IL299507A - Lighting device for handheld surgical instrument with smoke evacuation system - Google Patents

Description

92477014v.

LIGHTING DEVICE FOR HANDHELD SURGICAL INSTRUMENT WITH SMOKE EVACUATION SYSTEM CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to and the benefit of U.S. Non-provisional Application No. 16/918,449, filed July 1, 2020, and is a Continuation-In-Part of U.S.

Application Serial No. 16/519,744 filed July 23, 2019, the disclosures of which are herein incorporated by reference in their entireties.

BACKGROUND OF THE INVENTION 1. Field of the Invention The subject invention is directed to surgical instrumentation, and more particularly, to a battery powered lighting device used with a handheld electrosurgical instrument, which includes a smoke evacuation system. 2. Description of Related Art In medical practice, lighting devices are used to direct light at a specific area being operated on or examined. For example, lighting devices can be used in conjunction with a handheld electrosurgical device, such as a BOVIE® pencil, which is typically used to incise tissue during a surgical procedure.

Some instruments known in the art include an integral light source, but these devices are generally expensive and relatively bulky. Cordless and corded lighting devices for surgical tools are also known in the art, but these can also add bulk, preventing a user from manipulating the tool with precision or in confined spaces.

Other instruments known in the art include an integral smoke evacuation conduit, but these devices are generally expensive and provide usability challenges due to added bulk that impacts ergonomics.

Additionally, many lighting devices, especially corded devices and overhead lights, require constant repositioning, are assistant-dependent to hold or re-position, and - 2 - 92477014v. can be disruptive to a surgical field. Furthermore, corded lighting devices, as well as light sources that are integrated into a tool can become hot, burning the user and/or patient, and possibly even causing a fire.

Headlights can be used as an alternative to a lighting device during a surgical procedure. However, similar to lighting devices, headlights are bulky, commonly require cables to connect to a power source, require constant readjustment, and can pose a potential safety hazard. Moreover, being worn on the head of the surgeon, they are at a distance from the surgical field, decreasing their effectiveness, and they can cause fatigue and strain if worn for an extended period of time.

It is known that when handheld lighting devices, overhead lights and/or headlamps are employed during a surgical procedure, the hands/tools of the surgeon can block the light and cast a shadow on the surgical site, which is undesirable. Those shadows require the user to reposition the lighting sources regularly, and can even require the surgeon to move their head to try to angle the headlamp towards the surgical site differently.

A particularly useful battery powered lighting device designed for attachment to a handheld electrosurgical device, and in particular, for use with a BOVIE® pencil, is disclosed in commonly assigned U.S. Patent No. 9,851,060, the disclosure of which is herein incorporated by reference in its entirety. This device overcomes the deficiencies of the prior art lighting devices described above.

The use of a handheld electrosurgical device, such as a BOVIE® pen to incise tissue, typically creates surgical smoke when energy is imparted to tissue cells during surgery. The heat from the energy vaporizes the intracellular fluid, which increases the pressure inside the cell and eventually causes the cell membrane to burst. When this happens, a plume of smoke containing mostly water vapor is released into the operating 25 - 3 - 92477014v. room. At the same time, the heat chars the protein and other organic matter within the cell, releasing contaminants, such as carbonized cell fragments and gaseous hydrocarbons.

These small particles and gases are potentially hazardous if inhaled. If they are not evacuated from the surgical site nearest to the location where the surgical smoke is created, they can become airborne and inhaled. This has led to the development and use of smoke evacuation systems during surgical procedures. A smoke evacuator is basically a vacuum pump with one or more filters designed to remove surgical smoke and aerosol from an operative site and filter out contaminants. In addition, they may return filtered air to the operating room.

Given the increasing need and desire for surgical evacuation systems in operating rooms, the inventors have determined that it would be advantageous to incorporate such a system directly into a battery powered lighting device used with a handheld electrosurgical instrument. The subject disclosure presents several new and useful embodiments of a battery powered lighting device for use with an electrosurgical instrument, such as a BOVIE® pencil, which incorporates a smoke evacuation system. - 4 - 92477014v.

SUMMARY OF THE DISCLOSURE The subject invention is directed to new and useful lighting devices for installation on a handheld surgical instrument, and preferably, for releasable attachment to a handheld electrosurgical instrument. More particularly, the subject invention is directed to a lighting device for attachment to a handheld electrosurgical instrument that includes an elongated housing having opposed proximal and distal end portions and defining an interior chamber containing a battery powered light assembly for illuminating a surgical site, wherein the housing has at least one smoke evacuation passage associated therewith that extends from an inlet located adjacent, near or proximate to the distal end portion of the housing to an outlet located adjacent, near or proximate to the proximal end portion of the housing for removing smoke generated at the surgical site.

In one embodiment of the lighting device, the smoke evacuation passage is located within the housing of the lighting device, separated from the interior chamber by an interior wall of the housing. In another embodiment of the lighting device, the smoke evacuation passage is located outside of the housing of the lighting device, separated from the interior chamber by an exterior wall of the housing.

A connective fitting is associated with the outlet of the smoke evacuation passage for connecting the smoke evacuation passage with a smoke evacuation tube that communicates with a source of suction. Preferably, a filter element is located within at least one of the smoke evacuation passage or located in the smoke evacuation tube. It is envisioned that the smoke evacuation passage could have any cross-sectional configuration, including, for example, a rectangular cross-sectional configuration, a square cross-sectional configuration, an oval cross-sectional configuration or a circular cross-sectional configuration. 25 - 5 - 92477014v.

In yet another embodiment of the lighting device, the associated smoke evacuation passage extends through a nozzle assembly that is detachably connected to an exterior side wall of the housing of the lighting device. In such an embodiment, the nozzle assembly may be detachably connected to an exterior side wall of the housing by way of a snapping connection mechanism, including an engagement flange on the exterior wall of the housing and a pair of deflectable engagement tangs on the nozzle assembly, or vice versa. Alternatively, the associated nozzle assembly may be detachably connected to an exterior side wall of the housing by way of a sliding tongue and groove connection mechanism, including a groove portion on the exterior wall of the housing and a tongue portion on the nozzle assembly, or vice versa. In yet another embodiment, the nozzle assembly may be detachably connected to an exterior side wall of the housing by way of an adhesive strip.

Preferably, the associated nozzle assembly includes an inlet nozzle, a smoke evacuation tube extending proximally from the inlet nozzle and a barbed connective fitting at a proximal end of the smoke evacuation tube. The inlet nozzle includes at least one inlet orifice adapted and configured to maximize smoke evacuation coverage and performance, because the inlet nozzle can be positioned close to cautery site where the smoke is created. In this regard, it is also envisioned that the inlet nozzle could be configured to telescope or otherwise extend distally so that it may be positioned is in close proximity to source of smoke creation.

A filter element can be disclosed in at least one of the inlet nozzle, barbed connective fitting, or the smoke evacuation tube. A coupling is operatively associated with the smoke evacuation tube for securing the tube to a surgical instrument.

Preferably, the battery powered lighting assembly includes a printed circuit board that includes at least one LED lighting component, at least one battery cell, and a 25 - 6 - 92477014v. switching mechanism. An actuation button is associated with the housing for actuating the switching mechanism. In an embodiment of the invention, at least one rotatable fans is located within the smoke evacuation passage, and it is operatively connected to the printed circuit board of the battery powered light assembly. The fan may be configured to direct air flow from the smoke evacuation passage or to draw air flow into the smoke evacuation passage.

In an embodiment of the subject invention, the housing of the lighting device includes a clamping mechanism for selectively attaching the lighting device to the surgical instrument. The clamping mechanism include a generally U-shaped clamp body having a pair of opposed parallel clamping arms, and wherein an adjustable holding screw is associated with one clamping arm and an interior surface of the other clamping arm has a compliant material plate thereon. The clamping mechanism is pivotably connected to the housing about a pivot axis that extends perpendicular to a longitudinal axis of the elongated housing.

In another embodiment of the subject invention, the interior chamber of the housing has conical bore for receiving a distal end portion of the surgical instrument.

In this embodiment, the battery powered lighting assembly is adapted and configured to activate or otherwise turn on when the distal end portion of the surgical instrument is received within the conical bore. Conversely, the battery powered lighting assembly is adapted and configured to deactivate or otherwise turn off when the distal end portion of the surgical instrument is removed from the conical bore.

The subject invention is also directed to a kit for performing a surgical procedure that includes a packaging enclosure, a battery powered lighting device contained within the packaging enclosure configured for attachment to a handheld surgical instrument, and a smoke evacuation nozzle assembly contained within the 25 - 7 - 92477014v. packaging enclosure configured for attachment to the lighting device. The kit may further include a handheld surgical instrument within the packaging enclosure for performing a surgical procedure.

Preferably, the smoke evacuation nozzle assembly includes an inlet nozzle, a smoke evacuation tube extending proximally from the inlet nozzle and a barbed connective fitting at a proximal end of the smoke evacuation tube, and a clamping mechanism is associated with the tube for selectively attaching the tube to a surgical instrument.

The subject invention is also directed to a method for performing a surgical procedure including the steps of attaching a lighting device to a surgical instrument wherein the lighting device has a smoke evacuation passage associated therewith, either integrally or connectively, and connecting an outlet of the smoke evacuation passage to a source of suction, such as, for example, a smoke evacuator or suction device. The method may further include the steps of using the surgical instrument to perform electrocautery, and activating the source of suction to perform smoke evacuation through an inlet of the smoke evacuation passage.

Preferably, the step of attaching the lighting device to the surgical instrument includes automatically activating a light source of the lighting device, and the method further includes the step of removing the lighting device from the surgical instrument and thereby automatically deactivating the light source. Preferably, the step of connecting an outlet of the smoke evacuation passage to a source of suction includes attaching a smoke evacuation tube to a first side of the lighting device, and the method further includes the steps of detaching the smoke evacuation tube from the first side of the lighting device and reattaching the smoke evacuation tube to a second side of the lighting device. 25 - 8 - 92477014v.

The subject invention is also directed to a lighting device for attachment to a handheld electrosurgical instrument that includes an elongated housing having opposed proximal and distal end portions and defining an interior chamber containing a battery powered lighting assembly for illuminating a surgical site, wherein the housing has a smoke evacuation tube associated therewith for removing smoke generated at the surgical site, and the smoke evacuation tube is adapted and configured to extend and retract relative to the distal end portion of the housing to accommodate end effectors of differing lengths associated with the handheld electrosurgical instrument, such as, for example, cautery blades, loops or needles.

The smoke evacuation tube includes a proximal body portion for communicating with a source of suction and a distal body portion having a distal suction inlet for receiving smoke generated at the surgical site and a proximal connective barb for providing a sealed connection with a distal end of the proximal body portion, and more particularly for connecting to tubing associated with a source of suction and to provide a good seal.

In one embodiment of the subject invention, the distal body portion of the smoke evacuation tube includes an elongated track that is adapted and configured to slidingly cooperate with a rail on an exterior wall of the housing. Preferably, the housing has rails on opposed side walls thereof for cooperating with the elongated track of the distal body portion of the smoke evacuation tube. Alternatively, the housing has elongated tracks on opposed side walls thereof for cooperating with a rail of the distal body portion of the smoke evacuation tube.

Alternatively, the distal body portion of the smoke evacuation tube is adapted and configured to be selectively attached to the housing at a location along the length thereof by an adhesive patch, band, or strap. Alternatively, a hook-and-loop, cable tie, 25 - 9 - 92477014v. string, or other attachment mechanism could be used. In another embodiment of the subject invention, the distal body portion of the smoke evacuation tube includes an elongated ratchet rack that is adapted and configured to cooperate with a deflectable pawl associated with an exterior wall of the housing. Preferably, the housing has deflectable pawls on opposed side walls thereof for cooperating with the elongated ratchet rack of the distal body portion of the smoke evacuation tube.

In yet another embodiment of the subject invention, the distal body portion of the smoke evacuation tube includes an elongated gear rack that is adapted and configured to cooperate with at least one pinion gear associated with an exterior wall of the housing. Preferably, the housing has pinion gears on opposed side walls thereof for cooperating with the elongated gear rack of the distal body portion of the smoke evacuation tube. Alternatively, at least one pinion gear is associated with the distal body portion of the smoke evacuation tube that is adapted and configured to cooperate with an elongated gear rack on the housing.

In another embodiment of the subject invention, the distal body portion of the smoke evacuation tube includes a mounting flange for engaging a rail on an exterior wall of the housing, and the distal body portion includes a telescoping inner tube that is extendable and retractable relative to the distal body portion through axial rotation by way of a helical thread to provide the distal suction inlet. Preferably, the housing has rails on opposed side walls thereof for engaging the mounting flange of the distal body portion of the smoke evacuation tube.

In still another embodiment of the subject invention, the distal body portion of the smoke evacuation tube includes a mounting flange for engaging a rail on an exterior wall of the housing, and the distal body portion includes a plurality of graduated telescoping inner tube members that are relatively extendable and retractable with 25 - 10 - 92477014v. respect to the distal body portion. Preferably, the housing has rails on opposed side walls thereof for engaging the mounting flange of the distal body portion of the smoke evacuation tube.

The subject invention is also directed to a lighting device for attachment to a handheld electrosurgical instrument that includes an elongated housing having opposed proximal and distal end portions and defining an interior chamber containing a battery powered lighting assembly for illuminating a surgical site, the interior chamber defining a conical bore extending from the proximal end portion of the housing for receiving a distal end portion of the electrosurgical instrument, the housing having a smoke evacuation tube associated therewith for removing smoke generated at the surgical site. Preferably, the smoke evacuation tube is configured to extend and retract relative to the distal end portion of the housing, and the lighting assembly is activated when the distal end portion of the electrosurgical instrument is received in the conical bore and deactivated when the distal end portion of the electrosurgical instrument is removed from the conical bore. It is envisioned and well within the scope of the subject disclosure that the smoke evacuation tube assembly could include at least one filter element for filtering particles and debris drawn into the smoke evacuation tube from the surgical site.

The subject invention is also directed to a method that includes the steps of attaching a smoke evacuation tube to a handheld electrosurgical instrument for removing smoke generated at a surgical site, and then adjusting the smoke evacuation tube relative to a distal end of the electrosurgical instrument to accommodate end effectors of differing length installed in the electrosurgical instrument. The method further includes the step of attaching a lighting device to a distal end portion of the electrosurgical instrument for illuminating the surgical site, wherein the step of 25 - 11 - 92477014v. attaching the smoke evacuation tube involves attaching the smoke evacuation tube to the lighting device. The step of adjusting the smoke evacuation tube involves extending the smoke evacuation tube distally with respect to the distal end of the lighting device, and retracting the smoke evacuation tube proximally with respect to the distal end of the lighting device.

These and other features of the lighting devices of the subject invention will become more readily apparent to those having ordinary skill in the art to which the subject invention appertains from the detailed description of the preferred embodiments taken in conjunction with the following brief description of the drawings. - 12 - 92477014v.

BRIEF DESCRIPTION OF THE DRAWINGS So that those skilled in the art will readily understand how to make and use the lighting device of the subject invention without undue experimentation, preferred embodiments thereof will be described in detail herein below with reference to the figures wherein: Fig. 1 is a perspective view of a lighting device having an internal smoke evacuation passage separated from a surgical instrument to which it may be attached; Fig. 2 is a perspective view of the lighting device with internal smoke evacuation passage attached to the surgical instrument shown in Fig. 1; Fig. 3 is a perspective view of the lighting device with internal smoke evacuation passage attached to a surgical instrument, with smoke evacuation tubing connected thereto; Fig. 4 is a front elevational view of the lighting device with internal smoke evacuation passage attached to a surgical instrument; Fig. 5 is a rear elevational view of the lighting device with internal smoke evacuation passage attached to a surgical instrument; Fig. 6 is a frontal perspective view of the lighting device shown in Fig. 1; Fig. 7 is a front elevational view of the lighting device shown in Fig. 6; Fig. 8 is a side elevational view of the lighting device shown in Fig. 6; Fig. 9 is a rear elevational view of the lighting device shown in Fig. 6; Fig. 10 is a posterior perspective view of the lighting device shown in Fig. 6; Fig. 11 is an exploded perspective view of the lighting device shown in Fig. 6, with parts separated for ease of illustration; - 13 - 92477014v.

Fig. 12 is a cross-sectional view of the lighting device with internal smoke evacuation passage taken along line A-A of Fig. 7; Fig. 13 is a perspective view of a lighting device with an internal smoke evacuation passage that includes an internal fan, which is separated from a surgical instrument to which it may be attached; Fig. 14 is a perspective view of the lighting device of Fig. 13 attached to the surgical instrument; Fig. 15 is a perspective view of the lighting device and surgical instrument of Fig. 14, with smoke evacuation tubing connected thereto; Fig. 16 is a front elevational view of the lighting device and surgical instrument of Fig. 15; Fig. 17 is a rear elevational view of the lighting device and surgical instrument of Fig. 15; Fig. 18 is a frontal perspective view of the lighting device shown in Fig. 13; Fig. 19 is a front elevational view of the lighting device shown in Fig. 18; Fig. 20 is a side elevational view of the lighting device shown in Fig. 18; Fig. 21 is a rear elevational view of the lighting device shown in Fig. 18; Fig. 22 is a posterior perspective view of the lighting device shown in Fig. 18; Fig. 23 is a perspective view of the printed circuit board, LEDs, switch and fan subassembly housed within the lighting device of Fig. 18; Fig. 24 is an exploded perspective view of the lighting device of Fig. 18, with parts separated for ease of illustration; Fig. 25 is a cross-sectional view of the lighting device taken along line B-B of Fig. 19; - 14 - 92477014v.

Fig. 26 is a perspective view of a surgical lighting device with an attachable smoke evacuation subassembly separated from a surgical instrument; Fig. 27 is a perspective view of the surgical lighting device shown in Fig. with the smoke evacuation subassembly attached thereto engaged on the distal end portion of the surgical instrument; Fig. 28 is a front elevational view of the assembly shown in Fig. 27 illustrating a left side attachment; Fig. 29 is a front elevational view of the assembly shown in Fig. 27 illustrating a right side attachment; Fig. 30 is a right side elevational view of the assembly shown in Fig. 27; Fig. 31 is a top plan view of the assembly shown in Fig. 27; Fig. 32 is a partial section view taken along line C-C of Fig. 31; Fig. 33 is an exploded perspective view of the lighting device shown in Fig. 26; Fig. 34 is a top plan view of the lighting device shown in Fig. 26; Fig. 35 is a cross-sectional view taken along line D-D of Fig. 34; Fig. 36 is a perspective view of the subassembly with printed circuit board, battery, switch and LED housed in the lighting device shown in Fig. 26; Fig. 37 is a front end view of the subassembly shown in Fig. 36; Fig. 38 is a side elevational view of lighting device shown in Fig. 26; Fig. 39 is a partial cross-sectional view taken along line E-E of Fig. 38, illustrating the sliding mechanism for detachably connecting the smoke evacuation subassembly to the lighting device; Fig. 40 is a front end view of the lighting device shown in Fig. 36; Fig. 41 is a perspective view of the smoke evacuation nozzle assembly shown in Fig. 26; 25 - 15 - 92477014v.

Fig. 42 is a front end view of the smoke evacuation nozzle assembly shown in Fig. 41; Fig. 43 is a side elevational view of the smoke evacuation nozzle assembly shown in Fig. 41; Fig. 44 is an enlarged localized view of the connective tongue shown in Fig. 42; Fig. 45 is a bottom plan view of the smoke evacuation nozzle assembly shown in Fig. 41; Fig. 46 is a perspective view of another surgical lighting device with a detachable attachable smoke evacuation subassembly separated from a surgical instrument; Fig. 47 is a perspective view of the surgical lighting device shown in Fig. with the smoke evacuation subassembly attached thereto engaged on the distal end portion of the surgical instrument; Fig. 48 is a front elevational view of the assembly shown in Fig. 47 illustrating a left side attachment; Fig. 49 is a front elevational view of the assembly shown in Fig. 47 illustrating a right side attachment; Fig. 50 is a top plan view of the assembly shown in Fig. 47; Fig. 51 is a right side elevational view of the assembly shown in Fig. 47; Fig. 52 is a partial section view taken along line G-G of Fig. 51; Fig. 53 is a right side elevational view of lighting device shown in Fig. 46; Fig. 54 is a top plan view of the lighting device shown in Fig. 46; Fig. 55 is a front end view of the subassembly shown in Fig. 46; Fig. 56 is a partial cross-sectional view taken along line H-H of Fig. 53; - 16 - 92477014v.

Fig. 57 is a perspective view of the smoke evacuation nozzle assembly shown in Fig. 46; Fig. 58 is a front end view of the smoke evacuation nozzle assembly shown in Fig. 57; Fig. 59 is a rear end view of the smoke evacuation nozzle assembly shown in Fig. 57; Fig. 60 is an enlarged localized view of the connective arms shown in Fig. 59; Fig. 61 is a perspective view similar to that of Fig. 46, wherein the smoke evacuation tube extending from the nozzle assembly includes a clip for engaging a proximal end portion of the surgical instrument; Fig. 62 is a perspective view as in Fig. 61, with the clip on the smoke evacuation tube engaged to the proximal end portion of the surgical instrument; Fig. 63 is a top plan view of the assembly shown in Fig. 62; Fig. 64 is a right side elevational view of the assembly shown in Fig. 62; Fig. 65 is a rear end view of the assembly shown in Fig. 62; Fig. 66 is an exploded side elevational view of the smoke evacuation passage shown in Fig. 62, which includes the nozzle assembly, smoke evacuation tube, engagement clip and barbed connector; Fig. 67 is an assembled side elevational view of the smoke evacuation passage shown in Fig. 62; Fig. 68 is a cross-sectional view of barbed connector taken along line K-K of Fig. 67 illustrating a possible location for a filter element; Fig. 69 is a rear end view of the smoke evacuation passage shown in Fig. 62; Fig. 70 is a front end view of the smoke evacuation passage shown in Fig. 62; - 17 - 92477014v.

Fig. 71 is a perspective view similar to that of Fig. 46, wherein the nozzle assembly includes an adhesive strip for securing the smoke evacuation passage to the lighting device, which is shown separated from a surgical instrument; Fig. 72 is a perspective as in Fig, 71, with the lighting device positioned on the distal end portion of the surgical instrument and with the nozzle assembly of the smoke evacuation passage attached to the lighting device with the adhesive strip; Fig. 73 is a front end view of the assembly shown in Fig. 72 with the adhesive strip in an unsecured condition; Fig. 74 is a front end view of the assembly shown in Fig. 72 with the adhesive strip in a secured condition; Fig. 75 is a top plan view of the assembly shown in Fig. 72 with the adhesive strip in a secured condition; Fig. 76 is a right side elevational view of the assembly shown in Fig. 72 with the adhesive strip in a secured condition; Fig. 77 is a bottom plan view of the assembly shown in Fig. 72 with the adhesive strip in a secured condition; Fig. 78 is a perspective view of a lighting device with an external smoke evacuation passage, which is separated from a surgical instrument to which it may be attached; Fig. 79 is a perspective view of the lighting device with an external smoke evacuation passage attached to the distal end portion of the surgical instrument shown in Fig. 78; Fig. 80 is a top plan view of the assembly shown in Fig. 79; Fig. 81 is a right side elevational view of the assembly shown in Fig. 79; 25 - 18 - 92477014v.

Fig. 82 is a front end view of the assembly shown in Fig. 79; Fig. 83 is a perspective view of the lighting device shown in Fig. 79, with the smoke evacuation tubing disconnected from the external smoke evacuation passage; Fig. 84 is a perspective view of the lighting device shown in Fig. 79, with the smoke evacuation tubing connected to the external smoke evacuation passage; Fig. 85 is a front end view of the lighting device shown in Fig. 84; Fig. 86 is a cross-sectional view taken along line L-L of Fig. 85; Fig. 87 is a front end view of a tube-shaped smoke evacuation inlet nozzle; Fig. 88 is a side elevational view of inlet nozzle shown in Fig. 87; Fig. 89 is a cross-sectional view taken along line M-M of Fig. 87; Fig. 90 is a perspective view of a multi-orifice smoke evacuation inlet nozzle configured to distribute suction across a distance to better pull surgical smoke covering a wider area in the surgical field; Fig. 91 is an exploded perspective view of the inlet nozzle shown in Fig. 90; Fig. 92 is a front end view of the inlet nozzle shown in Fig. 90; Fig. 93 is a side end view of the inlet nozzle shown in Fig. 90; Fig. 94 is an exploded perspective view of a kit having a packaging enclosure configured to retain the lighting device and smoke evacuation assembly shown in Fig. 61; Fig. 95 is a perspective view of the kit shown in Fig. 94 with the lighting device and smoke evacuation assembly packaged within the enclosure; Fig. 96 is a top perspective view of the packaging enclosure shown in Fig. 94; Fig. 97 is a bottom perspective view of the packaging enclosure shown in Fig. 94; - 19 - 92477014v.

Fig. 98 is an exploded perspective view of a kit having a packaging enclosure configured to retain the lighting device, smoke evacuation assembly and surgical instrument shown in Fig. 61, wherein the surgical instrument has a connective wire (those skilled in the art will readily appreciate that the wire was excluded in previous drawings for ease of illustration); Fig. 99 is a perspective view of the kit shown in Fig. 98 with the lighting device, smoke evacuation assembly and surgical instrument packaged within the enclosure; Fig. 100 is perspective view of another lighting device separated from a surgical instrument to which it may be attached, which includes multiple external smoke evacuation passages; Fig. 101 is a perspective view of as in Fig. 100 with the lighting device attached to the distal end portion of the surgical instrument; Fig. 102 is a perspective view of the assembly shown in Fig. 101, with a smoke evacuation tube connected to the smoke evacuation passage on the right side of the lighting device; Fig. 103 is a perspective view of the assembly shown in Fig. 101, with a smoke evacuation tube connected to the smoke evacuation passage on the left side of the lighting device; Fig. 104 is a top plan view of the assembly shown in Fig. 102; Fig. 105 is a front end view of the lighting device shown in Fig. 100; Fig. 106 is a side elevational view of the lighting device shown in Fig. 100; Fig. 107 is a cross-sectional view taken along line N-N of Fig. 106; Fig. 108 is a perspective view of a lighting device attached to the distal end portion of a surgical instrument, wherein the lighting device has multiple distinct 25 - 20 - 92477014v. attachment locations for attaching a smoke evacuation passage thereto, and wherein the inlet nozzle of a smoke evacuation passage is attached to a bottom one of those attachment locations; Fig. 109 is a side elevational view of the assembly shown in Fig. 108; Fig. 110 is a front end view of the assembly shown in Fig. 108; Fig. 111 is perspective view of the assembly shown in Fig. 108 with the inlet nozzles of two separated two smoke evacuation passages are attached to the lighting device at two different locations; Fig. 112 is a side elevational view of the assembly shown in Fig. 111; Fig. 113 is a front end view of the assembly shown in Fig. 111; 10 - 21 - 92477014v.

Fig. 114 is a perspective view of a surgical lighting device attached to a surgical instrument and shown with a smoke evacuation tube separated from the lighting device, wherein the smoke evacuation tube is configured to slide back and forth relative to the lighting device along a rail; Figs. 115 and 116 are perspective views showing the sliding smoke evacuation tube of Fig. 114 attached to the lighting device on opposite sides of the housing; Figs. 117 through 119 are perspective views showing the surgical instrument with different types and lengths of electrodes and the sliding smoke evacuation tube positioned at different locations relative to the housing of the lighting device to complement the different electrodes; Fig. 120 is a front elevational view of the surgical instrument, lighting device and sliding smoke evacuation tube; Fig. 121 is a partial top plan view of the surgical instrument, lighting device and sliding smoke evacuation tube; Fig. 122 is a cross-sectional view taken along line N-N of Fig. 121; Fig. 123 is a perspective view of the lighting device shown in Fig. 114; Figs. 124 - 127 are top, left side, front and right side views of the lighting device shown in Fig. 123; Fig. 128 is an enlarged localized view of area P taken from Fig. 126; Fig. 129 is a perspective view of the distal portion of the sliding smoke evacuation tube shown in Fig 114, which includes a suction inlet; Fig. 130 is a front elevational view of the suction inlet of the smoke evacuation tube; Fig. 131 is a cross-sectional view taken along line R-R of Fig. 130; 25 - 22 - 92477014v.

Fig. 132 is a perspective view of another smoke evacuation tube of the subject invention separated from the lighting device; Fig. 133 through 135 are perspective view showing the smoke evacuation tube attached to the housing of the lighting device with an adhesive strap; Figs. 136 through 138 are perspective views showing the surgical instrument with different types and lengths of electrodes and the smoke evacuation tube strapped to the lighting device and positioned at different locations relative to the housing of the lighting device to complement the different electrodes; Fig. 139 is a partial top plan view showing the smoke evacuation tube strapped to the lighting device; Fig. 140 is a partial bottom plan view showing the smoke evacuation tube strapped to the lighting device; Fig. 141 is a front elevational view of the surgical instrument, lighting device and strapped smoke evacuation tube; Fig. 142 is a perspective view of the distal portion of the strapped smoke evacuation tube shown in Fig. 132, which includes a suction inlet; Fig. 143 is a front elevational view of the suction inlet of the smoke evacuation tube shown in Fig. 142; Fig. 144 is a cross-sectional view taken along line S-S of Fig. 143; Fig. 145 is a perspective view of a surgical lighting device attached to a surgical instrument and shown with a smoke evacuation tube separated from the lighting device, wherein the smoke evacuation tube is configured to slide incrementally back and forth relative to the lighting device along a ratchet rack that interacts with a pawl associated with the housing of the lighting device; - 23 - 92477014v.

Figs. 146 and 147 are perspective views showing the smoke evacuation tube of Fig. 145 attached to the lighting device on opposite sides of the housing; Figs. 148 through 150 are perspective views showing the surgical instrument with different types and lengths of electrodes and the smoke evacuation tube incrementally positioned at different locations relative to the housing of the lighting device to complement the different electrodes; Fig. 151 is a partial top plan view showing the smoke evacuation tube attached to the lighting device with the locking pawl in engaged in the toothed rack; Fig. 152 is a partial bottom plan view showing the smoke evacuation tube attached to the lighting device; Fig. 153 is a front elevational view of the surgical instrument, lighting device and smoke evacuation tube as shown in Fig. 151; Fig. 154 is an enlarged localized view of area U taken from Fig. 152; Fig. 155 is a cross-sectional view taken along line T-T of Fig. 151; Figs. 156 through 158 are front, bottom and side views of lighting assembly shown in Fig. 145; Fig. 159 is an enlarged localized view of area V taken from Fig. 156; Fig. 160 is an enlarged localized view of area W taken from Fig. 157; Fig. 161 is a perspective view of the distal portion of the smoke evacuation tube shown in Fig. 145; Figs. 162 and 163 are front and side views of the suction inlet of the smoke evacuation tube shown in Fig. 161; Fig. 164 is an enlarged localized view of area Y taken from Fig. 162; Fig. 165 is a cross-sectional view taken along line X-X of Fig. 162; - 24 - 92477014v.

Fig. 166 is a perspective view of a surgical lighting device attached to a surgical instrument and shown with a smoke evacuation tube separated from the lighting device, wherein the smoke evacuation tube is configured to translate incrementally back and forth relative to the lighting device along a gear rack that interacts with a pinion gear associated with the housing of the lighting device; Figs. 167 and 168 are perspective views showing the smoke evacuation tube of Fig. 166 attached to the lighting device on opposite sides of the housing; Figs. 169 through 171 are perspective views showing the surgical instrument with different types and lengths of electrodes and the smoke evacuation tube incrementally positioned at different locations relative to the housing of the lighting device to complement the different electrodes; Fig. 172 is a front elevational view of the view of the surgical instrument, lighting device and smoke evacuation tube as shown in Fig. 166; Fig. 173 is an enlarged localized view of area Z taken from Fig. 172; Fig. 174 is a partial side elevational view showing the smoke evacuation tube attached to the lighting device with the gear rack and pinion cooperatively engaged; Fig. 175 is a partial top plan view showing the smoke evacuation tube attached to the lighting device with the gear rack and pinion cooperatively engaged; Fig. 176 is a cross-sectional view taken along line AA-AA of Fig. 175; Fig. 177 is a perspective view of the distal portion of the smoke evacuation tube shown in Fig. 166; Figs. 178 and 179 are front and side views of the suction inlet of the smoke evacuation tube shown in Fig. 177; Fig. 180 is a bottom plan view of the smoke evacuation tube of Fig. 177; Fig. 181 is a cross-sectional view taken along line AB-AB of Fig. 178; 25 - 25 - 92477014v.

Fig. 182 is a perspective view of a surgical lighting device attached to a surgical instrument and shown with a smoke evacuation tube separated from the lighting device, wherein the smoke evacuation tube includes a telescoping distal portion that moves relative to the tube by way of a screw thread; Figs. 183 and 184 are perspective views showing the smoke evacuation tube of Fig. 182 attached to the lighting device on opposite sides of the housing; Figs. 185 through 187 are perspective views showing the surgical instrument with different types and lengths of electrodes and the telescoping smoke evacuation tube positioned at different locations relative to the housing of the lighting device to complement the different electrodes; Fig. 188 is a front elevational view of the surgical instrument, lighting device and telescoping smoke evacuation tube as shown in Fig. 182; Fig. 189 is a partial side elevational view showing the telescoping smoke evacuation tube attached to the lighting device; Fig. 190 is a partial top plan view showing the telescoping smoke evacuation tube attached to the lighting device; Figs. 191 and 192 are front and side elevational views of the lighting device shown in Fig. 182; Fig. 193 is an exploded perspective view of the view of the telescoping smoke evacuation tube shown in Fig. 182; Fig. 194 is an assembled perspective view of the view of the telescoping smoke evacuation tube shown in Fig. 182; Figs. 195 and 196 are front and side elevational views of the telescoping smoke evacuation tube shown in Fig. 182; Fig. 197 is a cross-sectional view taken along line AC-AC of Fig. 196; 25 - 26 - 92477014v.

Fig. 198 is an enlarged localized view of area AD taken from Fig. 197; Fig. 199 is a perspective view of the telescoping portion of the smoke evacuation tube shown in Fig. 193; Fig. 200 is a front elevational view of suction inlet of the tube shown in Fig. 199; Fig. 201 is a perspective view of the distal body portion of the telescoping smoke evacuation tube shown in Fig. 193; Fig. 202 is a front elevational view of the distal body portion of the telescoping smoke evacuation tube shown in Fig. 201; Fig. 203 is a cross-sectional view taken along line AE-AE of Fig. 202; Fig. 204 is a perspective view of a surgical lighting device attached to a surgical instrument and shown with a smoke evacuation tube separated from the lighting device, wherein the smoke evacuation tube includes a plurality of telescoping sections that are extendable and retractable; Figs. 205 and 206 are perspective views showing the telescoping smoke evacuation tube of Fig. 204 attached to the lighting device on opposite sides of the housing; Figs. 207 through 209 are perspective views showing the surgical instrument with different types and lengths of electrodes and the telescoping smoke evacuation tube extended to different positions relative to the housing of the lighting device to complement the different electrodes; Fig. 210 is a front elevational view of the surgical instrument, lighting device and telescoping smoke evacuation tube as shown in Fig. 204; Fig. 211 is a partial top plan view showing the telescoping smoke evacuation tube attached to the lighting device; 25 - 27 - 92477014v.

Fig. 212 is a cross-sectional view taken along line AF-AF of Fig. 211; Figs. 213 and Fig. 214 are front and side elevational views of the lighting device shown in Fig. 204; Fig. 215 is an exploded perspective view of the telescoping smoke evacuation tube shown in Fig. 204; Fig. 216 is a perspective view of the telescoping smoke evacuation tube shown in Fig. 204; Fig. 217 is a front plan view of the telescoping smoke evacuation tube shown in Fig. 216; Fig. 218 is a cross-sectional view taken along line AG-AG of Fig. 217; Fig. 219 is an enlarged localized view of area AE taken from Fig. 218; Fig. 220 is a side elevational view of the telescoping smoke evacuation tube shown in Fig. 216 in a fully extended condition; Fig. 221 is a cross-sectional view taken along line AJ-AJ of Fig. 220; Fig. 222 is an enlarged localized view of area AK from Fig. 221; Fig. 223 is an enlarged localized view of area AL from Fig. 221; and Fig. 224 is an enlarged localized view of area AM from Fig. 221. - 28 - 92477014v.

Claims (37)

- 47 - 92477014v. WHAT IS CLAIMED IS:

1. A lighting device for attachment to a handheld electrosurgical instrument comprising: an elongated housing having opposed proximal and distal end portions and defining an interior chamber containing a lighting assembly for illuminating a surgical site, the housing having a smoke evacuation tube associated therewith for removing smoke generated at the surgical site, wherein the smoke evacuation tube is configured to extend and retract relative to the distal end portion of the housing.

2. A lighting device as recited in Claim 1, wherein the smoke evacuation tube includes a proximal body portion for communicating with a source of suction and a distal body portion having a distal suction inlet for receiving smoke generated at the surgical site and a proximal connective barb.

3. A lighting device as recited in Claim 2, wherein the distal body portion of the smoke evacuation tube includes an elongated track that is adapted and configured to slidingly cooperate with a complementary structure on an exterior wall of the housing.

4. A lighting device as recited in Claim 3, wherein the housing has structure on opposed side walls thereof for cooperating with the elongated track of the distal body portion of the smoke evacuation tube. - 48 - 92477014v.

5. A lighting device as recited in Claim 2, wherein the distal body portion of the smoke evacuation tube is adapted and configured to be selectively attached to the housing at a location along the length thereof by an adhesive or fastener.

6. A lighting device as recited in Claim 2, wherein the distal body portion of the smoke evacuation tube includes an elongated ratchet rack that is configured to cooperate with a deflectable pawl associated with an exterior wall of the housing.

7. A lighting device as recited in Claim 6, wherein the housing has deflectable pawls on opposed side walls thereof for cooperating with the elongated ratchet rack of the distal body portion of the smoke evacuation tube.

8. A lighting device as recited in Claim 2, wherein the distal body portion of the smoke evacuation tube includes an elongated gear rack that is configured to cooperate with at least one pinion gear associated with an exterior wall of the housing.

9. A lighting device as recited in Claim 8, wherein the housing has at least one pinion gear on opposed side walls thereof for cooperating with the elongated gear rack of the distal body portion of the smoke evacuation tube. 20 - 49 - 92477014v.

10. A lighting device as recited in Claim 2, wherein the distal body portion of the smoke evacuation tube includes a mounting flange for engaging a structure on an exterior wall of the housing, and the distal body portion includes a telescoping inner tube that is extendable and retractable relative to the distal body portion through axial rotation by way of a helical thread.

11. A lighting device as recited in Claim 10, wherein the housing has structure on opposed side walls thereof for engaging the mounting flange of the distal body portion of the smoke evacuation tube.

12. A lighting device as recited in Claim 2, wherein the distal body portion of the smoke evacuation tube includes a mounting flange for engaging a structure on an exterior wall of the housing, and the distal body portion includes a plurality of graduated telescoping inner tube members that are relatively extendable and retractable with respect to the distal body portion.

13. A lighting device as recited in Claim 12, wherein the housing has structure on opposed side walls thereof for engaging the mounting flange of the distal body portion of the smoke evacuation tube. 20 - 50 - 92477014v.

14. A lighting device as recited in Claim 1, wherein the lighting assembly includes a printed circuit board having at least one LED lighting component, at least one battery cell, and a switch for activating the lighting assembly.

15. A lighting device as recited in Claim 14, wherein the interior chamber of the housing has a conical bore extending from the proximal end portion of the housing for receiving a distal end portion of the electrosurgical instrument.

16. A lighting device as recited in Claim 15, wherein the switch is configured to activate the lighting assembly when the distal end portion of the electrosurgical instrument is received in the conical bore and deactivate the lighting assembly when the distal end portion of the electrosurgical instrument is removed from the conical bore.

17. A lighting device as recited in Claim 1, further comprising at least one filter element operatively associated with the smoke evacuation tube. - 51 - 92477014v.

18. A lighting device for attachment to a handheld electrosurgical instrument comprising: an elongated housing having opposed proximal and distal end portions and defining an interior chamber containing a battery powered lighting assembly for illuminating a surgical site, the interior chamber defining a conical bore extending from the proximal end portion of the housing for receiving a distal end portion of the electrosurgical instrument, the housing having a smoke evacuation tube associated therewith for removing smoke generated at the surgical site, wherein the smoke evacuation tube is configured to extend and retract relative to the distal end portion of the housing.

19. A lighting device as recited in Claim 18, wherein the lighting assembly is activated when the distal end portion of the electrosurgical instrument is received in the conical bore and deactivated when the distal end portion of the electrosurgical instrument is removed from the conical bore.

20. A lighting device as recited in Claim 18, wherein the lighting assembly includes a printed circuit board that includes at least one LED lighting component, at least one battery cell, and a switch for activating the lighting assembly.

21. A lighting device as recited in Claim 18, wherein the smoke evacuation tube includes a proximal body portion for communicating with a source of suction and a distal body portion having a distal suction inlet for receiving smoke generated at the surgical site and a proximal connective barb. 25 - 52 - 92477014v.

22. A lighting device as recited in Claim 21, wherein the distal body portion of the smoke evacuation tube includes an elongated track that is configured to slidingly cooperate with a rail on an exterior wall of the housing.

23. A lighting device as recited in Claim 22, wherein the housing has structure on opposed side walls thereof for cooperating with the elongated track of the distal body portion of the smoke evacuation tube.

24. A lighting device as recited in Claim 21, wherein the distal body portion of the smoke evacuation tube is adapted and configured to be selectively attached to the housing at a location along the length thereof by an adhesive or fastener.

25. A lighting device as recited in Claim 21, wherein the distal body portion of the smoke evacuation tube includes an elongated ratchet rack that configured to cooperate with a deflectable pawl associated with an exterior wall of the housing.

26. A lighting device as recited in Claim 25, wherein the housing has deflectable pawls on opposed side walls thereof for cooperating with the elongated ratchet rack of the distal body portion of the smoke evacuation tube.

27. A lighting device as recited in Claim 21, wherein the distal body portion of the smoke evacuation tube includes an elongated gear rack that is configured to cooperate with at least one pinion gear associated with an exterior wall of the housing. - 53 - 92477014v.

28. A lighting device as recited in Claim 27, wherein the housing has at least one pinion gear on opposed side walls thereof for cooperating with the elongated gear rack of the distal body portion of the smoke evacuation tube.

29. A lighting device as recited in Claim 21, wherein the distal body portion of the smoke evacuation tube includes a mounting flange for engaging a structure on an exterior wall of the housing, and the distal body portion includes a telescoping inner tube that is extendable and retractable relative to the distal body portion through axial rotation by way of a helical thread to provide the suction inlet.

30. A lighting device as recited in Claim 29, wherein the housing has structure on opposed side walls thereof for engaging the mounting flange of the distal body portion of the smoke evacuation tube.

31. A lighting device as recited in Claim 21, wherein the distal body portion of the smoke evacuation tube includes a mounting flange for engaging a structure on an exterior wall of the housing, and the distal body portion includes a plurality of graduated telescoping inner tube members that are relatively extendable and retractable with respect to the distal body portion to provide the suction inlet.

32. A lighting device as recited in Claim 31, wherein the housing has structure on opposed side walls thereof for engaging the mounting flange of the distal body portion of the smoke evacuation tube. - 54 - 92477014v.

33. A lighting device as recited in Claim 18, further comprising at least one filter element operatively associated with the smoke evacuation tube.

34. A method comprising the steps of: a) attaching a smoke evacuation tube to a handheld electrosurgical instrument for removing smoke generated at a surgical site; and b) adjusting the smoke evacuation tube relative to a distal end of the electrosurgical instrument to accommodate end effectors of differing length installed in the electrosurgical instrument.

35. A method according to Claim 34, further comprising the step of attaching a lighting device to a distal end portion of the electrosurgical instrument for illuminating the surgical site, and wherein the step of attaching the smoke evacuation tube involves attaching the smoke evacuation tube to the lighting device.

36. A method according to Claim 35, wherein the step of adjusting the smoke evacuation tube involves extending the smoke evacuation tube distally with respect to a distal end of the lighting device.

37. A method accruing to Claim 35, wherein the step of adjusting the smoke evacuation tube involves retracting the smoke evacuation tube proximally with respect to a distal end of the lighting device.