Sterile battery charging

Abstract

To provide a sterile battery charging device for charging in a sterile field and an assembly thereof.SOLUTION: A battery charging assembly includes: a base unit 12 having a first interface 20 and a second interface 22; and a high capacity battery connectable to the first interface and a low capacity battery connectable to the second interface. The base unit obtains power from the high capacity battery and transmits power to the low capacity battery. The high capacity battery and the low capacity battery are interchangeably connectable to the base unit.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to and the benefit of U.S. Provisional Patent Application No. 62 / 790,076, entitled "Sterile Battery Charging," filed January 9, 2019, and U.S. Provisional Patent Application No. 62 / 812,276, entitled "Sterile Battery Charging," filed March 1, 2019.

[0002] The present invention relates to surgical power systems and, more particularly, to a sterile battery charging apparatus and assembly. [Background technology]

[0003] 2. Description of Related Art Batteries used to power surgical instruments are typically sterilized before use so that they can be used in a sterile field. When the battery runs out of power, it is replaced with a new battery. In smaller instruments, the battery life may be unreasonably short, requiring one or more changes during surgery. Because this can be time consuming, it is convenient to recharge the batteries during surgery when the surgical instruments are not in use. This effectively extends the operating time of the surgical instruments before a battery change is required.

[0004] Placing a corded charger in the sterile field to accomplish this task presents some undesirable challenges. The power cord connected to the charger and plugged into a power outlet can pose a tripping hazard to anyone (such as a surgeon or nurse) walking at any given interval between the sterile field and a wall. Another challenge relates to the sterile field itself. Having a power cord running between a sterile charger and a non-sterile power outlet introduces an opportunity for contamination.

[0005] Therefore, a need exists for a stand-alone battery charger with no external connections.

[0006] Related Art Section Disclaimer Explanation: To the extent that specific patents / publications / products are described in this Related Art Section Description or elsewhere in this disclosure, these descriptions should not be construed as an admission that the described patents / publications / products are prior art under patent law. For example, some or all of the described patents / publications / products may not be early enough in time, may not reflect subject matter developed early enough in time, and / or may not be sufficiently effective to amount to prior art for patent law purposes. To the extent that a particular patent / publication / product is discussed above in this Related Art Section Description and / or throughout the application, the description / disclosure is incorporated herein in its entirety by reference. Summary of the Invention

[0007] Embodiments of the present invention are directed to a sterile battery charging device and assembly for charging within a sterile field. According to one aspect, the device includes a base unit having a first interface and a second interface. The first interface is configured to receive a first battery and the second interface is configured to receive a second battery. The base unit obtains power from the first battery and transmits power to the second battery. The first battery and the second battery are interchangeably mountable to the base unit.

[0008] According to another aspect, the assembly includes a first interface and a second interface. The assembly further includes a high capacity battery connectable to the first interface and a low capacity battery connectable to the second interface. The base unit obtains power from the high capacity battery and sends power to the low capacity battery. The high capacity battery and the low capacity battery are interchangeably connectable to the base unit.

[0009] According to yet another aspect, the invention is a method for charging a surgical battery, the method including the steps of: (i) providing power to a base unit in a sterile field, (ii) sterilizing the battery, (iii) introducing the battery into the sterile field after sterilization, (iv) charging the battery in the sterile field with power from the base unit, (v) using the battery in the sterile field for a surgical procedure, and (vi) recharging the battery in the sterile field with power from the base unit.

[0010] These and other aspects of the invention will be apparent from and elucidated with reference to the embodiment(s) described hereinafter. [Brief description of the drawings]

[0011] The present invention will be more fully understood and appreciated from a reading of the following detailed description in conjunction with the accompanying drawings, in which: The accompanying drawings illustrate only typical embodiments of the disclosed subject matter and are not intended to limit the scope of the disclosed subject matter, to which other equally effective embodiments may be permissible. Reference will now be made briefly to the accompanying drawings, in which: [Figure 1] FIG. 1 is a schematic perspective view of a base unit according to one embodiment. [Diagram 2] FIG. 2 is a schematic perspective view of an adapter connected to a base unit according to one embodiment. [Diagram 3] FIG. 3 is a schematic perspective view of a low capacity (device) battery connected to the adapter of FIG. [Figure 4] FIG. 4 is a flow chart of a wireless charging platform according to one embodiment. [Diagram 5] FIG. 5 is a flow chart of a wireless charging method according to one embodiment. [Figure 6] FIG. 6 is a schematic perspective view of a surgical power system, according to one embodiment. [Figure 7] 7A and 7B are schematic perspective views of a high-capacity battery sliding into and connected to a base unit, according to one embodiment. [Figure 8] FIG. 8 is a schematic perspective view of a high capacity battery, according to an exemplary embodiment. [Figure 9] FIG. 9 is a schematic perspective view of a high-capacity battery mounted on a large surgical instrument, according to one exemplary embodiment. [Figure 10] FIG. 10 is a schematic perspective view of the adapter of FIG. [Figure 11] FIG. 11 is a schematic perspective view of a low capacity battery, according to an exemplary embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Aspects of the present invention and its specific features, advantages, and details are described more fully below with reference to non-limiting examples illustrated in the accompanying drawings. Descriptions of well-known structures are omitted so as not to unnecessarily obscure the details of the invention. It should be understood, however, that the detailed description and specific non-limiting examples, while illustrating aspects of the present invention, are given by way of illustration only and not by way of limitation. Various substitutions, modifications, additions, and / or arrangements within the spirit and / or scope of the underlying inventive concept will be apparent to those skilled in the art from this disclosure.

[0013] Referring now to the drawings, in which like reference numbers refer to like parts, FIG. 1 shows a base unit 12 of a sterile battery charging apparatus 10. The base unit 12 is shown as being removably attached or fixed to a surgical power system 14. An exemplary surgical power system 14 is a Hall® powered tool system. In the illustrated embodiment, the surgical power system 14 is a Hall® Lithium Charger. (FIG. 6). The surgical power system 14 has one or more base units 12 connected to it. According to an embodiment in which the surgical power system 14 is a Hall® Lithium charger, there are four base units 12 connected to the Hall® Lithium chargers 14, as shown in FIG. 6. The surgical power system 14 can be placed on a desk or wall mounted for a surgical procedure.

[0014] 1, the base unit 12 is substantially planar and rectangular. In the illustrated embodiment, the base unit 12 has a plate 16 connected to a surface 18 of the surgical power system 14. The base unit 12 further includes a first interface 20 and a second interface 22. The first interface 20 is used to connect to the high-capacity battery 24 to obtain power from the battery 24. Thus, the first interface 20 is used as a power source for the sterilization battery charging device 10 and is responsible for providing charging power. The second interface 22 is used to connect to the low-capacity battery 26. As a result of the interchangeable attachment of the high-capacity battery 24 and the low-capacity battery 26 to the base unit 12, power can be drawn from the high-capacity battery 24 and then transferred to the low-capacity battery 26.

[0015] In one embodiment, the first interface 20 is one or more battery rails. Specifically, as shown in FIG. 1, the first interface 20 is a pair of spaced apart battery rails connected to the plate 16 of the base unit 12. The battery rails 20 extend substantially parallel to one another along and / or on the plate 16 of the base unit 12. The battery rails 20 are designed to connect to sterilizable high-capacity batteries 24. The high-capacity batteries 24 are used with large surgical instruments such as saw handpieces. They provide consistent, long-lasting, sustainable power for large bone and total joint replacement procedures. An exemplary sterilizable high-capacity battery 24 is shown in FIG. 8. The high-capacity batteries 24 (including the embodiment shown in FIG. 8) are fully autoclavable and can be lithium batteries.

[0016] To draw power from the high-capacity battery 24, the high-capacity battery 24 is attached to the base unit 12. Specifically, as shown in Figures 7A and 7B, the high-capacity battery 24 slides between battery rails 20 on the base unit (Figure 7A) until the high-capacity battery 24 locks into place or otherwise achieves a depleted / charged position on the base unit 12 (Figure 7B). The battery rails 20 hold the high-capacity battery 24 in place while the base unit 12 draws power from the high-capacity battery 24.

[0017] Still referring to FIG. 1, the second interface 22 is one or more battery terminals. In the illustrated embodiment, there are two battery terminals 22 on the base unit 12. The battery terminals 22 are adapted to connect to sterilizable low-capacity batteries 26. Low-capacity batteries 26 are used in small precision surgical instruments such as drills, shaver blades, and burrs. These low-capacity batteries 26 are compact and lightweight. They provide powerful and reliable power for surgical procedures including small bone, sports medicine, and minor trauma. An exemplary sterilizable low-capacity battery 26 is shown in FIG. 11. The low-capacity batteries 26 (including the embodiment shown in FIG. 11) are fully autoclavable and can be lithium batteries.

[0018] In an alternative embodiment, the base unit 12 is adapted for wireless charging (e.g., non-contact charging via a primary coil in the base unit 12). (The secondary coil would penetrate the low-capacity (instrument) battery 26, as would be understood by one skilled in the art.) Using wireless charging is advantageous because the low-capacity (instrument) battery 26 may remain connected to the surgical instrument (e.g., shaver blade) during charging. The surgical instrument connected to the low-capacity (instrument) battery 26 simply needs to be placed in proximity to the sterile battery charging apparatus 10 (i.e., base unit 12) for charging to occur.

[0019] Referring now to FIG. 4, a flow chart of the wireless charging platform 100 is shown, according to one embodiment. The wireless charging platform 100 may be powered by a universal USB 102, a common wall adapter power source (e.g., AC-DC) 104, a rechargeable battery power bank 106, or a standalone power source integrated into the platform hardware 100A. Alternative methods of power supply as mentioned above provide power to the wireless charging platform 100 via a wireless platform power input 108. This technique may involve the use of cables or wires, but allows for flexibility in using various input power configurations. The platform hardware may be integrated into support devices such as, for example, surgical tables and instrument stands (e.g., Mayo stands). Wireless charging accessories may include, but are not limited to, battery-powered foot controls, tablets and / or laptops for sterile use, remote controls for console controls (e.g., cameras, pumps, light sources), and surgical lights and LEDs (e.g., handset lights, helmets, and space suits).

[0020] A method 200 for wireless charging in a sterile field is shown and described with reference to the flow chart of FIG. 5. First, a non-sterile battery (or other power source), such as one of the high and low capacity batteries 24, 26, is obtained (step 202) and cleaned outside the sterile field (step 204). The battery 24, 26 may then be charged outside the sterile field (step 206). The battery 24, 26 is then sterilized (step 208). Sterilization may be completed using an autoclave or other equivalent certified sterilization technique. After sterilization, the battery 24, 26 is charged in the sterile field when in chargeable proximity to the base unit 12 (step 210). The battery 24, 26 may then be used in a surgical procedure (step 212). If the battery 24, 26 is at a low power or otherwise low energy level, the battery 24, 26 is placed in chargeable proximity to the base unit 12 for recharging within the sterile field (steps 214, 210).

[0021] Alternatively, the battery pack can be reduced in physical size through the use of a hybrid power system. A hybrid power system incorporates a smaller rechargeable cell or battery with a supercapacitor boost circuit connected to the cell or battery. The supercapacitor can be charged quickly (less than 10 seconds) compared to a rechargeable cell or battery. This type of powered surgical system can be charged on a typical instrument stand with a charger platform.

[0022] Referring now to FIG. 2, a schematic perspective view of an adapter 28 is shown, according to one embodiment. The adapter 28 can be connected to allow charging of a low capacity battery 26 (if desired, the low capacity battery 26 can be directly connected in another embodiment). In the embodiment shown in FIG. 2, the adapter 28 is an L3500 Small Bone Lithium Power Adapter (FIG. 10). The adapter 22 is configured to connect to a low capacity battery 26 for charging. In the embodiment shown in FIG. 10, the L3500 Small Bone Lithium Power Adapter 28 is adapted to connect to a sterilizable, low capacity (instrument) battery 26, such as the one shown in FIG. 11.

[0023] 3, a schematic perspective view of a low-capacity battery 26 connected to an adapter 28 is shown. A partially discharged low-capacity (instrument) battery 26 is connected to the adapter 28 to initiate the charging effect. In one embodiment, a high-capacity battery 24 is mounted on the surgical power system 14 and, due to the number of base units 12 available, is depleted as the low-capacity battery 26 is charged. Multiple high-capacity batteries 24 may be used to extend the run time of a single low-capacity battery 26. Alternatively, multiple low-capacity batteries 26 may be charged at one time. The connection to the low-capacity battery 26 may be via a physical connection (e.g., a pin on the base unit 12) or a wireless connection. A wireless connection does not require the low capacity battery 26 to be removed from the surgical instrument, whereas a wired connection does.

[0024] The advantage of using existing high capacity batteries 24 as the charger power source is twofold. First, high capacity batteries 24 are already available for use in complimentary devices. Second, they are designed to be sterilizable. Thus, worn batteries 24, 26 can be replaced with charged batteries 24, 26, thereby reducing the number of batteries 24, 26 used in a procedure and reducing the time required to replace batteries 24, 26 which interrupts the procedure.

[0025] Although embodiments of the present invention have been particularly shown and described with reference to certain exemplary embodiments, it will be understood by those skilled in the art that various changes in details may be made therein without departing from the spirit and scope of the invention as defined by the claims, which may be supported by the written description and drawings. Moreover, when an exemplary embodiment is described with reference to a particular number of elements, it will be understood that the exemplary embodiment may be implemented utilizing any of the particular number of elements or less.

Claims

1. 1. A battery charging device, comprising: a base unit having a first interface and a second interface, the first interface configured to receive a first battery and the second interface configured to receive a second battery; the base unit obtains power from the first battery and transmits power to the second battery; The battery charging apparatus, wherein the first battery and the second battery are interchangeably attachable to the base unit.

2. The apparatus of claim 1 , wherein the base unit is substantially planar.

3. The apparatus of claim 1 , wherein the base unit is substantially rectangular.

4. The apparatus of claim 1 , wherein the first interface is a pair of spaced, substantially parallel rails extending along the base unit.

5. 5. The apparatus of claim 4, wherein the first battery cell is slidable within the pair of spaced, substantially parallel rails.

6. The device of claim 1 , wherein the second interface is one or more battery terminals.

7. The device of claim 1 , wherein the first battery and the second battery are sterilizable.

8. 1. A battery charging assembly comprising: a base unit having a first interface and a second interface; a high capacity battery connectable to the first interface; a low-capacity battery connectable to the second interface; the base unit obtaining power from a high capacity battery and transmitting power to the low capacity battery; A battery charging assembly, wherein the high capacity battery and the low capacity battery are interchangeably connectable to the base unit.

9. 9. The assembly of claim 8, further comprising an adapter connected between the second interface and the low capacity battery.

10. 10. The assembly of claim 9, wherein the low capacity battery is a device battery connectable to the adapter.

11. The assembly of claim 8 , wherein the first interface is a pair of spaced, substantially parallel rails extending along the base unit.

12. 12. The assembly of claim 11, wherein a high capacity battery is slidable within said pair of spaced, substantially parallel rails.

13. The assembly of claim 8 , wherein the second interface is one or more battery terminals.

14. 9. The assembly of claim 8, wherein the high capacity battery and the low capacity battery are sterilizable.

15. 1. A method of charging a surgical battery, comprising: providing power to a base unit in the sterile field; sterilizing the battery; introducing the battery into the sterile field after sterilization; charging the battery with power from the base unit in the sterile field; using the battery in a surgical procedure in the sterile field; and recharging the battery with power from the base unit in the sterile field.

16. The method of claim 15 , wherein the base unit includes a primary coil and the battery has a secondary coil.

17. The method of claim 16 , wherein the primary coil wirelessly charges the secondary coil.

18. The method of claim 15 , wherein the battery is connectable to the base unit.

19. The method of claim 15 , further comprising connecting the battery to a surgical instrument.

20. introducing a rechargeable battery into the sterile field; attaching the rechargeable battery to the base unit in the sterile field; and 16. The method of claim 15, further comprising obtaining power from the rechargeable battery via the base unit to recharge the battery.

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