Abstract:
The invention is a disposable cover handle cover for a surgical light head, and more particularly to a single-piece, integrally-formed disposable handle cover for a surgical light head and the like. The disposable cover includes a single-piece hollow member having a first open end adapted to receive the positioning handle of the surgical light head housing a camera and a second open end generally opposite the first end. The second end is closed off by a lens disposed within and integral with the hollow body.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates generally to a disposable handle cover for a surgical light head, and more particularly to a single-piece, integrally-formed disposable handle cover for a surgical light head and the like. 
     2. Description of Prior Art 
     Light heads used in sterile environments, such as in an operating room and/or surgical surroundings, are often handled during a procedure to adjust the angle and position of the light and/or camera in the handle of the light head. Disposable covers for protecting the sterility of these fixtures often are constructed of several assembled pieces resulting in unnecessary manufacturing, handling and shipping expenses. 
     The present invention addresses these problems and provides a unitarily formed single-piece cover for the handle of a surgical light head that is disposable. 
     In addition, the present invention addresses these problems by providing a unitarily formed single-piece cover for the handle of a surgical light head that can be formed in a single process of one part. 
     SUMMARY OF THE INVENTION 
     In one embodiment, the invention is a disposable cover for a camera housed in a positioning handle of a surgical light head. The cover includes a single-piece, hollow member having a first open end adapted to receive the positioning handle of the surgical light head housing the camera and a second open end generally opposite the first end. The second end is closed off by a lens disposed within and integral with the hollow body. In a preferred form, the lens is recessed from the second end within the hollow body to protect the lens from unwanted contact. 
     In another embodiment, the invention is an injection molded disposable cover for a camera housed in a positioning handle of a surgical light head. The cover includes an injection molded, single-piece hollow member having a first open end adapted to receive the positioning handle of the surgical light head housing the camera and a second open end generally opposite the first end. A molded lens integral with the hollow body is disposed at and recessed within the second end. In a preferred form, the outside surface of the hollow member is textured and generally translucent, and the lens is transparent to allow light to pass through to the camera within the handle of the surgical light head. 
     In another embodiment, the invention is a method for forming a disposable camera cover for a camera housed in a positioning handle of a surgical light head. The method includes injecting resin into a mold having a form of a hollow member. The hollow member includes a first open end adapted to receive the positioning handle of the surgical light head housing the camera and a second open end generally opposite the first end. A lens integral with the hollow body is disposed at and recessed within the second end. In a preferred form, the method includes forming the lens and hollow member together as a single-piece within the mold. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       While the specification concludes with claims particularly pointing out and distinctly claiming the invention, it is believed that the present invention will be better understood from the following description taken in conjunction with the accompanying drawings, in which: 
         FIG. 1  is a perspective view of surgical light head with a handle covered by a disposable cover according to one aspect of the present invention; 
         FIG. 2  is a perspective view of the disposable cover shown in  FIG. 1 ; 
         FIG. 3  is a sectional view of the disposable cover taken along line  3 - 3  in  FIG. 2 ; and 
         FIG. 4  is a perspective view of the removable tab shown according to one aspect of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to the Figures, there is generally disclosed in  FIGS. 1-4  a disposable cover for the handle of a light head (e.g., surgical light head). Surgical light heads, such as the one illustrated by way of example in  FIG. 1 , are commonly used in sterile environments (e.g., operating rooms) for directing light onto a desired area and capturing video at the same time. Surgical light heads can vary in size, shape and light output. Generally, a surgical light head  12  such as illustrated in  FIG. 1  includes a positioning handle  14  that extends generally perpendicularly outward from the light emitting surface. Video capturing (e.g., camera) equipment is generally housed within the handle  14 . The camera in the handle  14  is configured to capture images/video from surgical procedures and/or for clinical teleconferencing. Using the handle  14  a physician or technician is able to control the position and direction of the camera in the handle  14  and the light emitted from the light head. 
     As best illustrated in  FIGS. 2-3 , the cover  10  comprises a generally elongated hollow body or member  16 . The body  16  is generally cylindrical or tubular in shape. The body  16  includes a first end  18  that is open. When the cover  10  is mounted on the handle  14 , the handle  14  is received into the body  16  through the open first end  18  of the cover  10 . The body also includes a second end  20  opposite the first end  18  of the cover  10 . In one aspect of the invention, the contour of the body  16  tapers generally from a larger to smaller profile from the first end  18  to the second end  20 . In another aspect of the invention, the first end  18  of the body  16  includes a collar  30  having a generally larger diameter profile to accommodate a collar on the handle  14  of the light head  12 . The body  16  of the cover  10  from the collar  30  to the second end  20  is generally tubular (i.e., a fixed diameter along this defined length). The second end  20  terminates in a rim  24 . A lens  22  is recessed within the body  16  of the cover  10  behind the rim  24 . The lens  22  extends across the body  16  of the cover  10  to close off the second end  20  at an optimal depth (e.g., ½-¾ of an inch) behind the rim  24 . The lens  22  is recessed within the second end  20  behind the rim  24  to protect the lens from incidental or unwanted contact. The thickness of the sidewalls of the body  16  and lens  22  are generally thin (e.g., 80-120 thousandths of an inch). 
     In one aspect of the invention, the collar  30  is configured to secure the cover  10  to the handle  14  of the light head  12 . For example, the collar  30  includes a tab  28  (as best illustrated in  FIG. 4 ) having a detent  32  that creates an interference fit against the outside surface of the handle  14  or a counter reciprocal feature on the outside surface of the handle  14 . The interference between these features removably secures the cover  10  to the handle  14  to prevent the cover  10  from unintentionally separating from the handle  14 , particularly during manipulation of the light head  12 . According to one aspect of the invention, the tab  28  is perforated along edges contiguous with the collar  30  to allow the tab  28  and detent  32  to be separated from the collar  30  to prevent reuse of the cover  10 . 
     The cover  10  is preferably manufactured or produced as a single-piece. In one aspect, the lens  22  is single unitary piece integral with the body  16  of the cover  10 . The cover  10  is preferably injection molded as a single, unitary piece. In a preferred form, the cover  10  is injection molded from a clear thermoplastic resin, such as for example, a polycarbonate material. Other thermoplastic materials, that are preferably clear, are also contemplated such as urethane, polystyrene, polyethylene, polymethyl methacrylate, etc. The mold is configured with cosmetic texturing (e.g., by in-mold texturing) to create a frosted appearance of the surface  26 , such as a textured, generally translucent appearance. The lens  22  is left untextured (e.g., polished steel tooling is used for surfaces of the mold forming the lens  22 ) and possesses the optically-clear, transparent properties of the clear thermoplastic material used to form the cover  10 . In this embodiment, the lens  22  is configured of the same material used to produce the body  16  of the cover  10  and is molded-in with the body  16  of the cover  10 , for example, during the injection molding process. 
     The single-piece construction of the cover  10  prevents the unnecessary and unwanted handling, shipping and stocking of multiple parts for constructing a single handle cover. The rim  24  extending outward from the lens  22  also helps to protect the lens  22  from being damaged, scratched, scuffed or dirtied during handling, packaging, shipping, attachment and/or use. The cosmetically frosted surface  26  of the body  16  camouflages smudges and other contrasting marks received during handling, packing, shipping, attachment and/or use. Text and other advertising/branding artwork and text can also be included on the surface  26  and be clearly visible due to the contrasting frosted surface  26  of the cover  10 . 
     The above specification, examples, and information provide a description of the manufacture and use of the compositions of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.