Patent Publication Number: US-2017347860-A1

Title: Suction valve

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to and any benefit of U.S. Patent Application No. 62/346,847, filed Jun. 7, 2016, the content of which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     The present disclosure relates to endoscopic systems, more particularly, suction valves for endoscopes. 
     Suction valves are used to control the suction function of an endoscope during endoscopic procedures. For example, a suction valve for an endoscope may be inserted into a suction cylinder of the endoscope to provide suction to the endoscope. When the suction valve is in a normal position, suction to the distal tip of the endoscope is blocked by the valve. When suction is desired, an operator engages the suction valve (e.g. by depressing the valve) to open the suction channel to create negative pressure that draws air or fluid into the opening of the instrument channel of the endoscope. When the operator releases the suction valve, the valve returns to its normal position blocking air flow and stops the suctioning. 
     SUMMARY 
     Various embodiments of a suction valve for an endoscope are discussed herein. 
     In some embodiments, a suction valve stem comprises a button head, and a stem body connecting to the button head. The stem body comprises: an air passage through the center bore of the stem body, a recessed slot disposed on the stem body below the button head and above the side opening, a sealing area disposed on the stem body below the side opening, and a flat disposed on the stem body. The air passage comprises a side opening disposed on side surface of the stem body and a bottom opening disposed at a bottom end of the stem body. The recessed slot is disposed 90 degrees from the side opening. The flat is disposed 90 degrees from the side opening. The flat has a fluid communication to the bottom end of the stem body. 
     In some embodiments, a suction valve comprises a stem, a spring, a spring cup, and a boot, wherein the bottom end of the stem extends through the spring, the spring cup, and the boot. 
     In some embodiments, an endoscopic valve kit comprises a suction valve, an air/water valve, and a biopsy valve. 
     In some embodiments, a method for molding a suction valve stem comprises placing a mold parting line along the length of a non-sealing area. 
     In some embodiments, a method for molding a suction valve stem comprises pulling cross opening core pins in the same direction as the mold opening direction. 
     In some embodiments, a method for molding a suction valve stem comprises pulling the axial opening core pin in a direction that is perpendicular to the mold opening direction. 
     In some embodiments, a method for molding a suction valve stem comprises pulling the recessed slot cores in a direction that is perpendicular to the mold opening direction. 
     In some embodiments, a method for molding a suction valve stem comprises pulling the button head core pin in a direction that is perpendicular to the mold opening direction. 
     In some embodiments, a method for molding a suction valve stem comprises forming a sealing area in opposing halves of a mold cavity. 
     In some embodiments, a method for molding a suction valve stem comprises forming a sealing area without draft angle along the length of the sealing area. 
     In some embodiments, a method for molding a suction valve stem comprises ejecting the part from the mold in the same direction as the mold opening direction. 
     In some embodiments, a method for molding a suction valve stem comprises forming a recessed ejector pin mark near or on the sealing area. 
     Additional features and advantages of various embodiments will be set forth in part in the description that follows, and in part will be apparent from the description, or may be learned by practice of various embodiments. The objectives and other advantages of various embodiments will be realized and attained by means of the elements and combinations particularly pointed out in the description and appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Features and advantages of the general inventive concepts will become apparent from the following detailed description made with reference to the accompanying drawings. 
         FIG. 1A  is a perspective view of an embodiment of a suction valve of the present subject matter; 
         FIG. 1B  is a cross sectional view of the suction valve in  FIG. 1A ; 
         FIG. 2A  is a perspective view of an embodiment of a stem of the present subject matter; 
         FIG. 2B  is a side view of the stem in  FIG. 2A ; 
         FIG. 2C  is a front view of the stem in  FIG. 2A ; 
         FIG. 2D  is a front cross sectional view of the stem in  FIG. 2A ; 
         FIG. 3A  is a cross sectional view at the distal end of an embodiment of a stem body of the present subject matter; 
         FIG. 3B  is a cross sectional view at the distal end of another embodiment of a stem body of the present subject matter; 
         FIG. 3C  is a cross sectional view at the distal end of a third embodiment of a stem body of the present subject matter; 
         FIG. 3D  is a cross sectional view at the distal end of a fourth embodiment of a stem body of the present subject matter; 
         FIG. 3E  is a cross sectional view at the distal end of a fifth embodiment of a stem body of the present subject matter; 
         FIG. 4  is a side view of the stem of the present subject matter; 
         FIG. 5  is a front view of the stem of the present subject matter; 
         FIG. 6  is a perspective view of the stem of the present subject matter; and 
         FIG. 7  shows a stem made by a molding method embodiment of the present subject matter. 
     
    
    
     DETAILED DESCRIPTION 
     This Detailed Description merely describes exemplary embodiments in accordance with the general inventive concepts and is not intended to limit the scope of the invention or the claims in any way. Indeed, the invention as described by the claims is broader than and unlimited by the exemplary embodiment set forth herein, and the terms used in the claims have their full ordinary meaning. 
     The general inventive concepts will now be described with occasional reference to the exemplary embodiments of the invention. This general inventive concept may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the general inventive concepts to those skilled in the art. 
     Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art encompassing the general inventive concepts. The terminology set forth in this detailed description is for describing particular embodiments only and is not intended to be limiting of the general inventive concepts. As used in this detailed description and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. 
     Unless otherwise indicated, all numbers, such as for example, numbers expressing quantities of ingredients, percentages or proportions of materials, reaction conditions, and other numerical values used in the specification and claims, are to be understood as being modified in all instances by the term “about.” Accordingly, unless otherwise indicated, the numerical properties set forth in the specification and claims are approximations that may vary depending upon the suitable properties sought to be obtained in the embodiments of the invention. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the general inventive concepts are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from error found in their respective measurements. 
     Aspects of the present disclosure relate to suction valves with improved fitment to endoscopes. The present invention also eliminates problems with leaks and leakage seen in other valves. Referring to  FIGS. 1A-1B , an exemplary suction valve  10  comprises a stem  20 , a spring  30 , a boot  40 , and a spring cup  50 . The stem  20  extends through the spring  30  and the spring cup  50 . In some embodiments, the boot  40  is placed over the spring cup  50 . In some other embodiments, the boot  40  is over-molded over the spring cup  50 , and therefore the boot  40  and the spring cup  50  are one-piece. The boot  40  comprises a sealing ledge that seals off the suction port in the endoscope. In an additional embodiment it is possible to combine parts  50 ,  52 , and  40  all into a single component (material). 
     Referring to  FIGS. 1B, 2A-2D , the stem  20  comprises a top part  22  and a stem body  24 . In some embodiments, the top part  22  of the stem  20  can also be referred to as a button head or button cap  22 . The spring cup  50  comprises tabs  52 . The stem  20  further comprises recessed slots  26 . The tabs  52  reside in the recessed slots  26  of the stem  20 . The recessed slots  26  allow the restricted movement of the stem  20  up and down on the spring cup  50 . The spring  30  maintains the stem  20  in its upper position, but the recessed slots  26  and the tabs  52  prevent the stem  20  from being separated from the spring cup  50 . When the suction valve  10  is actuated, the spring  30  is compressed and the stem  20  moves further down into the spring cup  50 . The recessed slots  26  limit how far down the stem  20  may travel because the tabs  52  will eventually come in contact with the top part of the stem  20 . 
     The stem  20  comprises the button head  22  and the stem body  24 . The stem body comprises a side opening  28  and a bottom opening  32 . In some embodiments, the stem body comprises a first side opening  28  at one side and a second side opening  281  at the opposite side. Fluid may pass horizontally through one of the first and second side openings  28 ,  281  and vertically though the bottom opening  32 . The side openings  28 ,  281 , and the bottom opening  32  may allow fluid to pass through the instrument channel of an endoscope when the suction valve  10  is actuated. 
     In some embodiments, the bottom opening  32  is disposed along a longitudinal axis of the stem body  24 . The side openings are disposed transverse to the bottom opening  32 . In some embodiments, one of the first and second side openings  28 ,  281  and the bottom opening  32  are perpendicular to each other. 
     The stem body  24  comprises recessed slots  26 . In some embodiments, the stem body  24  comprises two recessed slots  26 . In some embodiments, the recessed slots  26  are disposed at the top portion of the stem body  24 . In some embodiments, the recessed slots  26  are disposed on the top portion of the opposite surfaces of the top portion of the stem body  24 . In some embodiments, the recessed slots  26  are perpendicular to both the first and second side openings  28 ,  281 . The recessed slot  26  orients the first or second side openings  28 ,  281  in the correct direction when the suction valve  10  is connected to the endoscope. 
     In some embodiments, the stem  20  functions as a tool the user (clinician) actuates to control vacuum (suction) to the patient. The stem  20  is depressed to allow vacuum suction through an endoscope and is released to stop vacuum suction. 
     In some embodiments, the interface between the endoscope and the stem  20  is important because the suction valve  10  must actuate smoothly while creating a sealing surface that does not allow suction to be lost during use. If there is a poor interface between the stem and endoscope, a loss of air within a patient will occur due to vacuum suction leaking around the stem. The fitment also needs to generate a hydraulic seal to mitigate fluids suctioned up an endoscope from going back down into a patient. In some embodiments of stem  20 , the stem diameter may be precisely controlled to assure an air tight or nearly air tight seal within the suction cylinder/port of an endoscope. 
     Referring to  FIGS. 4-6 , in some embodiments, the stem body  24  comprises one seal area  34 . In some embodiments, the stem body  24  comprises two seal areas  34 . In some embodiments, the seal areas  34  are disposed on the bottom portion of the stem body  24  and below the side openings  28 ,  281 . In some embodiments, the seal areas  34  are disposed on the opposite surfaces of the stem body  24 . 
     In some embodiments, the seal area  34  may be disposed as high as the first or second side openings  28 ,  281 . In some embodiments, the seal area  34  may be disposed as low as the bottom of the stem body  24 . In some embodiments, the seal area  34  may be disposed as narrow as about the diameter of the first or second side openings  28 ,  281 . In some embodiments, the seal area  34  may be disposed as wide as about a half of the perimeter of the stem body  24 . In some embodiments, the minimum length of the seal area  34  is about 0.280 inches. In some embodiments, the maximum length of the seal area  34  is about 0.440 inches. In some embodiments, the minimum width of the seal area  34  is about 0.158 inches. In some embodiments, the maximum width of the seal area  34  is about 0.198 inches. 
     In some embodiments, the seal area  34  or the two seal areas  34  are ribbed and/or textured. However, the seal areas still are able to assure an air tight seal. The ribbed seal areas  34  may provide an easier movement of the stem  20 . 
     In some prior art, however, the substantial air tight seal between the suction cylinder/port of an endoscope and the stem sometimes causes a hydraulic lock when the stem is depressed. Such hydraulic lock may prevent the stem from be releasing back to the upper position. 
     Referring to  FIGS. 2A, 2C, 5 and 6 , in some embodiments, the stem body  24  further comprises flats  36 . In some embodiments, the stem body  24  comprises one flat  36 . In some embodiments, the stem body  24  comprises two flats  36 . In some embodiments, the flats are disposed on the opposite surface of the stem body  24 . In some embodiments, the flats  36  are disposed below the recessed slots  26  and on the bottom portion of the stem body  24 . In some embodiments, the flats  36  extend to the bottom end of the stem body  24 . In some embodiments, the flats  36  at least extend to the bottom level of the first or second openings  28 ,  281 . In some embodiments, the flats  36  extend to the middle of the first or second openings  28 ,  281 . In some embodiments, the flats  36  and the recessed slots  26  are separated and therefore prevent fluid communications from each other. In some embodiments, the flats  36  and the first and second side openings  28 ,  281  are separated and therefore prevent fluid communications from each other. 
     In some embodiments, the maximum length of the flat  36  is about 0.625 inches. In some embodiments, the minimum length of the flat  36  is about 0.450 inches. In some embodiments, the maximum width of the flat  36  is about 0.103 inches. In some embodiments, the minimum width of the flat  36  is about 0.020 inch. 
     Referring to  FIG. 6 , in some embodiments, the sealing area  34  and the flat  36  do not overlap. In some embodiments, the sealing area  34  and the flat  36  are adjacent to each other. 
     Referring to  FIG. 3A , in some embodiments, the cross sectional view of the flat  36  is a plane shape. Referring to  FIG. 3B , in some embodiments, the cross sectional view of the flat  36  is a concave shape. Referring to  FIG. 3C , in some embodiments, the cross sectional view of the flat  36  is a pit shape. Referring to  FIG. 3D , in some embodiments, the cross sectional view of the flat  36  is a slot shape. Referring to  FIG. 3E , in some embodiments, the cross sectional view of the flat  36  is a four-flat shape. Referring to  FIGS. 3A-3E , in some embodiments, the flat  36  and the internal channel  38  of the stem body are separated and therefore prevent fluid communications from each other. In some embodiments, the flat  36  helps to reduce noise while vacuum suction is in use. 
     The stem  20  may be formed from a suitable material or combination of material(s), such as plastic, polymeric material(s), metal, or the like. In some embodiments, the button head  22  of the stem  20  is made of plastic or polymeric materials, while the rest part of the stem  20  is made of metal materials. In some other embodiments, the button head  22  is made of plastic or polymeric materials, and the recessed slot part of the stem  20  is made of plastic or polymeric materials; while the rest part of the stem  20  (including of the first and second openings and the flat  28 ) is made of metal materials. In some other embodiments, the stem  20  is made of metal materials. 
     In some embodiments, the stem  20  is formed from ABS. Comparing to polycarbonate material often used in prior art, ABS allows the stem  20  to be more compliant in tight tolerance sealing applications. 
     While the suction valve  10  shown is suitable for use with Olympus® endoscopes, other embodiments of suction valves may be suitable for use with other types of endoscopes, such as Pentax®, Fujinon®, or the like. As such, the embodiments discussed herein may be modified to accommodate other types and/or brands of endoscopes. The suction valve  10  shown here may be used as disposable suction valve. In some other embodiments, the suction valve  10  may be used as reusable/reprocessable suction valve. 
     In various embodiments, an endoscope valve kit is provided that may include additional parts along with the suction valve combined together to be used with the suction valve. The kit may further include an air/water valve. The endoscopic valve kit may further include a biopsy valve. 
     Referring to  FIGS. 7A-7B , in some prior art molding method, the stem has no parting line on the sealing surface. The only parting line is in the non-critical area between the button head and the side openings. The parting line is the witness line of slide face shut offs that pull the retaining grooves. Directional drag marks near the side openings and at the bottom ends of the stem suggest that the stem was pushed out of a mold cavity going from the bottom of the stem to the top of the stem. 
     Continuing to address the prior art, the through side opening is likely pulled using a mechanical slide or a hydraulic core pull mechanism. This pin is “through the cavity block,” which means it operates through an opening in the cavity block below the parting line of the mold. This action can leave burrs on the opening in the cavity block that result in the drag marks seen in the center picture. These drag marks are essentially grooves in the surface of the plastic that prevent the stem from having a smooth sealing surface. 
     Referring to  FIG. 8 , some embodiments of the present subject matter disclose molding approach to tooling the stem. In specific, the method comprises to place the mold parting line on the non-sealing surfaces such as the flats which are located 90 degrees from the critical sealing areas. In some embodiments, the mold parting line is placed along the length of a non-sealing area. This leaves the critical sealing areas completely free of the tooling marks and leaves no drag marks from ejection from the mold. It allows the sealing areas to stay uniform and smooth and be completely parallel (no draft or taper) to the mating surface of the endoscope. In some embodiments, the cross opening core pins now pull in the same direction as the mold opening direction, leaving no burrs around the side openings that can leave artifacts in the sealing areas that can promote leaks. In some embodiments, the axial opening core pin is pulled in a direction that is perpendicular to the mold opening direction. In some embodiments, the recessed slot cores are pulled in a direction that is perpendicular to the mold opening direction. In some embodiments, the button head core pin is pulled in a direction that is perpendicular to the mold opening direction. In some embodiments, a seal area is formed in opposing halves of a mold cavity. In some embodiments, a sealing area has no draft angle along the length of the sealing area. In some embodiments, the part is ejected from the mold in the same direction as the mold opening direction. In some embodiments, an ejector pin mark near or on the sealing area is recessed. 
     While various inventive aspects, concepts and features of the general inventive concepts are described and illustrated herein in the context of various exemplary embodiments, these various aspects, concepts and features may be used in many alternative embodiments, either individually or in various combinations and sub-combinations thereof. Unless expressly excluded herein all such combinations and sub-combinations are intended to be within the scope of the general inventive concepts. Still further, while various alternative embodiments as to the various aspects, concepts and features of the inventions (such as alternative materials, structures, configurations, methods, circuits, devices and components, alternatives as to form, fit and function, and so on) may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the inventive aspects, concepts or features into additional embodiments and uses within the scope of the general inventive concepts even if such embodiments are not expressly disclosed herein. Additionally, even though some features, concepts or aspects of the inventions may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present disclosure; however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated. Moreover, while various aspects, features and concepts may be expressly identified herein as being inventive or forming part of an invention, such identification is not intended to be exclusive, but rather there may be inventive aspects, concepts and features that are fully described herein without being expressly identified as such or as part of a specific invention.