SURGICAL SMOKE TREATMENT SYSTEM FOR POLAR AND NONPOLAR GASES

Abstract

A surgical treatment system for contaminated air streams having particulate contamination, polar contamination and/or nonpolar contamination in the gas or vapor stream. A surgical smoke plume treatment system and method provide or define a multi-stage treatment process that mechanically filters the air stream, followed by nonpolar decontamination and then polar decontamination or treatment. The system may be used stand alone or incorporated and used with other surgical instruments or incorporated into an air handler adapted to decontaminate an air stream. A desiccant may optionally be used to remove water from the air stream.

Claims

1. A surgical smoke filtration system for receiving and treating vapor, comprising: a filter; an activated carbon surface for adsorption of primarily nonpolar gases; and a metallic gas catalyst for oxidation of primarily polar volatile gases; wherein said filter, said activated carbon surface, and said metallic gas catalyst define an integrated filtration module; and said integrated filtration module further comprises a connector or connection means to attach said filtration system and an output or output means to allow for expulsion of treated surgical smoke.

2. The surgical smoke filtration system as recited in claim 1 wherein said surgical smoke filtration system comprises a surgery instrument comprising: a tubular body having a passageway for evacuating vapor from a surgical site; said tubular body comprising an extension for cauterizing at said surgical site; said extension being conductive and adapted to be coupled to a power source for energizing said extension; said tubular body having an inlet end having said extension and an outlet end coupled to a vacuum source adapted to create a predetermined pressure in said passageway in order to evacuate vapor from said surgical site through said tubular body prior to, during or after use of said filtration system at said surgical site, said vapor comprising at least one of smoke, cauterizing vapor, gas, liquid or debris.

3. The surgical smoke filtration system as recited in claim 1 wherein said activated carbon is substantially nonpolar and a preferential adsorber of nonpolar gases; said activated carbon being activated by pyrolization, carbonization, or chemical activation, such that said activated carbon maintains nonpolar properties.

4. The surgical smoke filtration system as recited in claim 1 wherein said catalyst comprises a metallic substrate for catalyzing oxidation reactions of polar gases, including oxidation of aldehydes into other molecules, including carbon dioxide.

5. The surgical smoke filtration system as recited in claim 1 wherein an evacuated surgical smoke stream traverses said activated carbon surface and thence traverses said metallic gas catalyst in a substantially serial manner.

6. The surgical smoke filtration system as recited in claim 1 wherein said carbon surface comprises a form of powdered, granular, fibrous, extruded, impregnated, coated, or woven carbon.

7. The surgical smoke filtration system as recited in claim 1 wherein said carbon surface comprises a drying component, including at least one desiccant such as silica gel, calcium carbonate, calcium sulfate, calcium chloride, magnesium sulfate, coordination polymer, Zeolite, or molecular sieve to reduce polar competition from water vapor or humidity; wherein a condensation means such as cooling coil, dehumidifier or thermoelectric plate can be utilized in addition to or in lieu of desiccant.

8. The surgical smoke filtration system as recited in claim 1 wherein said filter comprises an outer housing with at least one connection to a surgical smoke collection means; said collection means comprising at least one of a tubing system, vacuum system, electrocautery hand piece, funnel, gas separator, surgical port, surgical trocar, or surgical instrument.

9. The surgical smoke filtration system as recited in claim 1 wherein said metallic gas catalyst comprises a catalyst surface containing at least one of titanium, silver, palladium, platinum, manganese, iridium, rhodium, copper, zirconium, or other metallic element capable of catalyzing oxidation or mixed oxidation-reduction reactions of organic molecules.

10. The surgical smoke filtration system as recited in claim 9 wherein said metallic gas catalyst and/or a catalyst substrate comprises a form of one or more honeycomb, foam, extrusion, plate, coating, granule, cylinder, sphere, bead, mesh, or similar to allow for adequate contact area with gas reactant.

11. The surgical smoke filtration system as recited in claim 1 comprising an internal activation means for activating said gas catalyst; said internal activation means comprising one or more of heating means, photon-generating means, electron-generating means, or electromagnetic radiation means.

12. The surgical smoke filtration system as recited in claim 10 wherein said activation means is located within a substantially enclosed housing of a filter cartridge; said filter cartridge further comprising a transit means for connecting said cartridge to an external power source for powering of said activation means.

13. The surgical smoke filtration system as recited in claim 1 wherein said surgical smoke filtration system comprises a cauterizing system for cauterizing a surgical site associated with a patient, said surgical smoke filtration system comprising: a tubular body having a passageway for evacuating vapor from the surgical site; said tubular body comprising an extension for cauterizing at the surgical site; said extension being conductive and adapted to be coupled to a power source for energizing said extension; said tubular body having an inlet end having said extension and an outlet end coupled to a vacuum source adapted to create a predetermined pressure in said passageway in order to evacuate vapor from said surgical site through said tubular body prior to, during or after use of said surgical smoke filtration system at the surgical site, said vapor comprising at least one of smoke, cauterizing vapor, gas, liquid or debris; and wherein said passageway is defined by said tubular body and causes said vapor resulting from the cauterizing at the surgical site to be evacuated through said tubular body.

14. The surgical smoke filtration system as recited in claim 13 wherein said tubular body is conductive and creates a conductive path for current to flow from a power source to said extension.

15. The surgical smoke filtration system as recited in claim 13 wherein said extension is integral with said tubular body and both are conductive.

16. The surgical smoke filtration system as recited in claim 13 wherein said tubular body is defined by a wall having at least one predetermined dimension, said wall defining said passageway and said extension.

17. The surgical smoke filtration system as recited in claim 16 wherein said extension comprising a cross-sectional dimension that is smaller than said at least one predetermined dimension.

18. The surgical smoke filtration system as recited in claim 13 wherein an elongated portion of said extension comprises a first surface and a generally opposing second surface, said first surface defining a working surface having a generally curved or arcuate portion.

19. The surgical smoke filtration system as recited in claim 18 wherein said working surface has a radius of curvature substantially approximating a radius of curvature of said first surface.

20. The surgical smoke filtration system as recited in claim 13 wherein said extension comprises a working surface that is generally planar.

21. The surgical smoke filtration system as recited in claim 13 wherein said extension is detachably secured to said tubular body with a predetermined connection, said tubular body and said extension both being conductive to permit said extension to cauterize at said surgical site.

22. The surgical smoke filtration system as recited in claim 21 wherein said predetermined connection is a least one of a threaded, press-fit, bayonet, or socket connection.

23. The surgical smoke filtration system as recited in claim 13 wherein said passageway is substantially centrally located in said tubular body to define a substantially linear or non-serpentine conduit for evacuating said vapor.

24. The surgical smoke filtration system as recited in claim 13 wherein said tubular body comprises an interior wall that defines said passageway, at least a portion of said interior wall having a catalyst coating.

25. An electrocautery and filtration system for cauterizing a surgical site associated with a patient and for treating vapor resulting therefrom, said electrocautery and filtration system comprising: an electrocautery instrument that generates the vapor during a surgical procedure; and a surgical smoke treatment system for receiving and treating said vapor, comprising: a filter; an activated carbon surface for adsorbtion of primarily nonpolar gases; and a metallic gas catalyst for oxidation of primarily polar volatile gases; wherein said filter, said activated carbon surface, and said metallic gas catalyst define an integrated filtration module; said integrated filtration module further comprises a connector or connection means to attach said electrocautery instrument and an output or output means to allow for expulsion of treated surgical smoke; wherein a passageway in said electrocautery instrument is defined by a tubular body and causes said vapor resulting from the cauterizing at the surgical site to be evacuated through said tubular body.

26. The electrocautery and filtration system as recited in claim 25 wherein said electrocautery instrument for cauterizing a surgical site comprises: a tubular body having a passageway for evacuating vapor from the surgical site; said tubular body comprising an extension for cauterizing at the surgical site; said extension being conductive and adapted to be coupled to a power source for energizing said extension; said tubular body having an inlet end having said extension and an outlet end coupled to a vacuum source adapted to create a predetermined pressure in said passageway in order to evacuate vapor from said surgical site through said tubular body prior to, during or after use of said electrocautery instrument at the surgical site, said vapor comprising at least one of smoke, cauterizing vapor, gas, liquid or debris.

27. The electrocautery and filtration system as recited in claim 25 wherein said activated carbon is substantially nonpolar and a preferential adsorber of nonpolar gases; said activated carbon being activated by pyrolization, carbonization, or chemical activation, such that said activated carbon maintains nonpolar properties.

28. The electrocautery and filtration system as recited in claim 25 wherein said catalyst comprises a metallic substrate for catalyzing oxidation reactions of polar gases, including oxidation of aldehydes into other molecules, including carbon dioxide.

29. The electrocautery and filtration system as recited in claim 25 wherein an evacuated surgical smoke stream traverses said activated carbon surface and thence traverses said metallic gas catalyst in a substantially serial manner.

30. The electrocautery and filtration system as recited in claim 25 wherein said carbon surface comprises a form of powdered, granular, fibrous, extruded, impregnated, coated, or woven carbon.

31. The electrocautery and filtration system as recited in claim 30 wherein said carbon surface comprises a drying component, including at least one desiccant such as silica gel, calcium carbonate, calcium sulfate, calcium chloride, magnesium sulfate, coordination polymer, Zeolite, or molecular sieve to reduce polar competition from water vapor or humidity; wherein a condensation means such as cooling coil, dehumidifier or thermoelectric plate can be utilized in addition to or in lieu of desiccant.

32. The electrocautery and filtration system as recited in claim 25 wherein said filter comprises an outer housing with at least one connection to a surgical smoke collection means; said collection means comprising at least one of a tubing system, vacuum system, electrocautery hand piece, funnel, gas separator, surgical port, surgical trocar, or surgical instrument.

33. The electrocautery and filtration system as recited in claim 25 wherein said metallic gas catalyst comprises a catalyst surface containing at least one of titanium, silver, palladium, platinum, manganese, iridium, rhodium, copper, zirconium, or other metallic element capable of catalyzing oxidation or mixed oxidation-reduction reactions of organic molecules.

34. The electrocautery and filtration system as recited in claim 33 wherein said metallic gas catalyst and/or a catalyst substrate comprises a form of one or more honeycomb, foam, extrusion, plate, coating, granule, cylinder, sphere, bead, mesh, or similar to allow for adequate contact area with gas reactant.

35. The electrocautery and filtration system as recited in claim 25 comprising an internal activation means for activating said gas catalyst; said internal activation means comprising one or more of heating means, photon-generating means, electron-generating means, or electromagnetic radiation means.

36. The electrocautery and filtration system activation means as recited in claim 34 wherein said activation means is located within a substantially enclosed housing of a filter cartridge; said filter cartridge further comprising a transit means for connecting said cartridge to an external power source for powering of said activation means.

37. The electrocautery and filtration system as recited in claim 25 wherein said cautery instrument comprises a cauterizing system for cauterizing a surgical site associated with a patient, said surgical smoke treatment system comprising: a tubular body having a passageway for evacuating vapor from the surgical site; said tubular body comprising an extension for cauterizing at the surgical site; said extension being conductive and adapted to be coupled to a power source for energizing said extension; said tubular body having an inlet end having said extension and an outlet end coupled to a vacuum source adapted to create a predetermined pressure in said passageway in order to evacuate vapor from said surgical site through said tubular body prior to, during or after use of said surgical smoke treatment system at the surgical site, said vapor comprising at least one of smoke, cauterizing vapor, gas, liquid or debris; and wherein said passageway is defined by said tubular body and causes said vapor resulting from the cauterizing at the surgical site to be evacuated through said tubular body.

38. The electrocautery and filtration system as recited in claim 37 wherein said tubular body is conductive and creates a conductive path for current to flow from a power source to said extension.

39. The electrocautery and filtration system as recited in claim 37 wherein said extension is integral with said tubular body and both are conductive.

40. The electrocautery and filtration system as recited in claim 37 wherein said tubular body is defined by a wall having at least one predetermined dimension, said wall defining said passageway and said extension.

41. The electrocautery and filtration system as recited in claim 40 wherein said extension comprising a cross-sectional dimension that is smaller than said at least one predetermined dimension.

42. The electrocautery and filtration system as recited in claim 37 wherein an elongated portion of said extension comprises a first surface and a generally opposing second surface, said first surface defining a working surface having a generally curved or arcuate portion.

43. The electrocautery and filtration system as recited in claim 42 wherein said working surface has a radius of curvature substantially approximating a radius of curvature of said first surface.

44. The electrocautery and filtration system as recited in claim 37 wherein said extension comprises a working surface that is generally planar.

45. The electrocautery and filtration system as recited in claim 37 wherein said extension is detachably secured to said tubular body with a predetermined connection, said tubular body and said extension both being conductive to permit said extension to cauterize at said surgical site.

46. The electrocautery and filtration system as recited in claim 45 wherein said predetermined connection is a least one of a threaded, press-fit, bayonet, or socket connection.

47. The electrocautery and filtration system as recited in claim 37 wherein said passageway is substantially centrally located in said tubular body to define a substantially linear or non-serpentine conduit for evacuating said vapor.

48. The electrocautery and filtration system as recited in claim 37 wherein said tubular body comprises an interior wall that defines said passageway, at least a portion of said interior wall having a catalyst coating.

49. An electrocautery system for cauterizing a surgical site associated with a patient, said electrocautery system comprising: a tubular body having a passageway for evacuating vapor from the surgical site; said tubular body comprising an extension for cauterizing at the surgical site; said extension being conductive and adapted to be coupled to a power source for energizing said extension; said tubular body having an inlet end having said extension and an outlet end coupled to a vacuum source adapted to create a predetermined pressure in said passageway in order to evacuate vapor from said surgical site through said tubular body prior to, during or after use of said electrocautery system at the surgical site, said vapor comprising at least one of smoke, cauterizing vapor, gas, liquid or debris; wherein said passageway is defined by said tubular body and causes said vapor resulting from the cauterizing at the surgical site to be evacuated through said tubular body; and a surgical smoke treatment system for receiving evacuated vapor and for treating it, said surgical smoke treatment system comprising: a mechanical filter; an activated carbon surface for adsorption of primarily nonpolar gases; and a metallic gas catalyst for oxidation of primarily polar volatile gases; wherein said mechanical filter, activated carbon surface, and metallic gas catalyst define an integrated filtration module; said integrated filtration module further comprises a connector or connection means to attach to said electrocautery system and an output or output means to allow for expulsion of treated surgical vapor.

50. The electrocautery system as recited in claim 49 wherein said tubular body is conductive and creates a conductive path for current to flow from a power source to said extension.

51. The electrocautery system as recited in claim 49 wherein said extension is integral with said tubular body and both are conductive.

52. The electrocautery system as recited in claim 51 wherein said tubular body is defined by a wall having at least one predetermined dimension, said wall defining said passageway and said extension.

53. The electrocautery system as recited in claim 52 wherein said extension comprising a cross-sectional dimension that is smaller than said at least one predetermined dimension.

54. The electrocautery system as recited in claim 52 wherein an elongated portion of said extension comprises a first surface and a generally opposing second surface, said first surface defining a working surface having a generally curved or arcuate portion.

55. The electrocautery system as recited in claim 54 wherein said working surface has a radius of curvature substantially approximating a radius of curvature of first surface.

56. The electrocautery system as recited in claim 55 wherein said extension comprises a working surface that is generally planar.

57. The electrocautery system as recited in claim 50 wherein said extension is detachably secured to said tubular body with a predetermined connection, said tubular body and said extension both being conductive to permit said extension to cauterize at said surgical site.

58. The electrocautery system as recited in claim 57 wherein said predetermined connection is at least one of a threaded, press-fit, bayonet, or socket connection.

59. The electrocautery system as recited in claim 49 wherein said passageway is substantially centrally located in said tubular body to define a substantially linear or non-serpentine conduit for evacuating said vapor.

60. The electrocautery system as recited in claim 49 wherein said activated carbon surface is substantially nonpolar and a preferential adsorber of nonpolar gases; said activated carbon surface being activated by pyrolization, carbonization, or chemical activation, such that said activated carbon surface maintains nonpolar properties.

61. The electrocautery system as recited in claim 49 wherein said metallic gas catalyst comprises a metallic substrate for catalyzing oxidation reactions of polar gases, including oxidation of aldehydes into other molecules, including carbon dioxide.

62. The electrocautery system as recited in claim 49 wherein an evacuated surgical smoke stream traverses said activated carbon surface and thence traverses said metallic gas catalyst in a substantially serial manner.

63. The electrocautery system as recited in claim 49 wherein said activated carbon surface comprises a form of powdered, granular, fibrous, extruded, impregnated, coated, or woven carbon.

64. The electrocautery system as recited in claim 63 wherein said activated carbon surface comprises a drying component, including at least one desiccant such as silica gel, calcium carbonate, calcium sulfate, calcium chloride, magnesium sulfate, coordination polymer, Zeolite, or molecular sieve to reduce polar competition from water vapor or humidity; wherein a condensation means such as cooling coil, dehumidifier or thermoelectric plate can be utilized in addition to or in lieu of desiccant.

65. The electrocautery system as recited in claim 49 wherein said mechanical filter comprises an outer housing with at least one connection to a surgical smoke collection means; said surgical smoke collection means comprising at least one of a tubing system, vacuum system, electrocautery hand piece, funnel, gas separator, surgical port, surgical trocar, or surgical instrument.

66. The electrocautery system as recited in claim 49 wherein said metallic gas catalyst comprises a catalyst surface containing at least one of titanium, silver, palladium, platinum, manganese, iridium, rhodium, copper, zirconium, or other metallic element capable of catalyzing oxidation or mixed oxidation-reduction reactions of organic molecules.

67. The electrocautery system as recited in claim 61 wherein said metallic gas catalyst and/or said metallic substrate comprises a form of one or more honeycomb, foam, extrusion, plate, coating, granule, cylinder, sphere, bead, mesh, or similar to allow for adequate contact area with gas reactant.

68. The electrocautery system as recited in claim 49 comprising an internal activation means for activating said metallic gas catalyst; said internal activation means comprising one or more of heating means, photon-generating means, electron-generating means, or electromagnetic radiation means.

69. The electrocautery system as recited in claim 68 wherein said internal activation means is located within a substantially enclosed housing of a filter cartridge; said filter cartridge further comprising a transit means for connecting said filter cartridge to an external power source for powering of said internal activation means.

70. The electrocautery system as recited in claim 49 wherein said tubular body comprises an interior wall that defines said passageway, at least a portion of said interior wall having a catalyst coating.

71. A surgical smoke treatment system comprising: a mechanical filter; an activated carbon surface for adsorption of primarily nonpolar gases; and a metallic gas catalyst for oxidation of primarily polar volatile gases; wherein said filter, carbon surface, and catalyst comprise an integrated filtration module; said module further comprising a connection means to attach a surgical smoke collection means, and an output means to allow for expulsion of treated surgical smoke.

72. The surgical smoke treatment system as recited in claim 71 wherein said activated carbon is substantially nonpolar and a preferential absorber of nonpolar gases; said activated carbon being activated by pyrolization, carbonization, or chemical activation, such that said activated carbon maintains nonpolar properties.

73. The surgical smoke treatment system as recited in claim 71 wherein said catalyst comprises a metallic substrate for catalyzing oxidation reactions of polar gases, including oxidation of aldehydes into other molecules, including carbon dioxide.

74. The surgical smoke treatment system as recited in claim 71 wherein an evacuated surgical smoke stream traverses said activated carbon surface and thence traverses said metallic gas catalyst in a substantially serial manner.

75. The surgical smoke treatment system as recited in claim 71 wherein said carbon surface comprises a form of powdered, granular, fibrous, extruded, impregnated, coated, or woven carbon.

76. The surgical smoke treatment system as recited in claim 75 wherein said carbon surfaces cooperates with a drying component, including at least one desiccant such as silica gel, calcium carbonate, calcium sulfate, calcium chloride, magnesium sulfate, coordination polymer, Zeolite, or molecular sieve to reduce polar competition from water vapor or humidity; wherein a condensation means such as cooling coil, dehumidifier or thermoelectric plate can be utilized in addition to or in lieu of desiccant.

77. The surgical smoke treatment system as recited in claim 71 wherein said filter comprises an outer housing with at least one connection to a surgical smoke collection means; said collection means comprising at least one of a tubing system, vacuum system, electrocautery hand piece, funnel, gas separator, surgical port, surgical trochar, or surgical instrument.

78. The surgical smoke treatment system as recited in claim 71 wherein said metallic gas catalyst comprises a catalyst surface containing at least one of titanium, silver, palladium, platinum, manganese, iridium, rhodium, copper, zirconium, or other metallic element capable of catalyzing oxidation or mixed oxidation-reduction reactions of organic molecules.

79. The surgical smoke treatment system as recited in claim 71 wherein said metallic gas catalyst and/or a catalyst substrate comprises a form of one or more honeycomb, foam, extrusion, plate, coating, granule, cylinder, sphere, bead, mesh, or similar to allow for adequate contact area with gas reactant.

80. The surgical smoke treatment system as recited in claim 71 comprising an internal activation means for activating said gas catalyst; said internal activation means comprising one or more of heating means, photon-generating means, electron-generating means, or electromagnetic radiation means.

81. The surgical smoke treatment system as recited in claim 80 wherein said activation means are located within a substantially enclosed housing of a filter cartridge; said cartridge further comprising a transit means for connecting said cartridge to an external power source for powering of said activation means.

82. A method for staged treatment of nonpolar and polar gases from surgical smoke comprising evacuation of surgical smoke from a surgical environment utilizing a collection means, directing surgical smoke to an enclosed filtration area, drying the surgical smoke via desiccant or condensation, absorption via activated carbon, and oxidation and/or reduction of polar gases via metallic catalyst.

Description

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

[0103] FIG. 1 is a perspective view of one embodiment of a system and method for treating a contaminated air stream;

[0104] FIG. 2 is a view taken along the line 2-2 in FIG. 1;

[0105] FIG. 3 is a view of polar and nonpolar gases, decontamination or filtration, preceded by mechanical filtration as shown in FIG. 1;

[0106] FIG. 4 is a view illustrating the catalytic reaction, similar to FIG. 3, that occurs in the catalytic area of the system;

[0107] FIG. 5 is another view, similar to FIG. 1, showing another embodiment of the invention;

[0108] FIG. 6 is a view illustrating the filtration system integrated with an air handler, either internally in the air handler or in a nozzle arm or end of the air handler; and

[0109] FIG. 7 is a view illustrating the filtration system used in combination with a surgical instrument, such as a cautery instrument.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0110] Referring now to FIGS. 1-7, a surgical smoke treatment system 10 and method are shown. It should be appreciated that the surgical smoke treatment system 10 is particularly adapted to treat polar and nonpolar gases as well as perform mechanical filtration of a contaminated air stream (AS). In one illustrative embodiment, the surgical smoke treatment system 10 is particularly adapted for use in creating a multi-stage treatment system based upon gas polarity to ensure complete treatment of dangerous vapors and compounds arising from a surgical plume, which can occur during a surgical procedure. The multi-stage treatment process and system provides for mechanical filtration of particulate matter, followed by optional gas desiccation, activated carbon adsorption of nonpolar gases, followed by a metallic catalytic oxidation of polar gases. In one preferred embodiment, these three elements are placed in series, co-housed in a removable cartridge for incorporation into a vacuum-powered smoke evacuation device, like the air handler 40 shown in FIG. 6 and which will be described in detail later herein. It should be understood that if the catalyst requires light or heat input, then these are provided within the cartridge with heat or light elements powered by the same or a separate device, such as the vacuum-powered smoke evacuation device like is shown and described herein.

[0111] Referring now to FIGS. 1-7, further details of an illustrative embodiment are shown. The surgical smoke treatment system 10 comprises a housing 12 that is generally cylindrical in the illustration being described, but it should be understood that it could be any desired shape that provides the various filtration areas and directs air flow. In the illustration being described, the housing 12 has a plurality of walls 12a, 12b and 12c that define separate areas 14a, 14b, 14c and 14d, all of which will be described in detail later herein. The housing 12 itself can be made of any suitable material such as a plastic, a metallic or a polymer material.

[0112] The housing 12 comprises at least one or a plurality of inlets 16 coupled to or integral with a first end wall 12d and at least one or a plurality of outlets 18 coupled to and integral with a second end wall 12e. The surgical smoke treatment system 10 may be coupled to, used with or integrated with an instrument like an electrocautery device 50, as shown and described in FIG. 7, or may be coupled to a vacuum powered smoke evacuation unit or air handler 40 (FIG. 6). In this regard, it should be understood that the surgical smoke treatment system 10 may be incorporated in the air handler 40. For example, FIG. 6 illustrates an air handler 40 owned and provided by the Assignee of the present application which is the subject of U.S. Pat. Nos. 10,702,435 and 11,185,457 and U.S. Publication No. 2022-0031545, all of which are expressly incorporated herein by reference and made a part hereof. It should be understood that the surgical smoke treatment system 10 may be incorporated directly inside the air handler 40 or in a nozzle arm 42 as illustrated in FIG. 6 or a nozzle end 44 of the air handler 40 as shown in FIG. 6.

[0113] The filtration areas 14a-14d and decontamination will now be described. Note in FIG. 1, that the area 14a is dedicated to provide an area for smoke intake from the plurality of inlets 16. It should be understood that contaminated air flows into the surgical smoke treatment system 10 in the direction of arrow A and that a vacuum source, such as the vacuum powered evacuation unit or air handler 40 (FIG. 6), provides a negative pressure on the outlets 18 to provide a vacuum through the surgical smoke treatment system 10. The contaminated air stream AS enters into the area 14a and passes through the apertures 12a1 of the wall 12a and enters into the area 14b for mechanical filtration that houses a mechanical filter 24. In the illustration being described, the mechanical filtration typically comprises an ultra-low penetration or high-efficiency air filter for particulate treatment, such as a HEPA filter or the like, for particulate treatment. The mechanical filter 24 may be mounted to the side of the housing 12 via sliding from a slot (not shown) in the side.

[0114] The air stream then passes through the apertures 12b1 of wall 12b where it enters the area 14c. This area 14c comprises a plurality of activated carbon granules 34 that are adapted to treat the vapor or plume of smoke as it passes by and is treated by the plurality of activated carbon granules 34 to treat the nonpolar vapor contaminants. In an illustrative embodiment, the areas 14a-14c may comprise an optional desiccant or silica gel 26 (FIG. 5) for adsorption of moisture and fluids. In the illustration, the carbon granules 34 are deposited in the area and interrupt the air stream as it passes through the area 14c. The carbon granules 34 can be placed in a mesh sack, mesh enclosure with a rigid frame, or in another external container (not shown) which allows for air to pass through while containing the carbon granules 34.

[0115] In the example, the activated carbon granules 34 are substantially nonpolar and a preferential adsorber of nonpolar gases and are activated by pyrolization, carbonization, or chemical activation, such that the activated carbon granules 34 maintains nonpolar properties. After the treatment by the mechanical filtration of nonpolar gases in the area 14b and nonpolar gases in area 14c, the air stream passes through the apertures 12c1 of wall 12c and into the area 14d where the polar gas portion of the vapor or air stream AS is treated. In this regard, while most toxic gases arising from surgical smoke, vapor or plumes are nonpolar, certain gases, particularly oxygenated gases, such as ethers, aldehydes, ketones and esters are polar. Formaldehyde in particular is a highly toxic polar gas. These polar pollutants have only limited adsorption by activated carbon in the area 14c.

[0116] The area 14d comprises metallic catalyst surfaces 28a for the metallic gas catalyst 28 as illustrated in FIG. 2. In one illustrative embodiment, the metallic gas catalyst 28 comprises a catalyst surface 28a (FIG. 4) containing at least one of titanium, silver, palladium, platinum, manganese, iridium, rhodium, copper, zirconium, or other metallic element capable of catalyzing oxidation or mixed oxidation-reduction reactions of organic molecules. Moreover, the metallic gas catalyst 28 comprises a form of one or more honeycomb, foam, extrusion, plate, coating, granule, cylinder, sphere, bead, mesh, or similar to allow for adequate contact area with gas reactant. The metallic catalyst 28 is represented in FIGS. 1-5 as bars or circles, but it should be understood that they could comprise any suitable shape. The metallic catalyst 28 is affixed either on the walls of the housing 12, on a foam, mesh, granule, airfoil, blade, or on the surface of a mechanical filter 24. The features of the catalytic oxidation are shown schematically in FIG. 2 and in more detail in FIGS. 3 and 4. The nonpolar filtration area 14c has little or limited effect on the polar gases. This is in part due to competition with polar water vapor as a significant proportion of surgical smoke because a significant portion of the surgical smoke comprises water vapor or steam. Certain catalytic reactions are effective at the oxidation and inactivation of polar gases. Catalysts can catalyze at room temperature or under heat condition or applied energy (i.e., electronic or photonic energy) as mentioned earlier. Again, these catalysts are typically metal based, such as titanium, silver, palladium, platinum, zirconium, or manganese. Having the metallic catalyst surface 28a for the metallic gas catalyst 28 in the area 14d enables the surgical smoke treatment system 10 to effectively treat multiple types of polar contamination in the vapor or smoke plume.

[0117] The catalysts are placed in the area and mounted on an inside wall 12a of the housing 12 using conventional means, such as an adhesive hot weld. As mentioned earlier, the carbon granules 34 can be placed in a mesh sack, mesh enclosure with a rigid frame, or in another external container (not shown) which allows for air to pass through while containing the carbon granules 34.

[0118] During operation, mechanical filtration occurs first, followed by nonpolar gas filtration, and then followed by polar vapor or gas filtration. The inventor has found this specific order of filtration and decontamination to be important because mechanical filtration must occur first, or the whole system 10 may become contaminated with dust. Carbon filtration should occur second, removing most (nonpolar) volatile organic compounds (VOCs) and allowing for less competition for the catalyst 28. By providing all of these filtration approaches in one convenient housing 12, a large majority of the contaminants in the contaminated air stream AS can be treated.

[0119] Advantageously, in the illustration being described, the housing 12 is generally cylindrical and elongated as shown in FIGS. 1 and 2. The length and diameter dimensions may be variable, but in one illustrative embodiment they are about 12″×12″×6″. The surgical smoke treatment system 10 can be a stand-alone system used, for example, with a cautery instrument of the type described later herein relative to FIG. 7, or alternatively, it could be removably situated in or integrated with a decontamination system, such as in the nozzle end of the air handler 40 (FIG. 6) or in the main housing of an air handler 40 (FIG. 6). These features will be described later herein relative to FIGS. 6 and 7.

[0120] Referring now to FIGS. 3-5, mechanical filtration and treatment of the polar and nonpolar gases within the surgical smoke plume or vapor plume will now be described. As illustrated in FIG. 3, a vapor or plume SVP (FIG. 3) comprises a mixture of both polar and nonpolar toxic gases. The polar molecules are labeled 30, and the nonpolar molecules are labeled 32 for ease of illustration. The activated carbon granules is labeled 34 in FIG. 3, and the activated carbon granules 34 selectively adsorbs the nonpolar gas molecules 32.

[0121] As the air stream passes through the housing 12, the remaining polar molecules 30 (FIG. 3), pass from the area 14c and through the apertures 12c1 of the wall 12c and into area 14d. Polar molecules 30 transit past the metallic gas catalyst 28 and are oxidized at the metallic catalyst surface 28a as illustrated in FIG. 3. As mentioned earlier, the catalytic reaction can be enhanced or improved by applying an external heat or energy source 22 (FIG. 1) to facilitate or improve the catalytic reaction. Note that if the catalytic oxidation process requires heat or light, then the housing 12 may comprise the external heat or energy source 22 that is powered by a power source 20a of the vacuum source 20 as illustrated in FIG. 1.

[0122] Referring now to FIG. 4, details of the metallic catalyst surface 28a and the catalytic reaction are shown. For ease of illustration, it is presumed that the smoke vapor plume (SVP) comprises polar contamination. In the illustration being described, the catalyst comprises the metallic gas catalyst 28 described earlier herein having the metallic catalyst surface 28a. As the polar gas counters the metallic catalyst surface 28a, a catalytic reaction occurs which eliminates the polar gases in the vapor or gas stream. The toxic vapors or polar gases are consequently removed from the air stream AS. The metallic catalyst surface 28a needs to be exposed to the totality of the air stream AS.

[0123] In one illustrative embodiment, it is preferred to first remove the particulate materials via mechanical filtration with the mechanical filter 24 from the air stream at area 14a in FIG. 5 and then to treat the air stream and remove excess moisture or water. This can occur in any of the areas 14a-14c using an optional desiccant or silica gel 26 (FIGS. 1 and 5). Thereafter, the nonpolar gases are treated and removed (at area 14c′) and then subsequently, the polar gases are treated by the catalytic reaction in area 14d′. This is the order and sequence preferred to remove the H.sub.2O before the catalytic removal of polar gases because the catalytic conversion is more efficient. It should be understood that the water or moisture must be removed first because the polar volatile organic compound (VOC) will dissolve in water making catalytic removal more difficult. As mentioned earlier, heat or light may be provided by the external heat or energy source 22 (FIG. 1) to improve or facilitate the catalytic process.

[0124] Advantageously, the surgical smoke treatment system 10 and housing 12 are provided and co-housed in a removeable cartridge for incorporation into a vacuum-powered smoke evacuation device. For example, the Assignee of the present application contemplates that the surgical smoke treatment system 10 may be situated in an air handler 40 (FIG. 6) of the type currently marketed and distributed by the Assignee of the present application. In this regard, notice in FIG. 6, the air handler 40 is provided and has a nozzle arm 42 and a nozzle end 44 in which the surgical smoke treatment system 10 and the housing 12 may be integrated or situated. The air handler 40 may also comprise additional internal mechanical filtration. It is contemplated that the surgical smoke treatment system 10 could be situated in the air stream therein in order to treat the air stream before it exits the outlet 46 (FIG. 6). Advantageously, the housing 12 may be situated in the nozzle end 44 of the air handler 40 which, in turn, may be maneuvered in close proximity to a patient or operating area or other area where it is important to treat a decontaminated air stream in the manner described in the cited references. This unit can be used alone or in combination with the unit shown in FIG. 6 and which is the subject of U.S. Pat. Nos. 10,702,435 and 11,185,457 and U.S. Publication No. 2022-0031545, all of which are expressly incorporated herein by reference and made a part hereof. Several suitable unit(s) include the ILLUVIA®, ILLUVIA® SENSE, AEROCURE® or GERMZONE®, all of which are available from Aerobiotix, LLC located in Miamisburg, Ohio, and are contemplated to be used in combination with the surgical smoke treatment system 10 if desired.

[0125] Referring now to FIG. 5, another embodiment and schematic demonstrating the surgical smoke treatment system 10 is shown. In these embodiments, the same or similar parts are identified with the same part numbers, except that one prime mark (“′”) has been added to the part numbers for the different embodiment of FIG. 5. As with the prior embodiments, the contaminated surgical plume or vapor enters in the direction of arrow A and then into the area 14a′. A mechanical filter 24′ is situated in area 14a′ and captures airborne solids and particulates after the contaminated air stream AS is subject to drying using the optional desiccant or silica gel 26′. For ease of understanding, FIG. 5 illustrates (in the bottom portion of the figure) each type of contaminant gas that irradiates from the area 14a′-14d′ for ease of understanding. For example, area 14a′ filters out solids and particulates and this is shown in FIG. 5. Likewise, the optional desiccant or silica gel 26′ filters out or irradiates excess water molecules in a manner that is conventionally known. In one illustrative embodiment, the optional desiccant or silica gel 26′ may be a silica gel that performs the water adsorbtion. Thereafter, the nonpolar gases are filtered in area 14c′ and then the surfaces 28a′ for the metallic gas catalyst 28′ in area 14d′ treats the polar gas or vapor with the metallic gas catalyst 28′. The substantially nonpolar activated carbon granules 34′ are adapted to treat the contaminated air stream AS and remove nonpolar gases and vapors therefrom. As the air stream AS enters through the area 14d′, the metallic gas catalyst 28′ inactivates the toxic polar gases in the air stream AS. Ultimately, the treated and decontaminated vapor or smoke is expelled via the outlets 18′ and to the vacuum source 20′ (FIG. 1).

[0126] The surgical smoke treatment system 10′ and process described herein is effective at treating multiple types of contamination in a vapor or smoke stream. This is particularly useful in a surgical or hospital environment.

[0127] Referring now to FIG. 7, another illustrative adaptation or embodiment of the surgical smoke treatment system 10″ is shown in use and combination with an electrocautery device 50″. In this embodiment, the same or similar parts are identified with the same part numbers, except that a double prime mark (“″”) has been added to the part numbers for the embodiment of FIG. 7. The Inventor contemplates that the surgical smoke treatment system 10″ can be used in combination with a surgical instrument 50″. One type of surgical instrument that the surgical smoke treatment system 10″ could be used in combination with is illustrated in FIG. 7. The inventors contemplate that the electrocautery device 50″ could be used during a surgical procedure in a vacuum source, such as the air handler 40″, and may comprise an electronic and power supply 52″ and foot switch 54″ for operating the electrocautery device 50″ in the manner described earlier herein in the before-mentioned U.S. patents and U.S. patent applications. The surgical smoke treatment system 10″ is either integrated with or coupled to the vacuum source 20″. As mentioned earlier, the surgical smoke treatment system 10″ may be situated in the air handler 40″ or in, for example, a nozzle arm 42″ or nozzle end 44″ of the air handler 40″. Advantageously, the combination of using a surgical instrument with the surgical smoke treatment system 10″ is particularly advantageous in surgical procedures where plumes of smoke are generated by the electrocautery device 50″. As mentioned earlier, the plumes of smoke can have particulate contamination, polar contamination, and nonpolar contamination, all of which are treated by the surgical smoke treatment system 10″ before the air stream is exhausted into the local environment.

[0128] Returning to FIGS. 1-5, the multi-stage treatment process of gas desiccation, activated carbon adsorbtion of nonpolar gases followed by a metallic catalytic oxidation of polar gases occurs. In the preferred embodiment, these elements are placed in series, as illustrated in FIG. 1 and housed in a removable cartridge container or housing 12 that is generally cylindrical and made of a plastic, metallic or polymer material and adapted to house the mechanical filter and, optionally, the optional desiccant or silica gel 26 in any areas 14a-14c. The contaminated air passes in the direction of arrow A into the plurality of inlets 16 as a vacuum or negative pressure is being applied at the outlets 18. Contaminated air flow in the direction of arrow A enters the area 14a and passes past the wall 12a through the apertures 12a1 into the area 14b. In area 14b, as explained earlier herein, mechanical filtration occurs and the contaminated air continues to pass through the wall 12b and through the apertures 12b1, whereupon it enters area 14c where carbon granules 34 (with or without optional desiccant) treats the air stream with or eliminates any nonpolar vapor or gases before it passes through the wall 12c and through the apertures 12c1 of wall 12c and into the area 14d. As mentioned earlier, in area 14d, catalytic oxidation occurs providing the metallic gas catalyst 28 that will cause a catalytic reaction and to effectively eliminate any polar gases whereupon they are oxidized and inactivated once they are exposed to the metallic catalyst surface 28a in the area 14d. It should be understood that such catalysts can catalyze at room temperature, under heat conditions or under applied energy, such as electronic or photonic energy conditions. The typical catalysts are metal-based, such as titanium, silver, palladium, platinum, zirconium, or manganese.

[0129] Returning to FIG. 1 and as mentioned earlier, note that if the catalytic oxidation process requires heat or light, then the housing 12 may comprise the external heat or energy source 22 (FIG. 1) that is powered by a power source 20a of the vacuum source 20 as illustrated.

ADDITIONAL COMMENTS AND CONSIDERATIONS

[0130] 1. It should be understood that the activated carbon granules 34 are substantially nonpolar and a preferential adsorber of nonpolar gases. The activated carbon granules 34 may be activated by pyrolization, carbonization, or chemical activation, such that the activated carbon maintains nonpolar properties. [0131] 2. As mentioned earlier, the metallic gas catalyst 28 in the area 14d provides the metallic catalyst surface 28a for catalyzing oxidation reactions of polar gases, including oxidation of aldehydes into other molecules, including carbon dioxide.

[0132] During operation an evacuated surgical smoke stream traverses the metallic catalyst surface 28a and traverses the metallic gas catalyst 28 in a substantially serial manner. The inventor has found the specific order of filtration and decontamination to be important because mechanical filtration must occur first, or the whole system 10 becomes contaminated with dust. Carbon filtration should occur second, removing most (nonpolar) VOCs and allowing for less competition for the catalyst.

[0133] In one illustrative embodiment, the carbon surface comprises a form of powdered, granular, fibrous, extruded, impregnated, coated, or woven carbon. [0134] 3. In one illustrative embodiment, a drying component, such as the optional desiccant or silica gel 26, may comprise calcium carbonate, calcium sulfate, calcium chloride, magnesium sulfate, coordination polymer, Zeolite, or molecular sieve to reduce polar competition from water vapor or humidity. [0135] 4. Alternatively, a condensation means such as a cooling coil, dehumidifier or thermoelectric plate can be utilized in addition to or in lieu of the optional desiccant or silica gel 26. [0136] 5. The surgical smoke treatment system 10 comprises the outer housing 12 and the inlets 16 and outlets 18 for connection to a smoke collection means or device, such as the air handling unit 40 (FIG. 6). The collection means or device may comprise at least one of a tubing system, vacuum system, electrocautery handpiece, funnel, gas separator, surgical port, surgical trocar, or surgical instrument. [0137] 6. In one illustrative embodiment, the metallic gas catalyst 28 comprises a catalyst surface 28a (FIG. 4) containing at least one of titanium, silver, palladium, platinum, manganese, iridium, rhodium, copper, zirconium, or other metallic element capable of catalyzing oxidation or mixed oxidation-reduction reactions of organic molecules. Moreover, the metallic gas catalyst 28 comprises a form of one or more honeycomb, foam, extrusion, plate, coating, granule, cylinder, sphere, bead, mesh, or similar to allow for adequate contact area with gas reactant.

[0138] Advantageously, the surgical smoke treatment system 10 provides a process and method for multiple stages for activating the gas catalyst by an internal activation mean comprising one or more of a heating means, photon-generating means, electron-generating means, or electromagnetic radiation means.

[0139] Advantageously, another embodiment of this invention, including all embodiments shown and described herein, could be used alone or together and/or in combination with one or more of the features covered by one or more of the claims set forth herein, including but not limited to one or more of the features or steps mentioned in the Summary of the Invention and the claims.

[0140] While the system, apparatus and method herein described constitute preferred embodiments of this invention, it is to be understood that the invention is not limited to this precise system, apparatus and method, and that changes may be made therein without departing from the scope of the invention which is defined in the appended claims.