Abstract:
Liquid collection apparatus usable during surgery, comprising a shallow tray defining a liquid receiving zone that is upwardly exposed for receiving liquid dropping from a surgery area, and a liquid collector in a zone for collecting dropping liquid while allowing a surgeon to tread over a collector, during surgery.

Description:
This application claims priority over provisional application Ser. No. 60/341,501, filed Dec. 20, 2001. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention relates generally to liquid collection apparatus usable during surgery to collect liquid drainage from the surgery area; and more particularly concerns an easily manipulated liquid collection tray and liquid collector in the tray allowing surgeon treading over the collector. 
     During surgery, liquid such as sterile water supplied or used as irrigation liquid is commonly allowed to drain to the floor and collects there. This increases floor slipperiness and interferes with surgical procedures. There is need for improvements in such collection and disposal methods, as well as ease of handling and manipulation of collection and disposal apparatus, as well as ease of rolling travel of operating room heavy equipment over such apparatus, and need for foot comfort of persons standing in such a surgery area. 
     SUMMARY OF THE INVENTION 
     It is a major object of the invention to provide improved apparatus meeting the above needs. Basically, the improved liquid collection apparatus usable during surgery comprises 
     a) a shallow tray defining a liquid receiving zone that is upwardly exposed for receiving liquid dropping from a surgery area, 
     b) and a liquid collector in said zone for collecting said dropping liquid while allowing a surgeon to tread over said collector, during surgery. 
     In one of its forms, the liquid collector comprises a tube lying generally horizontally in said tray zone, the tube having at least one liquid inlet, and at least one suction outlet. As will be seen, the tube typically extends horizontally and n the tray liquid receiving zone, and has at least one suction inlet and one suction outlet. The tube preferably has multiple liquid inlets spaced along its length, and is flexible. Also, the tube may extend to a perimeter wall defined by the tray for communication with a suction line outside the tray. 
     It is another object to provide an easily handled, as for example foldable, tray structure, which may consist of flexible plastic foam, as for example closed cell polyethylene foam. 
     A further object is to provide a liquid collector that comprises a porous mat received in the tray to extend horizontally to allow surgeon treading on the mat, as during surgery. The mat typically extends over a liquid collection tube in the tray, as referred to. At least some liquid collecting on the mat drains through the mat, or over its edges to collect in the tray for removal, as by the tube referred to. 
     Yet another object is to provide a releasable holder or holders for holding the mat in position in the tray. Such holder or holders may compress hook and pile material between mat and tray surfaces; and certain of such holders may extend flatly, proximate corners defined by the mat and tray. The gap or gaps between the mat edge or edges and tray peripheral wall or walls typically has width substantially less than the surgeon&#39;s shoe or boot width, i.e. the gap is less than about 4 inches. 
     These and other objects and advantages of the invention, as well as the details of an illustrative embodiment, will be more fully understood from the following specification and drawings, in which: 
    
    
     
       DRAWING DESCRIPTION 
         FIG. 1  is a perspective view of a preferred embodiment of collector tray apparatus embodying the invention, and suction tube in the tray; 
         FIG. 2  is a perspective view of a mat to fit in the tray; 
         FIG. 3  is a vertical section taken through the tray, tube and mat; 
         FIG. 4  is an enlarged fragmentary section showing a surgeon&#39;s foot treading on the mat, and over the suction tube; 
         FIG. 5  is a fragmentary section showing a grate modification; 
         FIGS. 6   a  and  6   b  are sections showing drain tube exiting modification; 
         FIG. 7  is a cross-section taken through a modified drain tube; 
         FIG. 8  is a cross-section taken through two trays that are joined end-to-end; and 
         FIG. 9  is a cross-section showing a non-slip upper surface of batting in the tray. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  shows a preferred shallow tray  10  defining a liquid receiving zone  11  bounded by a peripheral wall  12  defining side wall stretches  12   a–   12   d . Shallow zone is upwardly exposed for receiving liquid dropping from a surgery area, i.e. an operating table. Such liquid typically includes water and body fluid as indicated at  13  in  FIG. 3 , dropping toward the tray. The tray preferably consists of lightweight flexible plastic foam, enabling easy folding for removal and disposal. Closed cell polyethylene foam is preferred. Wall stretches  12   a–   12   d  extend peripherally across the tray thin flat bottom wall  12   e , and have overall height “L” above the top of bottom wall  12   e  less than about 1 inch. Side wall stretches may be bonded as at  15  to the bottom wall. 
     Also shown in  FIG. 1  is a liquid collection tube  16  extending or lying generally horizontally in zone  11 , as on the top surface of bottom wall  12   e . The tube outer diameter is less than the height of the wall stretches, to enable suction of liquid from tray zone  11  into the tube interior via small holes or ports  17  spaced along the tube serpentine length, as shown. The tube has at least one inlet hole  17  and preferably a multiplicity of such holes or ports; and it has a suction outlet as for example at  19  proximate the wall stretch  12   a . A suction line  20  outside the tray is connected in series with tube  16 . Several such tubes  16  may be used. A suction source is indicated at  21 . 
     The liquid collection apparatus preferably includes a mat  23  which is laid in the tray to cover the major area of the zone  11 . Mat  23  is porous to allow drainage of liquid received on its upper surface through the mat, for collection. In this regard, the mat may consist of non-woven fibrous material such as polyester fiber. The mat functions to reduce splashing and as a treading surface, as for example is illustrated in  FIG. 4  showing a surgeon&#39;s shoe or boot  26  applying downward loading on the mat upper surface at  23   a , such loading being distributed for downward application to the tray bottom wall  12   e .  FIG. 4  also shows a portion of tube  16  below boot  26  being squeezed or deflected by the mat, the mat serving to transmit substantial loading to the wall  12   e  independently of transmission through tubing  16 , whereby suction is maintained along the tube length. Also, the walls  12   a–   12   d  and mat are configured and sized to allow any required rolling travel of operating room equipment onto or over the walls and mat, as indicated by wheel  31  and leg  32  of such equipment above the mat, in  FIG. 3 , locally compressing the resiliently compressible mat structure. Mat overall height is preferably between ½ inch and 2 inches so that the mat upper surface is approximately at the same level as the upper surfaces of the wall stretches  12   a–   12   d . One example of such known equipment is a Mayo Stand. 
       FIGS. 1 and 3  also show the provision of holders to retain edges of the mat in place on the top of the mat bottom wall  12   e . One example is the use of hook and pile layers (VELCRO)  40  and  41  on the top of wall  12   e , and on the bottom mat proximate their corners. At the time of use, the mat is placed in the tray so that the VELCRO layers interconnect; and after use as during surgery, the mat, tray and suction tubing are disposed of. Other adhesive can be used. Note also  FIG. 3  showing peripheral extent spacing  48  from walls  12   a  and  12   c.    
     Further unusual advantages in construction, function and results, are as follows: 
     1. The tray is comfortable to stand on due to preferred foam construction. Batting provides additional cushioning. Other products do not offer this dual cushioning feature. The tray may preferably be rectangular and in one example measures approximately 44 inches×62 inches and has 1 inch high rim. It is made from vacuum formed rigid plastic sheet material and has raised round bosses within the tray to serve as a platform for standing. The height of the bosses is typically about ½ inch and the high loft non-woven batting material, or mat, covers approximately the entire tray interior to serve as both a cushion and a non-splash material. One or more drains are provided in the rim of the tray to carry the fluid away. 
     In another embodiment, the tray is made of cardboard that is coated by waterproof material. 
     In a further embodiment, the tray is made from a closed cell foam material and the rim is made by bonding, folding or rolling-up the edges. The raised platform may be eliminated or bonded in place or may be a separate insert. 
     In an additional embodiment, the tray is a film with a frame i.e. walls bonded to it by adhesive or heat-sealing. 
     In yet another embodiment, the tray has U-shape to better conform to the surgical table. 
     2. Liquid draining onto the batting or tray does not puddle. It flows through the batting and is suctioned away. The surgeon is not standing in a puddle of water. 
     3. The tray keeps the operating room floor dry. This is very important, to prevent slips and falls of persons standing on the tray or batting and other of persons. 
     4. When the tray edges are constituted of soft foam, they allow or facilitate easy stepping onto the tray, without tripping. 
     5. The batting minimizes splashing of liquid draining onto its upper surface. Other conventional products do not provide this. 
     6. The batting can be held in place on the tray by various different techniques or methods. These include: VELCRO (hook and pile) adhesive, heat bonding, and/or mechanical holding. 
     7. A grate may be placed in the tray in addition to the batting. See  FIG. 5  showing a grate  50  under batting  23 , in tray  10 . 
     8. The material of the tray prevents skidding of the tray. Alternatively, non-skid patches may be placed on the underside of the tray for this purpose. Such patches appear at  51  in  FIG. 5 . 
     9. The batting may have a white or light color upper surface that permits easy visualization of collected tissue debris, and any dropped objects, such as instruments, by color contrast. One such light colored upper surface is seen at  52  in  FIG. 5 . 
     10. The tray can easily be fabricated from a flexible plastic film, a coated cardboard or rigid plastic, as by vacuum forming. 
     11. The drain tube  16   a  can exit the tray through its sidewall, or over the sidewall  12   a  as seen at  16   aa  in  FIG. 6   a . It could alternatively pass through a hole  53  in the center area of the tray, and then extend under the tray to the exteriors as seen in  FIG. 6   b.    
     12. The used tray is preferably flexible to be easily foldable or rollable. It can therefore be reduced in size for disposal or shipment. 
     13. Before disposal, lifting of one edge of the tray causes the liquid to run to the bottom edge and be easily suctioned out through drain line. 
     14. The tray has no sharp edges that could cause cuts during use or during disposal. This is very important because of the presence of the biological materials in and around the tray. Typically, all tray and batting materials are preferably soft. 
     15. The tray is preferably thermally insulating. This adds to the foot comfort of the user during use if the floor of the operating room is cold. The plastic or synthetic resinous material is thermally insulating, for this purpose, if that material is used. 
     16. The tray is electrically insulating. This adds a level of safety because of the presence of electrical outlets and equipment in the operating room during the surgical procedure. 
     17. The drain tube may have ribs on the inside diameter to prevent flow blockage. See  FIG. 7 , in which ribs  54  are formed to project radially from the bore  55  of a modified drain tube  16   d.    
     18. The tray or trays may be formed as a modular system. Several trays of smaller size may be joined together to create suitable are and configuration for optimal performance. See  FIG. 8  showing end wall interconnection, as via tongue and groove elements  58  and  59 , of two like modular trays  12   g . Batting in the trays appears at  23   a . Retainer tape or plastic extrusion can be used to join multiple trays. 
     19. The tray can be rolled or folded in half and interlocked with other trays for compact size suitable for UPS shipment. For example, the separate trays of  FIG. 8  can be folded, as at fold lines  60 , for shipment. 
     20. The drain tube has holes of a small size so that when some of the holes are covered with liquid and others open to air, there is a residual vacuum of at least 3 inches of water at points of suction. This permits liquid to be suctioned regardless of operating room floor slope. Also, the holes are sized and spaced so that there will always be suction at the hole or holes at the remote end of the tube. 
     21. The batting may have a non-slip upper surface, to prevent user&#39;s foot slippage, as when the batting is wet. For example, that upper surface may be textured, irregular or roughened to provide such non-slip quality, as seen at  61  in  FIG. 9 . A thin disposable film  62  covers the tray. 
     22. The tray may consist of open cell foam, with waterproof film on top. It can then be compressed or vacuum packed to make its volume smaller for shipping. Polyurethane foam can be used, for this purpose. 
     23. To control the battery and make it of uniform height, (to prevent tripping hazard) a net material can be used to retain the mat and secure it to the foam tray. This also eliminates need for adhesive between battery and tray foam. 
     24. The hole pattern in tubing can be varied in size and location for optimum suction control. The holes can be punched, for clean edges. The tubing material (vinyl) is preferably soft to allow chairs to roll over it and to make it comfortable to stand on. The foam used for the tray allow the tubing to pass through the wall without use of sealant. 
     25. Other applications for the system include use on flooring in ambulances, rescue helicopters, burn units, morgues, and other medical areas. 
     26. The tray, mat and tubing system, when discarded or moved, holds its fluid contents, preventing spilling of fluid onto the floor. 
     27. Channels or guides can be provided in the mat, to retain the tubing. 
     28. The mat can be used for EMS, on which a patient lies while being transported. Thermal insulating properties maintain the patient warm, and help prevent hypothermia, while keeping an ambulance floor clean.