some embodiments, an additional lens holder may be included for positioning the lenses adjacent the distal end1bof the body1and for providing fluid sealing to the outer housing.

FIGS. 3A-3D and 4show exemplary configurations of the lens3that can be used in the illumination assembly ofFIGS. 2A-2D.FIGS. 3A-3Dshow top, perspective, front and side views of a first embodiment of the lens, andFIG. 4shows a perspective view of a second embodiment of the lens. The lens3is formed from a transparent material, and may be molded from a transparent plastic, polymer or glass material. As shown inFIGS. 3A-3D, the lens3is includes two lens portions3a,3bconnected by the bridge3c, with each lens portion corresponding to one of the light sources or one of the sets of light sources. The bridge3cdoes not participate in directing light. Each lens portion3a,3bmay be fabricated separately and then joined, or the entire lens3may be fabricated as a single lens unit.

As shown, each lens portion3a,3bis a plano-convex lens, and in particular a plano-convex aspherical lens that includes a convex surface3a1,3b1and a planar surface3a2,3b2. When assembled into the suction device, the convex surfaces3a1,3b1of the lens portions3a,3bare light inlet surfaces that face the light sources and the reflector4, while the planar surfaces3a2,3b2are light output surfaces that face outside of the outer housing. As shown inFIGS. 3A-3D, the lens portions3a,3b, and/or the planar surfaces3a2,3b2of the lens portions3a,3b, are angled with respect to each other. With this construction, the light directed from each of the planar surfaces3a2,3b2is directed toward the same target area.

FIG. 4shows a second exemplary embodiment of a lens3that can be used in the suction device ofFIGS. 2A-2D. The lens3inFIG. 4, as inFIGS. 3A-3B, includes two lens portions3a,3bconnected by a bridge3c, and is a plano-convex lens. In this embodiment, each lens portion3a,3bis a toroidal aspheric lens having two unequal radii. Each lens portion3a,3bhas a doughnut surface having two different radii and is described by a circular arc of radius R1revolving around an axis that is located R2from the farthest point of the arc. In addition, the distance between the center of the arc being swept and the axis around which it is being swept is R2-R1.

In the illustrative embodiment ofFIG. 4, in each lens portion3a,3b, the radius of the arc R1is 8 mm (or 0.3150 inches), and R2, which is the distance from the farthest point of the arc to the axis around which the arc is revolving, is 11 mm (or 0.4331 inches). InFIG. 4, the dotted line extending upwardly from the center of the 8 mm arc (R1) is perpendicular to the axis of rotation, which is defined by the lower dotted line dimensioned at 11 mm (R2). In this illustrative embodiment, R2−R1is 3 mm (0.1181 inches). InFIG. 4, the revolving axis is tilted 12 degrees away from the suction device's overall optical axis, or from the axis of the suction tube. The effect of this tilt is to introduce a “wedge” into the optical path so as to bend the light rays outward. The distance between the optical channel in the lens portion3a,3bofFIG. 4to the center of the lens3is around 3.730 mm (0.147 inches), and the channel-to-channel distance is 7.46 mm (0.294 inches), which has a meaning similar to the interpupillary distance typically specified for human eyeglasses.

As shown inFIG. 4, the two lens portions3a,3b, are joined by two flat bridges of material3cto form a single molded part. The opening3din the center of the lens3is formed for accommodating the suction tube13, and in some embodiments may include sealing features (not shown), such as a pocket for an O-ring or gasket to seal to the suction tube. In addition, the lens3may also have a raised peripheral rim (not shown) for mounting the lens or another configuration to assist in mounting the lens.

Depending on the light sources used in the illumination assembly, their positioning and the reflector used or not used in the illumination assembly, the shape of the lens portions3a,3bmay be modified in order to achieve the desired uniform illumination in the target area of 40 mm diameter or other desired target areas. Alternative types of lenses that are suitable for use in the illumination assembly include other plano-convex lenses, such as plano-convex spherical lenses, bi-convex spherical lenses, meniscus spherical lenses, other types of plano-convex aspherical lenses, bi-convex aspherical lenses, meniscus aspherical lenses, plano-toroidal lenses, bi-toroidal lenses, any combination of two or more of these lenses, and/or any combination of any of these types of lenses with one or more cylindrical lenses.

FIGS. 2E-2Ishow another configuration of the illumination assembly, which also includes the pair of light sources, such as LEDs, the reflector4, which is a concave multi-faceted reflector with a reflective concave surface, and the lens3disposed adjacent the distal edge of the body and covering the opening in the distal end1bof the body. As inFIGS. 2A-2D, each of the light sources is positioned adjacent to a side of the suction tube13so that each light source emits light radially relative to the central axis of the suction tube13.

As inFIGS. 2A-2D, the lens3of the embodiment inFIGS. 2E-2Iincludes two lens portions3a,3b, each of which corresponds to the respective light source or set of light sources, and the lens portions3a,3bare connected to one another by a bridge, forming a single unit. An exemplary configuration of the lens3used in the illumination assembly ofFIGS. 2E-2Iis shown inFIGS. 3E-3H. Although the shape of the lens3inFIGS. 3E-3His somewhat different from the lens ofFIGS. 3A-3B, the features thereof are similar to the lenses described herein above. Moreover, the characteristics of the lens3inFIGS. 3E-3Hare similar to those of the lens shown inFIG. 4discussed above.

As inFIGS. 2A-2D, the reflector4is positioned so as to partially surround the light sources and to reflect light emitted from the light sources towards the lens3. However, the reflector4in the embodiment ofFIGS. 2E-2Iincludes a recess or cutout4ain the top4band back4ewalls, with the cutout4abeing shaped and sized wo that the reflector4can be positioned within the distal end1bof the body1and the suction tube13can then be inserted into the recess or cutout4a. Specifically, in the present embodiment, the recess or cutout4ais provided at the top of the reflector4, rather than the bottom of the reflector, in order to modify the assembly process of the suction device.

An exemplary reflector4is shown inFIGS. 5E-5H, which show the top view (FIG. 5E), a perspective front view (FIG. 5F), a front view (FIG. 5G) and a side view (FIG. 5H) of the reflector. The features and configuration of the reflector inFIGS. 5E-5His similar to those of the reflector shown inFIGS. 5A-5B, and the principles for designing and customizing the facets and optical characteristics of the reflector4ofFIGS. 5E-5Hare similar to those described above. As discussed above, unlike the reflector ofFIGS. 5A-5B, the reflector of the present embodiment has a cutout4ain the top wall4band the back wall4eto allow the reflector to be assembled into the illumination assembly first before assembling the suction tube13. In addition, in the embodiment ofFIGS. 5E-5H, the reflector4includes a lip4faround the front periphery thereof for positioning and holding the reflector within the distal end1bof the body.

As discussed above, the illumination assembly of the present invention is configured to project light toward the distal tip of the suction tube and the light sources and optical elements are arranged so as to project a significant portion of the total light emitted by the one or more light sources uniformly into the target area surrounding the distal tip of the suction tube. The present invention also achieves this without substantially increasing the size of the suction device, particularly the size of the distal end1bof the body1of the suction device. There are different specific arrangements of the light sources and optical elements that would satisfy these requirements of the invention, including the arrangement described above with respect toFIGS. 1A-2Iand other exemplary arrangements described in more detail below.

The illustrative configuration of the light sources and optical elements of the illumination assembly described above with respect toFIGS. 1A-2Iis shown schematically inFIGS. 6A-6B, whereinFIG. 6Ashows a top view of the distal end of the suction device100positioned in close proximity to the target surface to be illuminated andFIG. 6Bshows a front view thereof, which is viewed from the target surface looking proximally. As shown inFIGS. 6A and 6B, the illumination assembly includes two light sources15, or two sets of light sources, with each light source15positioned adjacent to the side of the suction tube13and emitting light radially relative to the central axis of the suction tube13. Specifically, each light source15is positioned with its rear surface, which is opposite to the light-emitting surface, as close as possible to the suction tube13while also having an air gap between the light source15and the suction tube13, so that the axis of its cone of emitted light is pointing radially away from the suction tube13. The air gap between the light source15and the suction tube13keeps the suction tube thermally isolated from the light sources15.

The illumination assembly further includes an optical reflector4, as described above, and a lens having a pair of lens portions, as described above, or having two separate lenses3a,3b, as schematically shown inFIGS. 6A and 6B. The reflector4, or in some embodiments a concave mirror, is positioned so as to intercept a significantly large portion of the light emitted from the light sources15. As can be seen inFIG. 6A, the light rays emitted from the light sources15get intercepted by the reflector4and are then redirected, by reflection, so as to pass through the lenses3a,3b, each of which is made of a transparent material and has a surface geometry designed to refract the light rays in a manner so as to maximally and uniformly illuminate the target area. The lenses3a,3bmay have a configuration described above with respect toFIGS. 3A-3HorFIG. 4, or may have a different configuration suitable for directing and shaping the light from the light sources and the reflector4to uniformly illuminate the target area. The geometric designs and locations of the reflector4and the lenses3a,3b, along with the choice of material of the lenses3a,3b, work together to direct as much as possible of the light emitted from the light sources15into the desired area of the target surface, as well as to spread said light uniformly over the target area.

In the illustrative arrangement ofFIGS. 6A and 6B, the two light sources15are arranged at approximately 3 o'clock and 9 o'clock angular positions relative to the axis of the suction tube, with the 12 o'clock position being at the top and adjacent to the spine2when the suction device100is assembled. However, the light sources15may be provided at different angular positions, such as 2 o'clock and 10 o'clock or 4 o'clock and 8 o'clock, etc. Moreover, in other arrangements, one light source15or more than two light sources15may be arranged in other ways, such as a single light source above the suction tube13(e.g., at the 12 o'clock position) or three or more light sources around the suction tube13. In addition, in other arrangements the optical elements may include a lens instead of a combination of a lens and a reflector, or may include a reflector without using the lens.FIGS. 7A-10Bshow additional exemplary arrangements of the illumination assembly in the suction device100of the present invention.

FIGS. 7A-7Bshow a top view of the distal end of the suction device100positioned in close proximity to the target surface to be illuminated and a front view thereof, which is viewed from the target surface looking proximally. As shown inFIG. 7A, the illumination assembly includes a pair of light sources15, or two sets of light sources, each of which is provided adjacent to the side of the suction tube13. As in the embodiment shown inFIGS. 6A and 6B, the light sources are provided at 3 o'clock and 9 o'clock positions relative to the axis of the suction tube13. However, in some embodiments, their positions may be modified, e.g., at 2 o'clock and 10 o'clock, or 4 o'clock and 8 o'clock, or 4 o'clock and 10 o'clock, etc.

In this illustrative embodiment, the light sources15emit light in a direction along the suction tube13toward the distal end of the suction tube13, e.g., the axis of the cone of emitted light from each light source is substantially parallel to the axis of the suction tube. The illumination assembly also includes a lens with two lens portions, similar to the lens described above, or two separate lenses3a,3bhaving the characteristics of the lens described above. The lenses3a,3b, which are made from a transparent material, are positioned so as to capture a significantly large portion of the light energy emitted from the light sources15. The light rays emitted from the light sources15that get intercepted by the lenses3a,3bare preferably refracted in such a manner so as to maximally and uniformly illuminate the desired area of the target surface. The geometric design, location, and material of the lenses3a,3bwork to direct as much of the light emitted as possible from the light sources into the desired area of the target surface, as well as to spread the light uniformly over the target area.

As can be seen inFIGS. 7A and 7B, the optical elements of this illustrative illumination assembly do not include a reflector. However, in some embodiments, the arrangement ofFIGS. 7A, 7Bmay be modified to provide a reflector for reflecting some of the light from the light sources towards the lenses3a,3b, e.g., a reflector provided around the sides of the light sources to prevent light leaking around the sides of the lenses3a,3b.

FIGS. 8 and 9show additional arrangements of the illumination assembly of the present invention which uses more than two light sources.FIG. 8shows a front view of the distal end of the suction device100viewed from the target surface looking proximally, with the illumination assembly including three light sources15, or three sets of light sources.FIG. 9shows a front view of the distal end of the suction device100in which the illumination assembly includes four light sources15, or four sets of light sources. As shown inFIG. 8, the light sources15are provided at about 12 o'clock, 4 o'clock and 8 o'clock, with substantially uniform spacing between the light sources. However, in other configurations, the light sources15may be spaced differently so that the spacing between the light sources is not uniform, e.g., at about 12 o'clock, 3 o'clock and 9 o'clock. Similarly, inFIG. 9, the light sources15are provided at about 12 o'clock, 3 o'clock, 6 o'clock and 9 o'clock with substantially uniform spacing therebetween. However, in other configurations, the positions of the light sources15are not limited to those shown and may be varied, e.g., 2 o'clock, 4 o'clock, 8 o'clock and 10 o'clock, and the spacing between the light sources15does not have to be uniform.

In the arrangements shown inFIGS. 8 and 9, each illumination assembly includes a plurality of lenses3a-3dor a lens with a plurality of lens portions, with each lens3a-3dor lens portion corresponding to a light source15. The light rays emitted from the light sources15get intercepted by the lenses3a-3d, which refract the light rays so as to maximally and uniformly illuminate the desired area of the target surface. As in the other arrangements described above, the geometric design, location, and material of the lenses3a-3dare configured to direct as much as possible of the light emitted from the light sources15into the desired area of the target surface, as well as to spread the light uniformly over the target area.

FIGS. 10A and 10Bshow a further illustrative arrangement of the illumination assembly of the suction device100in which the optical elements include a reflector and do not use a lens.FIG. 10Ashows a top view of the distal end of the suction tube13, which is positioned in close proximity to the target area to be illuminated, whileFIG. 10Bshows a front view thereof. In this arrangement, the illumination assembly includes two light sources15or two sets of light sources, which are positioned similarly toFIGS. 6A and 6Bso as to radially emit light relative to the axis of the suction tube13. The number of the light sources15or sets of light sources may be varied and their arrangement around the suction tube13may also be different from the arrangement shown inFIGS. 10A and 10B. The illumination assembly ofFIGS. 10A-10Balso includes one or more reflectors4, which intercept a significantly large portion of the light emitted from the light sources15and redirect the light toward the target area. The one or more reflectors4may have the configuration shown inFIGS. 5A-5DorFIGS. 5E-5Hand described above, or may be configured as two separate reflectors4each of which redirects light from a corresponding light source or set of light sources. In the embodiments which use a multi-faceted concave reflector4described above, the facets of the reflector4are arranged so that light from the light sources is redirected to the target area and so that the redirected light is substantially uniformly distributed in the target area.

The arrangements of the light sources15and the optical elements of the illumination assemblies shown inFIGS. 6A-10Bare illustrative and may be modified depending on the desired illumination brightness, the size and shape of the target area, and available space within the medical device.

Other components of the suction device100shown inFIGS. 1A-1Gwill now be described with reference toFIGS. 11A-11D.FIGS. 11A and 11Cshow top views of the suction device100with the spine2and the battery cover10removed, whileFIGS. 11B and 11Dshow side cross-sectional views of the suction device100with the battery cover removed.FIGS. 11A and 11Bshow one embodiment of the internal components of the suction device100, whileFIGS. 11C-11Dshow another embodiment of the internal components of the suction device100. The same numbering is used for the same or similar components of the suction device100.

As shown inFIGS. 11-11D, the suction tube13extends from its distal tip which is outside of the outer housing and through the entire length or substantially entire length of the body1, and as shown inFIGS. 11B and 11D, the proximal tip of the suction tube13is fluidly coupled with the suction port6ain the rear cap6. In order to accommodate electrical components of the illumination assembly, including a controller assembly (a PCB controller assembly12) and one or more power sources (7inFIG. 11D), the body1of the outer housing increases in width or outer circumference near the proximal end thereof. The widened proximal portion of the body1may be used as a handle portion of the suction device. As shown inFIGS. 11B and 11D, the suction tube13in this illustrative embodiment is bent to substantially follow the general shape of the lower surface of the body1of the outer housing, such that the suction tube13extends under the electrical components of the illumination assembly housed within the outer housing. That is, the suction tube13of the suction device100extends through the body1of the outer housing from its distal end1bto its proximal end1aalongside the power source and other electrical components of the illumination assembly.

As shown inFIGS. 11A-11D, the electrical components of the illumination assembly include the controller assembly comprising a printed circuit board (PCB) controller assembly12for controlling the light sources of the illumination assembly. The PCB controller assembly12may use a rigid PCB controller or a flexible PCB controller. The PCB controller assembly12is connected to the switch, such as the button lever11described above, and to the light sources using suitable wiring, which may be part of a flexible circuit and in some embodiments includes exposed traces that are insertable into the PCB controller assembly12. In some embodiments, the PCB controller assembly includes ON/OFF control circuits for controlling the light sources. In other embodiments, the PCB controller assembly, which also includes a dimmer circuit and/or one or more circuits for controlling the sequence of turning ON/OFF and/or the color of the light sources, similar to the one described in U.S. Pat. No. 10,512,519, which is assigned to the same assignee herein and incorporated herein by reference, may be used in the suction device100of the present invention. As in the '519 patent, the internal surface of the body1may include ribs or projections which are used for holding the suction tube13in place and/or for positioning the PCB controller assembly12and for keeping it in place within the body1.

To power the light sources of the illumination assembly, one or more power sources7, such as batteries, can be connected to the PCB controller assembly12via springs16or similar electrical contacts and a central contact17mounted on the PCB controller assembly12. The springs16hold the batteries in place against the battery cover10when the batteries and the battery cover are installed, and electrically connect the batteries using electrical connection plates on the batteries, as shown and described in the '519 patent, or using other suitable electrical connectors. The central contact17on the PCB controller assembly12provides electrical conductivity between the batteries. In certain embodiments, such as the one shown inFIG. 11D, the central contact17is configured to have a push-tab14engage therewith so as to electrically isolate the batteries from one another in a “storage” configuration (resulting in an open circuit), and to electrically connect the batteries in a “use” configuration (resulting in a closed circuit). As mentioned herein above, the details of the push-tab assembly are described in the '519 patent, which is incorporated herein by reference, and the same or substantially the same push-tab assembly may be used in the suction device100of the present invention.

Referring toFIGS. 2D and 11A-11D, the suction device also includes a heat sinking assembly for dissipating heat generated by the light sources when providing illumination. The heat sinking members extend within the outer housing along at least a substantial portion of the length of the outer housing. Specifically, as shown inFIGS. 11A-11C, the heat sinking members8,9extend from the light sources through at least a portion of the body1. The heat sinking assembly ensures that the suction device will not heat up so as to damage patient tissues and that the suction device is safe to come into contact with patient tissues.

As shown inFIG. 2DandFIGS. 11A-11C, the heat sinking assembly includes one or more heat sinking members8,9, or heat sinking plates, each of which dissipates heat generated by a corresponding light source or set of light sources. In the illustrative configurations ofFIGS. 2D and 11A-11C, the heat sinking assembly includes a left heat sinking member8, such as a heat sinking plate, which is thermally coupled to the light source or set of light sources provided adjacent to the left side of the suction tube13, and a right heat sinking member9, such as a heat sinking plate, which is thermally coupled to the light source or set of light sources provided adjacent to the right side of the suction tube13.

The left heat sinking member8dissipates heat generated by a left light source, and the right heat sinking member9dissipates heat generated by a right light source, with the heat sinking members8,9extending from the corresponding light source along each side of the suction tube13and PCB controller assembly12to the proximal portion of the body1. The configuration of the heat sinking assembly is described in more detail below with reference toFIGS. 12A-12DandFIGS. 12E-12H.

FIG. 12Ashows an exemplary heat sinking member8, or heat sinking plate, for use in the heat sinking assembly of the present invention, andFIGS. 12B and 12Cshow assembly of a distal end of the heat sinking member8with the light source15of the illumination assembly.FIG. 12Dshows distal ends of the heat sinking members8,9assembled with the light sources15and the reflector4of the illumination assembly.

As shown inFIG. 12A, the heat sinking member8comprises an elongated plate, which has a curvature that follows the shape of the body. The heat sinking member8is formed from a material having high thermal conductivity that is able to readily conduct heat generated from the light sources15and/or from electrical components. In certain embodiments, the heat sinking member8is formed from a metallic material, such as copper, copper alloys, aluminum alloys, etc. However, other suitable heat sinking materials may be used.

As shown inFIG. 12A, the illustrative heat sinking member8includes a fin18or a widened portion at the proximal end8athereof corresponding in position to the thickened proximal portion of the body when assembled. The overall shape of the illustrative heat sinking member8is configured to extend along the side of the suction tube13, particularly the distal portion of the suction tube, and curves outwardly so as to extend along the PCB controller assembly12within the widened proximal portion of the body. However, the overall shape of the heat sinking member may vary depending on the configuration of the suction device or of the medical device in which it is used. The fin18of the heat sinking member8provides additional surface area for conduction, convection, and radiation in order to provide additional heat dissipation to the exterior of the housing (body1) and thence to the atmosphere or to the surgeon's hand.

In the present invention, the purpose of the heat sinking members8,9is to conduct heat as efficiently as possible from the light sources to the exterior surface of the housing, from which the heat can continue its journey to either the atmosphere or the surgeon's hand. It is desired that the heat is internally applied to as large a portion of the housing as possible so that the temperature rise of the housing remains small and to avoid the rise of temperature being so high that it would be uncomfortable or painful to hold the handle of the suction device. In some embodiments, the outer housing of the suction device is formed from plastic. Since plastic has poor thermal conductivity, it would require a large temperature difference to spread the heat around the housing from one place to another. In these embodiments, copper or other efficient thermally conducting materials are used for the heat sinking members8,9, and a large area of the heat sinking members8,9is held close to the housing in order to conduct and convect the heat to the housing and through the housing to the exterior face of the housing.

The illustrative heat sinking member8may also include one or more positioning projections19for positioning the heat sinking member8relative to the suction tube and for maintaining its position within the body. The positioning projections19also provide additional surface area for heat transfer to the housing body1. In the present invention, the heat sinking member8is also insulated as much as feasible from the suction tube in order to keep the suction tube cool since its distal end comes into contact with the patient.

In the illustrative heat sinking member8ofFIG. 12A, as shown in more detail inFIGS. 12B and 12C, the distal end8bincludes one or more openings8cor cutouts for assembly with the light source15or a set of light sources, and in some embodiments, the distal end8bmay be recessed or reduced in thickness in order to accommodate the light source15or a set of light sources.FIG. 12Bshows the distal end8bof the heat sinking member8assembled with one light source15, whileFIG. 12Cshows the engagement between the light source15and the opening8cin the heat sinking member8in more detail. It is understood that the heat sinking member8may be modified to be assembled with multiple light sources15using the same or similar engagement therebetween.

In the illustrative embodiment ofFIGS. 12B-12C, the light source15is mounted on a flexible circuit20by soldering the light source15onto a flexible circuit substrate20aor using other suitable techniques for mounting the light source15thereon. Flexible circuits with one or more light sources mounted thereon described in U.S. Pat. No. 10,512,519, incorporated herein by reference, are suitable for use in the illumination assembly of the present invention. The light source is inserted into the opening8cin the distal end8bof the heat sinking member8, as shown inFIGS. 12B and 12C, so that the light emitting surface of the light source15is exposed through the opening8c. With this arrangement, the distal end8bof the heat sinking member8surrounds the light source15so as to absorb the heat generated by the light source15.

InFIGS. 12B-12C, thermally conductive tape21, and in particular, thermally conductive double-sided adhesive tape, is used to thermally and mechanically connect the light source15and the flexible circuit20to the heat sinking member8. Specifically, thermally conductive double-sided tape21is provided between the heat sinking member8and the flexible circuit20so as to attach the flexible circuit20to the heat sinking member8. The thermally conductive tape21provides a thermal interface between the heat sinking member and the flexible circuit20with the light source15. Bergquist BP100-0.005-00-1010 thermally conductive tape or similar tape which is thermally conductive (0.8 W/m-° K), electrically insulating and preferably having a thickness of about 0.005″ or smaller is suitable for use as the thermally conductive tape in this assembly. In some embodiments, suitable thickness of the thermally conductive tape is between 0.008″ and 0.005″.

FIG. 12Dshows how the heat sinking members8,9with the light sources15mounted on flexible circuits20are assembled with the reflector4of the illumination assembly. As discussed above with respect toFIGS. 5A-5D, the reflector4includes a cutout4ain the back and bottom walls4d,4ethereof. The cutout4ais sized so as to allow the distal ends8b,9bof the heat sinking members8,9assembled together with the light sources15and flexible circuits20to pass through the cutout4ain the back wall4dso that the light sources15are surrounded by the reflector4. As shown inFIG. 12D, the distal ends8band9bof the heat sinking members8,9are inserted into the reflector4through the cutout4a, and the light sources15assembled with the heat sinking members8,9face sidewalls4cof the reflector4. As discussed herein above, during operation of the illumination assembly, the light sources15shine light out side to side, radially away from the axis of the suction tube13, and the reflector4reflects the light toward the front of the device. Heat produced by the light sources15during operation is conducted away by the heat sinking members8,9, which allows the light sources15to operate safely at high brightness for long periods of time without overheating the suction device.

In the present illustrative embodiment, the flexible circuits20serve as thermal insulators between the heat sinks8,9and the suction tube13. That is, their substrate portion, typically made of Kapton or a similar polymer, has relatively low thermal conductivity, and is interposed between the heat sinks8,9and the tube13. Further, in some embodiments, there are ribs or protrusions on the body1that serve to hold the heat sinks8,9away from tube13as much as possible. The goal is to minimize heat transfer from the relatively hotter heat sinks8,9to the relatively cooler tube13, because said tube13extends distally out of the housing and typically comes into contact with patient tissue.

An important feature of the lighting assembly is that it minimally obscures the visualization of the target area by the operator. The constraints of uniform lighting pattern, light intensity, and heat dissipation create significant challenges to lighting assembly size, and resulting visualization impairment. These constraints are optimally addressed by:1. Mounting the LEDs such that light projects radially, and is then redirected and focused by a reflector and lens.2. Mounting the LEDs through a heat sink cutout, such that the heat sink is no thicker than the LED and adds no additional width to the assembly, and self-aligns the LED to the cutout for easy of assembly and maximum heat conduction.

AlthoughFIGS. 12A-12Dshow the heat sinking assembly that is configured for the illumination assembly arrangements shown inFIGS. 2A-2I, 6A-6B and 10A-10Bdescribed above, in other embodiments, the heat sinking assembly is modified so that the heat sinking members can be used with forward facing light sources, as inFIGS. 7A-9, or with light sources facing in other directions. For example, the distal ends of the heat sinking members8,9may be modified to include a flange or an L-shaped edge with an opening or a cutout for accommodating the light source. In addition, the heat sinking assembly may be modified to include more than two heat sinking members for use with illumination assemblies that include more than two light sources or more than two sets of light sources.

FIGS. 12E-12Hshow a modified sinking assembly, which has similar features to the sinking assembly ofFIGS. 12A-12D.FIGS. 12E-12Huse the same reference numbers for the same or similar features of the sinking assembly and detailed discussion thereof is omitted. In the embodiment ofFIGS. 12E-12H, the shape of the heat sinking member8is modified to include recesses or cutouts18ain the fin18portion of the heat sinking member8and to include a recess or notch8din the distal end8bof the heat sinking member. Such cutouts18aand notch8dare used for positioning the heat sinking member8within the body1. The other heat sinking member9has the same configuration as that shown inFIG. 12E.

FIGS. 12F and 12Gshow the heat sinking member8assembled together with the light source15mounted on a flexible circuit20, with the light source15being inserted into the opening8cin the distal end8bof the heat sinking member. As discussed above, the flexible circuit20is attached to the heat sinking member8using thermally conductive tape21.FIG. 12Hshows the heat sinking members8,9with the flexible circuits20assembled therewith being used with the reflector4. In the embodiment ofFIG. 12H, the reflector4shown inFIGS. 2E-2I and 5E-5His used with the heat sinking members8,9. However, in other embodiments, the reflector4ofFIGS. 2A-2DandFIGS. 5A-5Bmay be assembled with the heat sinking members8,9.

As discussed above with respect toFIGS. 1A-1G, the suction tube13of the suction device100passes through an opening in the lens3to the outside of the outer housing, and sealing may be added between the suction tube and the lens3so that the outer housing has a fluid tight construction. The sealing between the suction tube13and the lens3prevents bodily fluids from entering the outer housing of the suction device100. If bodily fluids enter the outer housing through the opening in the lens3, they could reduce the effectiveness of the reflector and the lens in reflecting/transmitting light, and can potentially damage the electrical components of the illumination assembly.FIGS. 13-18show different lens3to suction tube13sealing options for use in the suction device100of the present invention.

FIG. 13shows a cross-sectional view of the lens3to suction tube13sealing. InFIG. 13, the space or interface between the lens3and the suction tube13is sealed using a gasket22, which is inserted into the space between the lens3and the suction tube13from the front or light output surface of the lens. The gasket22has a substantially cylindrical shape sized to allow the suction tube to be inserted into the opening in the gasket22and includes a thickened rim22aor a flange at one end. The gasket22forms a seal between an inner diameter of the opening in the lens and the outer diameter of the suction tube13. The gasket22may be formed from silicone, rubber or other waterproof, elastomeric materials.

FIGS. 14A-Cshow another sealing arrangement between the lens3and the suction tube13. As shown inFIGS. 14A-14C, the distal end1bof the body1includes a gasket mount23for mounting a gasket22to seal the space between the lens3and the suction tube13. When the lens3is mounted to the distal end1b, the gasket mount23is positioned behind the lens3, inside the outer housing, and the gasket22is held between the lens3and the gasket mount23. In the illustrative embodiment shown, the gasket mount23has an opening23awhich corresponds substantially to the opening in the lens3, and the gasket22is ring-shaped with an opening that also corresponds substantially to the opening in the lens3. The opening in the gasket22is sized so as to allow the suction tube13to be inserted into the opening, and so that the gasket22tightly surrounds the suction tube13in order to seal the space between the suction tube13and the lens3. The shape of the gasket mount23is selected so as to avoid interference with the light being refracted by the lens3and to avoid formation of shadows. In the present illustrative example, the gasket mount23is circular in shape, corresponding to the opening in the lens and is attached to the body in positions corresponding to the bridge3cof the lens3. The gasket22may be formed from silicone, rubber or other waterproof, elastomeric materials. The gasket mount23may be molded from the same materials as the body1.

FIGS. 15A-15Dshow another example of sealing between the lens3and the suction tube13in which a gasket22is inserted from the back of the lens3and is held against the lens inside the outer housing. As shown in cross-sectional views ofFIGS. 15A and 15B, the gasket22is an O-ring which is held against the back surface of the lens3adjacent to the opening in the lens. The O-ring seals the space between lens3and the suction tube13inserted into the opening in the lens3. As in other embodiments, the O-ring gasket22is formed from an elastomeric material, such as rubber, silicone, plastic or the like.

As shown inFIGS. 15A-15C, a biasing member24, such as a spring, biases the gasket22against the lens3within the outer housing and prevents the gasket22from moving. As shown inFIG. 15C, the body1may include internal projections or ribs25against which the biasing member24is held in place, so that the biasing member24is provided between the internal projections25and the rear surface of the lens3. In this embodiment, it is important to arrange the gasket22, the internal projections25on the body and the biasing member24so that they do not block or interfere with the light emitted from the light sources and reflected from the reflector.FIG. 15Dshows an exemplary biasing member24which functions as a spring and can be injection molded from plastic or polymer materials. The biasing member24has a generally cylindrical shape with a through opening extending between two ends24a,24b. The biasing member24is configured to be positioned around the suction tube and one end24aof the biasing member is configured to push a seal against the rear surface of the lens. The biasing member24ofFIG. 15Dis capable of flexing in a direction A shown inFIG. 15D. Biasing members having a different shape and formed using injection molding are also suitable for sealing the spacing between the lens and the suction tube.

FIG. 16shows another example of sealing between the lens3and the suction tube13. In this example, the suction tube13includes an overmolded sealing member22provided on its outer surface which is shaped and sized so as to be partially inserted into the opening in the lens3and so as to seal the interface between the lens and the suction tube13. The overmolded sealing member22functions similarly to the gasket, but is overmolded on suction tube13so that no additional components are required for holding it in place relative to the suction tube13. The overmolded sealing member22may be configured as a Luer taper, which can be a Luer slip or slip-tip style connector shown inFIG. 16. In some cases, a Luer lock style connector with a male or female fitting that mates with a corresponding thread in the opening of the lens may be used. The overmolded sealing member22may be formed from plastic or polymer materials, and in some embodiments may be formed from elastomeric materials such as rubber, silicone or a polymer material.

FIG. 17shows an example of sealing between the lens3and the suction tube13in which the suction tube13includes a sealing portion13aconfigured to be partially inserted into the opening in the lens3and to seal the space between the lens3and the suction tube13. As shown inFIG. 17, the sealing portion13ais a portion of the suction tube13having a greater diameter or being larger in size and shaped so as to taper in the proximal direction of the suction tube. In certain embodiments, the suction tube13or just the sealing portion13aof the suction tube13may be coated with a polymer, rubber or silicone coating so as to improve the seal between the lens3and the suction tube13. The shape of the sealing portion13ais not limited to the shape shown inFIG. 17and may be varied.

FIG. 18shows another example of sealing provided between the lens3and the suction tube in which an adhesive material26, such as glue, or another sealing or caulking type material is provided between the lens3opening and the suction tube13. The adhesive or sealing material26may be applied to the opening in the lens3or to the interface between the lens and the suction tube13. The adhesive or sealing material26may be cured using UV light after application.

The sealing options described inFIGS. 13-18are illustrative and in other embodiments, other types of sealing or no sealing may be provided between the lens and the suction tube.

FIGS. 19A-31show an illustrative process of assembling the suction device100of the present invention, which may be the suction device100ofFIGS. 1A-1Gwith the illumination assembly ofFIGS. 2E-2I. The order of the assembly process proceeds in the order ofFIGS. 19A-31. However, in other embodiments, the order of some assembly steps may be changed in order to adjust the manufacturing process.

As shown inFIGS. 19A and 19B, the body1of the suction device100and the reflector4are provided and the reflector4is inserted into the distal end1bof the body1via an opening1cextending along the top of the body1. As shown inFIGS. 20A-20B, the lens3is then attached to the distal end1bof the body1so as to cover the opening1din the distal end1bof the body. In some embodiments, the lens3is attached to the body1using ultrasonic welding. In other embodiments, the lens3, and in particular, the periphery of the lens, is configured to allow the lens3to be snap fitted to or interlocked with the distal end1bof the body1. In yet other embodiments, the top opening1cin the body may extend to edge of the distal end1bof the body1and the lens3may be assembled into the body1by sliding into the opening1cand engaging with the sidewalls of the distal end1bof the body1. Other methods of attaching the lens3to the body1may be used, including gluing the lens3to the body1, etc.

As shown inFIGS. 21A-21C, the suction tube13is assembled into the suction device100by sliding the proximal end (tail end) of the suction tube13into the body1through the opening in the lens3. As shown inFIGS. 21B-21C, the suction tube13includes a gasket22attached thereto, with the gasket being similar to the one shown inFIG. 13. The gasket22is later partially slid into the opening in the lens3to provide sealing. As discussed above, other sealing options may be used instead of the gasket ofFIG. 13.

As shown inFIG. 22, the rear cap6is attached to the proximal end of the suction tube13by inserting the proximal end of the suction tube13into the suction port6aof the rear cap6. In the step shown inFIG. 23, the rear cap6is fastened to the proximal end1aof the body1. In certain embodiments, the edges of the rear cap6interlock with the edges of the proximal end1aof the body1to provide interlocking features between these components. In addition, or instead of the interlocking features, thread forming screws may be used to fasten the rear cap6to the proximal end1aof the body. As shown inFIG. 23, the gasket22on the suction tube13is partially inserted into the opening in the lens3to provide the sealing between the lens3and the suction tube13.

FIG. 24shows a heat sinking member8with a flexible circuit20attached thereto. The flexible circuit20includes one or more light sources (not shown) and electrical connections27which run along the length of the heat sinking member8and which have ends27aconfigured to connect with the PCB controller assembly12. The electrical connections27are encapsulated in or otherwise provided in the substrate of the flexible circuit20. In the assembly step ofFIG. 24, light source mounted on the flexible circuit20is positioned within the opening in the distal end of the sinking member8and the flexible circuit20is attached to the heat sinking member8using thermal tape, as described above. The wires27may also be attached to the heat sinking member8using thermal tape or using other means, or may remain unattached. For the suction device that includes two light sources or two sets of light sources, the other heat sinking member9is similarly assembled together with the other flexible circuit with the second light source or second set of light sources. When more than two light sources or sets of light sources are used, each heat sinking member is similarly assembled with the corresponding flexible circuit with the corresponding light source or set of light sources.

As shown inFIGS. 25A and 25B, the heat sinking members8,9are then positioned within the body1of the suction device by sliding each heat sinking member8,9into its corresponding position in the body1. As shown inFIG. 25A, the distal end1bof the body1includes ribs or internal projections for positioning the heat sinking members8,9so that an air gap is maintained between the heat sinking members8,9and the suction tube13. The air gap prevents transfer of heat to the suction tube13near the distal end thereof from the heat sinking members8,9and from the light sources15.

As shown inFIGS. 26A and 26B, the switch11, which is in the form of the button lever in the present embodiment, is attached to the spine2of the suction device. In the present embodiment, the button lever switch11is press fitted to the spine2. The spine2with the switch11connected thereto is then attached to the body1of the suction device as shown inFIG. 27. In one illustrative embodiment, the spine2is welded onto the body1so as to cover the distal and central portions of the top opening in the body1. However, in other embodiments, the spine2and the body1may be configured to interlock with one another so that the spine is slid onto the body1or snap fit onto the body1. Other methods of attaching the spine, such as using adhesive materials, may be used instead or in addition to the other attachment methods.

InFIGS. 28A and 28B, the PCB controller assembly12is placed into the proximal portion of the body1. Ribs or internal projections29on the inner surface of the body1may be used for holding the PCB controller assembly12in place. Exemplary projections for positioning the PCB controller are described in U.S. Pat. No. 10,512,519, which is incorporated herein by reference. As shown inFIG. 28B, the PCB controller assembly12is positioned on top of the suction tube13, which extends under the PCB controller assembly12all the way to the rear cap6. In addition, as can be seen inFIG. 28A, the PCB controller assembly12includes spring connectors16and the central connector17for electrically connecting the power source to the PCB controller assembly12. As shown inFIGS. 28A and 28B, the space formed above the PCB controller assembly12is provided for installation of the power source. As also shown inFIG. 28B, the heat sinking member8extends along one side of the PCB controller assembly12, and although not shown, the other heat sinking member9extends along the other side of the PCB controller assembly12.

After the PCB controller assembly12is placed in the body1of the suction device, the wires27connected to the light sources are connected to the PCB controller assembly12by plugging into an appropriate connector on the PCB controller assembly12, as shown inFIG. 29. The power source7, which includes two batteries, is then installed into the body1, as shown inFIG. 30. As can be seen, the batteries are inserted into the body1so that they are electrically connected to each other by the central connector17and so that they are electrically connected to the PCB controller assembly12using the spring connectors16, which are compressed after the batteries are inserted. When the batteries7are installed into the body1, they are positioned so that the PCB controller assembly12separates them from the suction tube13, which extends under the PCB controller assembly12. In addition, the heat sinking members8,9extend along the sides of the batteries. The internal projections29on the inner surface of the body may be used for maintaining an air gap between the PCB controller assembly12and the heat sinking members8,9and/or for maintaining an air gap between the batteries7and the heat sinking members8,9.

After the power source7is installed into the body1, the battery door10and the push-tab14are installed in the suction device as shown inFIG. 31. Specifically, the battery door10is attached to the body1so as to cover the top opening in the proximal portion of the body1, and a push-tab14is inserted into an opening10ain the battery door10so as to electrically isolate the batteries7from each other in the storage configuration. As can be seen inFIG. 31, the push-tab14slips over the central electrical connector17on the PCB controller assembly12, and is configured so that when the push-tab is in the “storage” position shown inFIG. 31, the push-tab electrically isolates the two batteries7from each other, i.e., breaks the circuit, so that the illumination assembly of the suction device cannot be turned ON even if the switch11is in the ON position. However, when the push-tab14is inserted further into the opening10ain the battery cover10to be in the “use” position, the terminals of the batteries7electrically connect with the central electrical connector17through an opening in the push-tab14so that the illumination assembly can be turned on using the switch11. In addition, in the “use” position, the push-tab14engages with the terminals or other portions of the batteries7so that when the battery door10is opened, the push-tab14forces the batteries7to be removed from the body1for disposal without requiring any physical contact between the user and the batteries7.

The suction device shown inFIG. 31is fully assembled and ready to be used. As mentioned above, the sequence of the specific steps of assembly may be varied in order to adjust for the manufacturing process. For example, assembly steps shown inFIGS. 24 and 26A, 26Bmay be performed before other steps in the sequence. Other variations may be made to the assembly process as needed.

OTHER EMBODIMENTS

FIGS. 32A-36Bshow other embodiments of the suction device of the present invention which use a different number of light sources, various positionings of the light sources and different configurations of optical elements.FIGS. 32A-32Bshow a portion of a suction device200including a suction tube113and an illumination assembly201that includes two light sources115and two lenses103corresponding to the light sources115mounted to the suction tube113. The light sources115may be mounted using a mount201a, which may be made from plastic or metal and which, in some illustrative embodiments may function as a heat sinking member or may be thermally coupled to the light sources115and to one or more further heat sinking members. InFIGS. 32A-32B, the light sources are positioned adjacent different sides of the suction tube113, offset from the top surface of the suction tube113, e.g., at around 2 o'clock and 10 o'clock, in order to reduce the size of the suction tube and to optimize its geometry.

The lenses103may be similar to those described above with respect toFIGS. 3A-4, e.g., aspheric or toric lenses. In some embodiments, the lenses103suitable for use with the illumination assembly201ofFIGS. 32A-32Band with other embodiments described herein are shown inFIGS. 32C-32F.FIG. 32Cis a top view of the lens103,FIG. 32Dis a rear perspective view of the lens103,FIG. 32Eis a rear view of the lens103andFIG. 32Fis a side view of the lens. As shown, the lens103has a convex front surface103acorresponding to a light output surface and a substantially flat rear surface103bcorresponding to a light inlet surface that receives light from the light source115. In this illustrative embodiment, the rear surface103bof the lens includes a microlens array103b1. The top surface103cof the lens is convex while the bottom surface103dof the lens103is concave to substantially follow the shape of the suction tube113.

FIGS. 32G and 32Hshow additional configurations of the illumination assemblies201with three light sources115and four light sources115, respectively. In the illustrative configuration ofFIG. 32G, three light sources115and corresponding lenses103are arranged around the suction tube113at substantially even intervals. In the illustrative configuration ofFIG. 32H, four light sources115are arranged adjacent to the suction tube113with a pair of light sources115arranged adjacent one side of the suction tube113, e.g., at around 8 o'clock and 10 o'clock, and another pair of light sources115arranged adjacent the other side of the tube113, e.g., at around 2 o'clock and 4 o'clock. InFIG. 32H, four lenses103are correspondingly arranged with the light sources115so as to direct light to the target area. The configuration of the lenses103may be as shown inFIGS. 32C-32F, wherein the light inlet surface of each lens103includes a microlens array, or may be as described in other embodiments herein.

FIG. 32Ishows a portion of the suction device200that includes the suction tube113and the illumination assembly201with three light sources115and three corresponding lenses103mounted adjacent the suction tube113.FIGS. 32J-32Lshow another example of a lens103that can be used in the illumination assembly ofFIG. 32Ior in the other illumination assemblies described herein. In this embodiment, the lens103includes a convex front surface103a, as shown inFIGS. 32K and 32L, and a concave rear surface103b, which is a light inlet surface. As shown inFIGS. 32J and 32L, the concave light inlet surface103bincludes a concave microlens array on its surface. The concave light inlet surface103bhas improved photon collection capabilities, thus improving the efficiency of the lens103.

In the embodiments shown inFIGS. 32A-32L, the light sources are oriented to emit light substantially along the length of the suction tube113, i.e., toward the target area. However,FIGS. 33A-36Bshow additional embodiments of the illumination assembly301in which the light sources215are oriented to emit light radially with respect to the central axis of the suction tube213.

FIGS. 33A and 33Bshow an illumination assembly301which includes two light sources215, each of which is mounted using a mount or a heat sinking member, similar to the embodiments described above, adjacent opposing sides of the suction tube (not shown). The light sources215are oriented away from the suction tube so as to emit light radially and the optical elements for directing and shaping the light beams include lenses or prisms203corresponding to the light sources215with reflective exterior surfaces203aprovided thereon. As shown, each lens203is positioned so as to receive light emitted from the corresponding light source215. The light emitted from the light source215passes through the lens to be reflected by the reflective exterior surface203aon the lens in a direction toward the target surface, which is in front of the suction tube. The reflected light travels through and is refracted by the respective lens203so as to provide illumination with substantially uniform brightness in the target area without shadows.

In the embodiment ofFIGS. 33A and 33B, each lens has a convex metal plated exterior surface so as to form a concave reflecting surface for reflecting the light from the light source215. The metal plated surface may include a plurality of facets in order to properly reflect the light. In other embodiments, instead of using metal plating, a reflective coating may be provided on the exterior surface of the lens. Alternatively, a separate reflector may be used instead of the reflective metal plating or coating.

FIG. 33Cshows a cross-sectional view of a portion of the illumination assembly301ofFIGS. 33A and 33Bto demonstrate light traveling within the lens or prism203, wherein the light emitted from the light source215is reflected by the reflective coating203aand directed toward the target area. As shown inFIG. 33C, the illustrative lens or prism203has an aspheric front surface, i.e., light outlet surface.

FIGS. 34A-Bshow an alternative configuration of the illumination assembly401in which two light sources315are provided within an outer housing304and oriented so as to face away from the suction tube313and to emit light radially as in the previous embodiment. The outer housing304includes a reflective inner surface304athereon for reflecting light emitted from the light sources315. A corresponding lens303is provided for each light source for refracting light reflected from the reflective surface. The reflective surface304ain this illustrative embodiment has a faceted geometry and is molded directly into the housing304. In some embodiments, the reflective surface304amay be metal plated or coated onto the inner concave surface of the housing304. As shown inFIG. 34B, the lenses303are provided as separate lenses that are sealingly coupled to the outer housing304.

FIGS. 34C and 34Dshow an exemplary configuration of the outer housing304that includes mounting clips304bfor mounting the light sources315to the outer housing304. As shown inFIGS. 34C and 34D, the outer housing304has a multi-faceted reflective inner surface304awhich is concave so as to reflect light emitted from the light sources toward the target area. The outer housing304also includes a cutout304cthat accommodates the suction tube therein and the mounting clips304bpositioned adjacent each side of the cutout304c. Each of the light sources315is mounted onto a flexible circuit, as described above, and the flexible circuit is then mounted into the mounting clip304bas shown inFIG. 34D. In some embodiments, the mounting clips304bmay be formed from heat sinking materials and/or thermally coupled to heat sinking plates for dissipating heat generated by the light sources.

FIGS. 35A-Band36A-B show exemplary illumination assemblies401in which the lenses303have different shapes and are sealingly assembled with the outer housing304that has a reflective concave surface. InFIGS. 35A-35B, the lens303is a one-piece lens with a cutout303ain the central lower portion thereof so accommodate the suction tube. The lens303is welded onto the outer housing304or otherwise attached to the outer housing304in a fluid-tight manner. After the suction tube313is assembled into the illumination assembly, a spine302or a cover for the outer housing304is attached to the outer housing304so as to seal the illumination assembly401. As shown inFIG. 35B, the spine or cover302includes a tongue302awhich fits into the cutout303ain the one-piece lens303.

In the illustrative embodiment ofFIGS. 36A and 36B, two separate lenses303are provided for the illumination assembly and a gasket seal322is provided for sealing around the perimeter of the lenses303to the outer housing304and to the suction tube313and for sealing the space between the two lenses303. With this construction, the tongue portion of the spine or cover302is eliminated, which also eliminates possibility of any light blocking.

AlthoughFIGS. 33A-36Bshow illumination assembly arrangements with two light sources, it is understood that these arrangements may be varied to include additional light sources, similar to the other embodiments described above. Thus, for example, the illumination assembly embodiments ofFIGS. 33A-36Bmay be modified to include three or four light sources distributed around the suction tube or may be modified to include multiple light sources at each location around the suction tube.

Flow Control Assemblies

The suction devices described herein above, as well as other suction devices that include other illumination assemblies or which do not include any illumination assembly, may include a flow control assembly for controlling suction through the suction tube.FIGS. 37A-52Bshow different embodiments of flow control assemblies.

FIGS. 37A-37Bshow a suction device500with a flow adjustment mechanism530for controlling suction through the suction tube513. The suction device500includes a body501, similar to the suction devices described herein above, and the body of the suction device500includes a proximal end501a, a distal end501band a neck portion501cwhich is an area where the span of the body narrows from a wider span (handle portion) to a narrower span in a distal direction. The flow adjustment mechanism530in this illustrative embodiment is provided in the neck portion501cof the body501. The flow adjustment mechanism530extends through the suction tube513and has an operating member531, such as a button, a slider or a trigger pivot, provided on the exterior of the body501to enable control by the user.

As shown inFIG. 37A, the flow control assembly530includes a stationary projection532within the suction tube513, which partially blocks the flow of air within the suction tube513. The flow control assembly530also includes a movable barrier or partition533which has a shape conforming to the stationary projection532so that when the movable barrier533is adjacent the stationary projection532, these two structures block the flow of air through the suction tube513. The movable barrier533is mechanically coupled to the operating member531which can move between an OFF position and an ON position. When the operating member531is in the OFF position, as shown inFIG. 37A, the movable barrier533is adjacent to the stationary projection532and the suction through the suction tube513is blocked. When the operating member531is moved to the ON position, the movable barrier533is moved away from the stationary projection532or removed from the flow path in the suction tube513so that suction is turned ON. As shown inFIG. 37A, the operating member531is a slider which is coupled to the movable barrier and when the slider531is moved to the ON position, this coupling causes the movable barrier533to be removed from the flow path in the suction tube. By sliding the slider531between the OFF and ON position, suction strength can be controlled over a continuous range so that suction is strongest when the slider531is all the way in the ON position. Specifically, the slider can be positioned anywhere between the ON and OFF positions to maintain the suction at the corresponding flow level in order to enable to continuously vary the flow level.

In some embodiments, a second operating member, such as a button or a potentiometer or a button slide switch, for controlling the illumination assembly is provided on the body separately from the operating member531for controlling the suction. For example, the second operating member may be provided on the opposite side of the body501from the slider531in the neck portion of the body. In other embodiments, the operating member531for flow control is integrated with the illumination assembly control.FIG. 37Bshows an exemplary embodiment in which a light triggering sensor534is provided within the body501of the suction device which is triggered by the slider531being brought into the ON position, or near the ON position. In this embodiment, when the slider531is brought into proximity with the light triggering sensor534by sliding the slider towards the ON position, the illumination assembly is turned ON so as to provide illumination. When the slider531is brought into the OFF position, the illumination assembly is caused to turn OFF.

In some embodiments, instead of the stationary projection and the movable barrier, the flow control assembly includes a stopcock mechanism or another type of valve in the suction tube which can be operated between an OFF and an ON position using a turning handle or similar operating member. In certain embodiments, the stopcock mechanism or valve operating member is provided in the neck portion of the body of the suction device.

The flow control assembly ofFIGS. 37A-Band the stopcock mechanism described above may be used with any type of suction tube, e.g., a flexible, pinchable tube or a metallic tube. In other embodiments, the flow control assembly is specifically adapted for use with a flexible tube as the suction tube, so as to pinch the suction tube closed to prevent air flow in the OFF position, and to open the suction tube to allow suction in the ON position.

FIG. 38Cshows a pinch clamp635which is used in the flow control assembly630ofFIGS. 38A-38B.FIGS. 38A and 38Bshow the view of the flow control assembly601from the outside of the body601of the suction device. InFIG. 38C, the pinch clamp635includes a first arm635aand a second arm635b, and the second arm635bincludes an engagement recess or tooth635c. In addition, the pinch clamp635has one or more pinching projections635dwhich pinch the tube when brought closer together. The first arm635aof the pinch clamp635can be operated by a user, as shown inFIG. 38Aby pressing down on the first arm635aso as to engage the tip of the first arm635awith the engagement recess635con the second arm635b. When the first arm635ais engaged with the engagement recess635c, the second arm635bcan be operated by a user to disengage the engagement recess635cfrom the first arm635a, as shown inFIG. 38B.

The flow control assembly ofFIGS. 38A-Band the pinch clamp635ofFIG. 38Ccan be modified as shown inFIGS. 38D-38Eand inFIG. 38Fto include separate first and second arms636and637which are configured to releasably engage with one another and which are configured to pinch the suction tube when engaged with one another. As shown inFIGS. 38D and 38E, the first arm636includes an engagement tooth636afor engaging with a recess637aor tooth formed on the second arm637and a pinching projection636bfor pinching the suction tube613against a stationary projection638when the first arm636is engaged with the second arm637. The first and second arms636,637are engaged by pushing down on the first arm636projecting from the body601of the suction device and disengaged by pushing the second arm637in a direction away from the first arm636. InFIGS. 38D and 38E, the second arm is mounted to the stationary projection638within the body of the suction device. In the embodiment shown, the second arm637is hollow or includes a through opening therein that allows the suction tube613to pass through it.

The flow control assembly630ofFIGS. 38D-38Eis further modified inFIG. 38Fby providing an operating lever636con the first arm636to make operation of the flow control assembly easier by requiring less input force by the user. The lever636cmay be offset to the side from the second arm637in order to allow the user to easily operate the second arm637to release the engagement between the two arms. Although inFIGS. 38A-E, the second arm includes one engagement recess or engagement tooth, in other embodiments, multiple recesses or teeth may be provided on the second arm in order to provide different positions of engagement between the first and second arms.

FIGS. 39A and 39Bshow another embodiment of a flow control assembly730that includes a detent slider mechanism. As shown inFIGS. 39A-39B, the flow control assembly730includes a movable slider735and a pinching arm736which moves between an open position and a pinched closed position based on the movement of the slider735. The slider735has an operating member735a, which can be in the form of a projection, that extends outside of the body701and which can be operated by a user to move the slider735between an OFF position, which is shown inFIG. 39Band an ON position, which is shown inFIG. 39A. The slider735also has a ramp735bthat gradually causes the pinching arm736to move toward the pinched closed position as the slider735slides between the OFF position and the ON position. In the OFF position, an engagement recess or plateau surface735con the slider735engages with the pinching arm736, which pinches the suction tube713closed as shown inFIG. 39B. This detent mechanism holds the slider735in the OFF position relative to the pinching arm736. As shown inFIGS. 39A-39B, in some embodiments, a stationary projection737may be provided within the body701against which the suction tube713is pinched by the pinching arm736.

FIGS. 46A-46Bshow another exemplary arrangement of a flow control assembly730that uses a detent slider mechanism.FIG. 46Ashows the flow control assembly730in the ON position that allows maximum suction through the suction tube713, whileFIG. 46Bshows the flow control assembly730in the OFF position in which the suction tube713is pinched closed. As shown, the flow control assembly730, similar toFIGS. 39A-39B, includes a movable slider735which slides between ON and OFF positions, e.g., slides front to back between the ON and OFF positions, and a pinching arm736, which moves to open and pinch closed the suction tube713based on the sliding motion of the movable slider735. As inFIGS. 39A-39B, the slider735of this example has the operating member735a, such as a projection, that can be operated by a user, and a ramp735bthat causes the pinching arm736to gradually move toward or away from the suction tube713. In the example ofFIGS. 46A-46B, the slide735includes a projection735cwhich is configured to engage with a plurality of recesses737provided along a portion of the body701so that the slide735can be locked at different positions between the OFF and ON positions to control suction strength. The length of the slider735and the pitch of the inclined plane of the ramp735bmay be varied in order to vary the amount of force required to move the operating member735afrom one position to another. For example, a longer slider735with a shallower pitch of the inclined plane of the ramp735cwill require a smaller force by the user to move the operating member735a.

FIG. 40shows another tube pinching flow control mechanism830which uses a scissor pinching clamp835having two arms configured to be operated between an open position and a closed position using two buttons or levers835a. When the buttons or levers835aare operated to pinch the suction tube813, the opposite ends of the respective arms are brought closer together so as to pinch the suction tube813from opposite sides. The pivot location between the two arms of the clamp835may be adjusted in order to provide sufficient height of the buttons or levers835aand in order to adjust input force required by a user.

FIGS. 41A-41Dshow a flow control assembly930that uses a rocker pinch valve935and a spring936, which is biased between two positions and which has a pinching member936a, in a form of a projection, cylindrical pin, plate, etc., attached thereto. A rocker pinch valve manufactured by the Z-Man Corporation is an exemplary rocker pinch valve suitable for use in the flow control assembly930. As shown inFIGS. 41A-41D, the rocker pinch valve935is engaged with the spring936so that in a first position (ON position) of the rocker935, shown inFIG. 41A, the spring936is biased in a direction away from the suction pipe913and in a second position (OFF position) of the rocker935, shown inFIG. 41D, the spring936is biased in a direction of the suction pipe913so that the pinching member936is brought into contact with the suction pipe913to pinch the suction pipe913closed.FIGS. 41A-Cshow the rocker935and the spring936being moved from the first position inFIG. 41Atoward the second position, wherein inFIGS. 41B and 41C, the rocker935applies a force to the spring936to bias the spring936toward the suction pipe913. The rocker pinch valve935may be any suitable rocker valve, such as an ON-OFF rocker pinch valve manufactured by Z-man corporation.

FIGS. 42A-42Dshow other views of the flow control assembly930ofFIGS. 41A-41D.FIGS. 42A and 42Cshow a portion of the suction tube body901viewed from the outside with the rocker pinch valve935visible from the outside. InFIG. 42A, the rocker pinch valve935is in the first position (ON position) that allows suction, and inFIG. 42C, the rocker pinch valve935is in the second position (OFF position) that pinches the suction tube closed.FIG. 42Bshows a more detailed view of the rocker pinch valve935together with the spring936, including the pinching member936a, being biased away from the suction tube (not shown), corresponding to the view ofFIG. 42A.FIG. 42Dshows a more detailed view of the rocker pinch valve935together with the spring936being biased toward the suction tube so as to pinch the suction tube closed, corresponding to the view ofFIG. 42C. As shown inFIGS. 42B and 42D, the spring936is coupled to the rocker pinch valve935by passing the spring936between two holding projections on the surface of the rocker pinch valve935. This engagement between the rocker pinch valve935and the spring936is exemplary and any other suitable coupling mechanisms may be used.

FIGS. 43A and 43Bshow another flow control mechanism1030which includes a push-through button1035for controlling the ON-OFF suction through the suction tube. InFIG. 43A, the push-through button1035is pushed up so that the suction flow through the suction tube is allowed (ON position), while inFIG. 43B, the push-through button1035is pushed down in order to turn off the suction through the suction tube (OFF position). It is contemplated that in other embodiments, the ON and OFF positions may be reversed. Inside the body1001of the suction device, the push-through button1035is connected to a valve or a barrier which is moved to block the suction through the suction tube when the button is moved to the OFF position, and moved out of the flow path when the button is in the ON position. The push-through button1035may be coupled with a bistable inversion mechanism to decrease throw required for switching between the ON and OFF positions.

FIGS. 44A and 44Bshow another flow control mechanism1130in which the suction is controlled using a pen click button1135for switching between the ON and OFF positions, with the pen click button being connected to a valve or a barrier which is moved to block the suction through the suction tube when the button is in the OFF position and moved away from the flow path to allow suction in the ON position. In addition, the button may be coupled with a mechanism to decrease throw. InFIG. 44A, the pen click button1135is in the OFF position, in which the suction is turned off, and inFIG. 44B, the pen click button1135is in the ON position, in which suction is turned on. However, these positions may be reversed in other embodiments.

FIGS. 45A-45Eshow a suction device1200with another illustrative flow control assembly1230for pinching the suction tube1213that uses a pivot cam follower mechanism. As shown, the flow control assembly1230includes a cam1235which has a predetermined profile designed to engage with a pivoting follower1236so as to cause the follower1236to pivot between a first position (ON position) away from the suction tube1213and a second position (OFF position) in which the follower1236pinches the suction tube1213closed. In the illustrative embodiment ofFIGS. 45A-45E, the cam1235includes a controller projection1235athereon that projects from the body1201of the suction device1200so that the user can move the controller projection1235ato rotate the cam1235between the ON and OFF positions.

As shown inFIGS. 45A and 45B, the cam1235and follower1236are at the ON position so that the follower1236abuts a recessed surface of the cam1235with a smaller radius and extends substantially along the suction tube1213without pinching the tube1213. InFIGS. 45C and 45D, the cam1235is rotated to the OFF position by moving the controller projection1235ain a direction of a proximal end of the suction device1200. As the cam1235is rotated toward the OFF position, the radius of the cam1235at the point of contact with the follower1236increases pushing the follower1236toward the suction tube1213so as to pinch the suction tube1213. As shown inFIG. 45D, the cam1235pivots and/or rotates between the ON and OFF positions around a first pivot point1235b, while the follower1236pivots between the ON and OFF positions around a second pivot point1236a. When the cam1235is rotated, friction between the faces of the cam1235and the follower1236holds the cam1235in place at all positions so that continuous flow adjustment can be achieved.

In some embodiments, a biasing member1237, such as a spring, may be added between the cam1235and the body1201of the suction device, as shown inFIG. 45E. The spring1237biases against the sidewall of the cam1235in a direction substantially perpendicular to the rotation of the cam1235. The spring1237adds friction to the face of the cam1235to lock it in place and to prevent it from rotating back to the open position.

FIGS. 47A-Bshow a portion of a suction device1300with another flow control assembly1330which uses a wedge slider1335that is configured to pinch the suction tube1313closed in one position (OFF position) and to open the suction tube1313in another position (ON position). As shown, the slider1335has a wedge shape and an operating projection1335aextending therefrom or connected thereto which can be operated by a user to slide the slider1335between the ON and OFF positions. InFIG. 47A, the wedge slider1335is in the ON position so that the wedge portion of the slider1335does not interfere with the suction tube1313and does not pinch the suction tube1313. InFIG. 47B, the wedge slider1335is in the OFF position so that the wedge portion of the slider1335pinches the suction tube1313closed to block the flow of air therethrough.

FIGS. 48A-48Bshow a suction device1400with a flow control assembly1430that is configured to pinch the suction tube1413from the side rather than from the top. In the exemplary embodiment ofFIGS. 48A-48B, the flow control assembly1430includes a cam wheel1435that has substantially flat side surfaces and a pinching projection1436on one side surface that abuts the suction tube1413. The cam wheel1435also has an operating projection1435athat can be operated by a user to move the cam wheel from an ON position, as shown inFIGS. 48A-48B, to an OFF position. In the ON position of the cam wheel1435, the pinching projection1436does not abut or engage with the suction tube1413so that suction can be provided through the suction tube1413. In the OFF position of the cam wheel, the pinching projection1436is moved to abut the suction tube1413and to pinch the suction tube1413closed so as to block suction through the suction tube1413. In this embodiment, the direction of the spring return force from the suction tube is changed so that it is not actively creating a moment around the axis of the cam wheel1435.

FIGS. 49A-49Cshow another illustrative embodiment of a flow control assembly1530that uses a cam wheel1535that directly interacts with the suction tube1513so as to pinch the suction tube1513closed in an OFF position, as shown inFIG. 49C. The cam wheel1535in this embodiment has a cam profile so that in an ON position, as shown inFIG. 49A, the cam wheel1535abuts the suction tube, or is adjacent to the suction tube, at a location where the radius of the cam wheel1535is the smallest so that the cam wheel does not pinch the suction tube1513. As shown inFIG. 49B, when an operating projection1535aon the cam wheel1535is moved from the ON position toward the OFF position, the radius of the cam wheel1535at a point of abutment with the suction tube1513increases to partially pinch the suction tube1513until the cam wheel1535is rotated to the OFF position in which the cam wheel1535pinches the suction tube1513closed.

FIGS. 50A and 50Bshow an illustrative flow control assembly1630that uses a rack and pinion mechanism. The flow control assembly1630of this embodiment includes a slider1635with an operating member1635aon one side for operation by a user and rack (or linear gear)1635bon another side configured to engage with a pinion (circular gear)1636. The pinion1636has a cam1637attached thereto, which rotates together with the pinion1636as the rack1635bslides with the slider1635. The cam1637interacts with a follower1638which is moved between a first position (ON position) shown inFIG. 50Aand a second position (OFF position) shown inFIG. 50Bas the cam1637rotates with the pinion1636. The geometry or profile of the cam1637causes the follower1638to move toward the suction tube1613as the slider1635moves from the ON position to the OFF position. In the present illustrative embodiment, the length of the slider is around 15 mm and the active circumference of the pinion1636is 335 degrees. The shape of the cam and follower is not limited to those shown inFIGS. 50A and 50Band may be adjusted based on the size and operating force requirements of the flow control assembly.

FIGS. 51A-51Bshow another illustrative flow control assembly1730that uses a rack and pinion mechanism. In this embodiment, the flow control assembly1730includes a slider1735with an operating member1735aand a rack1735bthereon, and a pinion cam1736which includes a plurality of teeth1736aaround a portion of its circumference and a cam surface1736bthat interacts with the suction tube1731. The slider1735is configured to move between a first position (ON position) shown inFIG. 51Ain which the cam surface1736bof the pinion cam1736does not pinch the suction tube1713, and a second position (OFF position) shown inFIG. 51Bin which the cam surface1736bof the pinion cam1736pinches the suction tube1713closed. The geometry of the pinion cam1736is configured to gradually pinch the suction tube1713as the slider1735moves between the first and second positions.

FIGS. 52A-52Bshow a further embodiment of a flow control assembly1830which includes an arcuate slider1835, a first arm1836hingedly connected to the arcuate slider1835, and a pinching arm1837hingedly connected to the first arm1836. The arcuate slider1835includes an operating projection1835awhich can be operated by a user to move the slider1835from an ON position shown inFIG. 52Ato an OFF position shown inFIG. 52B. When the arcuate slider1835is in the ON position, the first arm1836is positioned at an angle with respect to the pinching arm1837such that the pinching arm1837is retreated from the suction tube1813and does not pinch the suction tube1813. When the slider1835is moved toward the OFF position, the first arm1836is rotated relative to the pinching arm1837and applies a force on the pinching arm1837in a direction of the suction tube1813so that the pinching arm1837moves from a first position (ON position) in a direction toward the suction tube1813to a second position (OFF position) so as to pinch the suction tube1813closed. When the slider1835is in the OFF position, the return force of the suction tube1813trying to open up does not create a momentum to push the arc of the slider back to the ON position. That is, the flow control mechanism of this invention is self-locking. In some embodiments, a spring or another biasing member may be added to the flow control assembly1830to provide friction relief to allow the user to more easily move the operating projection1835abetween the ON and OFF positions.

The above described flow control assemblies can be used with the suction device of the present invention so as to provide suction control during use. The embodiments of the flow control assemblies described above are provided within the neck portion of the body of the suction device. However, in other embodiments, the flow control assembly may be provided in other portions of the body of the suction device, depending on the space available within the body. Moreover, the flow control assemblies of described above may be used in other medical devices that provide suction or fluids, including surgical retractors, catheters, electrocautery devices, etc. Moreover, the flow control assembly configurations are not limited to those specifically shown and described above and may be customized or modified for the specific geometry and requirements of the device in which it is used.

Although certain embodiments have been described in considerable detail herein, other embodiments, variations, and modifications that fall within the spirit and scope of the invention will be apparent to those skilled in the art. Therefore, the scope of any claims allowed for this application should not be limited to any specific embodiments or to any non-claimed details of the embodiments described herein.