U.S. patent application number 14/006628 was filed with the patent office on 2014-01-16 for insulation of rechargeable battery pack.
This patent application is currently assigned to COVIDIEN LP. The applicant listed for this patent is James S. Cunningham, William J. Dickhans, Russell D. Hempsetad, John J. Kappus, Duane E. Kerr, Eric R. Larson, William H. Nau, JR., Anthony B. Ross, Robert B. Stoddard. Invention is credited to James S. Cunningham, William J. Dickhans, Russell D. Hempsetad, John J. Kappus, Duane E. Kerr, Eric R. Larson, William H. Nau, JR., Anthony B. Ross, Robert B. Stoddard.
Application Number | 20140017118 14/006628 |
Document ID | / |
Family ID | 46932399 |
Filed Date | 2014-01-16 |
United States Patent
Application |
20140017118 |
Kind Code |
A1 |
Stoddard; Robert B. ; et
al. |
January 16, 2014 |
INSULATION OF RECHARGEABLE BATTERY PACK
Abstract
A battery autoclaving system is provided including a battery
pack having a housing, a battery cell disposed within the housing,
and an isolation region disposed between the housing and the
battery cell. The isolation region may be formed at least partially
from at least one of a thermal insulating material, a phase change
material or any combination thereof. The system may include a
temperature sensor adapted to sense at least one of a temperature
of the battery cell temperature of the isolation region. The system
may include and an autoclave configured to receive a temperature
indication from the temperature sensor and to inhibit autoclaving
when the temperature indication exceeds a predetermined value.
Inventors: |
Stoddard; Robert B.;
(Steamboat Springs, CO) ; Cunningham; James S.;
(Boulder, CO) ; Dickhans; William J.; (Longmont,
CO) ; Hempsetad; Russell D.; (Lafayette, CO) ;
Larson; Eric R.; (Boulder, CO) ; Kerr; Duane E.;
(Loveland, CO) ; Nau, JR.; William H.; (Longmont,
CO) ; Ross; Anthony B.; (Boulder, CO) ;
Kappus; John J.; (Denver, CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Stoddard; Robert B.
Cunningham; James S.
Dickhans; William J.
Hempsetad; Russell D.
Larson; Eric R.
Kerr; Duane E.
Nau, JR.; William H.
Ross; Anthony B.
Kappus; John J. |
Steamboat Springs
Boulder
Longmont
Lafayette
Boulder
Loveland
Longmont
Boulder
Denver |
CO
CO
CO
CO
CO
CO
CO
CO
CO |
US
US
US
US
US
US
US
US
US |
|
|
Assignee: |
COVIDIEN LP
MANSIFLED
MA
|
Family ID: |
46932399 |
Appl. No.: |
14/006628 |
Filed: |
March 30, 2012 |
PCT Filed: |
March 30, 2012 |
PCT NO: |
PCT/US12/31571 |
371 Date: |
September 20, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61469598 |
Mar 30, 2011 |
|
|
|
Current U.S.
Class: |
422/1 ; 422/105;
429/96 |
Current CPC
Class: |
A61L 2/24 20130101; A61L
2/28 20130101; H01M 10/0525 20130101; H01M 10/623 20150401; A61L
2/26 20130101; H01M 10/486 20130101; H01M 2220/30 20130101; A61L
2/07 20130101; H01M 2/1094 20130101; A61L 2202/14 20130101; Y02E
60/10 20130101 |
Class at
Publication: |
422/1 ; 429/96;
422/105 |
International
Class: |
H01M 10/50 20060101
H01M010/50; A61L 2/26 20060101 A61L002/26 |
Claims
1. An autoclavable battery pack for use with a surgical instrument,
comprising: providing the battery pack, wherein the battery pack
comprises: a housing; a battery cell disposed within the housing;
and an isolation region disposed between the housing and the
battery cell, wherein the isolation region is formed at least in
part from at least one of a thermal insulating material, a phase
change material, or a combination thereof; providing an autoclave
configured to accept the battery pack; inserting the battery pack
into the autoclave; sterilizing the battery pack in the autoclave;
and removing the battery pack from the autoclave after
sterilizing.
2. The method in accordance with claim 1, wherein the battery pack
further comprises a first and a second outer terminal connected to
a first and second battery terminal of the battery cell through at
least one of the housing or the isolation region.
3. The method in accordance with claim 1, further comprising
monitoring the temperature of at least one of the housing, the
battery cell, or the isolation region.
4. The method in accordance with claim 1, wherein the battery pack
further comprises at least one temperature sensor configured to
sense a temperature of at least one of the housing, the isolation
region, or the battery cell.
5. The method in accordance with claim 4, further comprising
providing an autoclave configured to accept the battery pack and to
sterilize the battery pack, wherein the autoclave is configured to
operably communicate with the at least one temperature sensor and
to provide an indication of temperature.
6. The method in accordance with claim 1, wherein the isolation
region further comprises at least two layers, wherein each layer is
formed from at least one of a phase change material or an
insulation material.
7. An autoclavable battery pack for use with a surgical instrument,
comprising: a housing; a battery cell disposed within the housing;
and an isolation region disposed between the housing and the
battery cell, wherein the isolation region is formed at least in
part from at least one of a thermal insulating material, a phase
change material, or a combination thereof.
8. The autoclavable battery pack in accordance with claim 7,
further comprising at least one temperature sensor configured to
sense the temperature of at least one of the housing, the isolation
region, or the battery cell.
9. The autoclavable battery pack in accordance with claim 7,
wherein the isolation region further comprises at least two layers,
wherein each layer is formed from at least one of a phase change
material or an insulation material.
10. The autoclavable battery pack in accordance with claim 7,
wherein the isolation region is formed from two or more materials
selected from the group consisting of one or more of a phase change
material and an insulation material.
11. The autoclavable battery pack in accordance with claim 7,
wherein the battery cell includes first and second outer terminals
and the autoclavable battery pack includes a sterile terminal cap
configured to selectively cover the first and second outer
terminals.
12. The battery pack in accordance with claim 14, wherein the
sterile terminal cap is puncturable such that at least one of the
first and second outer terminals may be accessed by puncturing a
portion of the sterile terminal cap.
13. A battery autoclaving system, comprising: an autoclavable
battery pack, comprising: a housing; a battery cell disposed within
the housing; and an isolation region disposed between the housing
and the battery cell, the isolation region being formed at least
partially from at least one of a thermal insulating material, a
phase change material, or a combination thereof; a temperature
sensor adapted to sense at least one of a temperature of the
battery cell or the temperature of the isolation region; and an
autoclave configured to receive a temperature indication from the
temperature sensor and to inhibit autoclaving when the temperature
indication exceeds a predetermined value.
14. The system in accordance with claim 13, wherein the isolation
region further comprises at least two layers, wherein each layer is
formed from at least one of a phase change material or an
insulation material.
15. The system in accordance with claim 13, wherein the isolation
region is formed from two or more materials selected from the group
consisting of one or more of a phase change material and an
insulation material.
16. The system in accordance with claim 13, wherein the battery
pack further comprises a sterile terminal cap configured to
selectively cover at least one of the first or second outer
terminals.
17. The system in accordance with claim 13, wherein the battery
cell is a Li-ion battery cell.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] The present application claims the benefit of and priority
to U.S. Provisional Patent Application Ser. No. 61/469,598, filed
Mar. 30, 2011, and claims the benefit of and priority to U.S.
Provisional Patent Application Ser. No. 61/469,607, filed Mar. 30,
2011; the contents of each of these is incorporated by reference
herein in its entirety for all purposes.
BACKGROUND
[0002] 1. Technical Field
[0003] The present disclosure relates to medical instruments and to
the use thereof. More particularly, the present disclosure is
directed to portable surgical devices and sterilization of
components thereof.
[0004] 2. Background
[0005] Portable surgical instruments are known in the medical arts.
Portable surgical instruments overcome some of the drawbacks that
are typically associated with surgical instruments that draw power
from electrical outlets. That is, outlet driven surgical
instruments utilize power cords that may create tripping and/or
entanglement hazards in an operating room environment.
[0006] Typically, the portable surgical instrument includes a
battery or battery assembly that is configured to removably couple
or "latch" to the portable surgical instrument. In an ideal
scenario, the battery or battery assembly remains coupled or
"latched" to the portable surgical instrument during the entirety
of the surgical procedure. However, in certain instances, the
battery or battery assembly has to be uncoupled or "unlatched" from
the portable surgical instrument during the surgical procedure. For
example, the battery or battery assembly may have to be unlatched
from the surgical instrument for sterilization (or
re-sterilization), charging (or recharging), replacement, and the
like.
[0007] As may be appreciated, removable batteries or battery
assemblies that are configured to quickly and easily couple or
latch to a handpiece of the portable surgical instrument may prove
advantageous in the surgical environment.
[0008] It may be desirable to re-sterilize a rechargeable battery
pack using an autoclave. However, this high temperature method is
above the temperature limits of currently available rechargeable
battery cells.
SUMMARY
[0009] Disclosed is an apparatus and method for insulating a
rechargeable battery pack to allow it to survive autoclave
sterilization.
[0010] In at least one aspect of this disclosure, a method for
autoclaving a battery pack includes providing the battery pack,
wherein the battery pack includes a housing, a battery cell
disposed within the housing, and an isolation region disposed
between the housing and the battery cell, the isolation region
being formed at least partially from at least one of a thermal
insulating material, a phase change material, or a combination
thereof.
[0011] In another aspect of this disclosure, the method may further
include inserting the battery pack into the autoclave, sterilizing
the battery pack in the autoclave, and removing the battery pack
from the autoclave after sterilization.
[0012] In yet another aspect of this disclosure, the battery pack
may further include a first and a second outer terminal connected a
first and second battery terminal of the battery cell through at
least one of the housing and the isolation region.
[0013] In yet another aspect of this disclosure, the method may
further include providing an autoclave configured to accept the
battery pack and to sterilize the battery pack.
[0014] In yet another aspect of this disclosure, the method may
further include monitoring the temperature of at least one of the
housing, the battery cell, and the isolation region.
[0015] In yet another aspect of this disclosure, the method may
further include providing a sterile terminal cap and placing the
sterile terminal cap over at least one of the first or second outer
terminals.
[0016] In yet another aspect of this disclosure, the battery pack
further comprises at least one temperature sensor configured to
sense a temperature of at least one of the housing, the isolation
region, or the battery cell.
[0017] In yet another aspect of this disclosure, the method may
further include providing an autoclave configured to accept the
battery pack and to sterilize the battery pack, wherein the
autoclave is configured to read the at least one temperature sensor
and provide an indication of temperature.
[0018] In yet another aspect of this disclosure, the isolation
region further includes at least two layers, wherein each layer is
formed from at least one of a phase change material or an
insulation material.
[0019] In yet another aspect of this disclosure, a battery pack may
include a housing, a battery cell disposed within the housing, and
an isolation region disposed between the housing and the battery
cell, the isolation region being formed at least partially from at
least one of a thermal insulating material, a phase change
material, or any combination thereof.
[0020] In yet another aspect of this disclosure, the battery pack
may further include at least one temperature sensor configured to
sense the temperature of at least one of the housing, the isolation
region, or the battery cell.
[0021] In yet another aspect of this disclosure, the isolation
region further includes at least two layers, wherein each layer is
formed from at least one of a phase change material or an
insulation material.
[0022] In yet another aspect of this disclosure, the isolation
region is formed from two or more materials selected from the group
consisting of a phase change material and an insulation
material.
[0023] In yet another aspect of this disclosure, the battery pack
may further include a sterile terminal cap configured to
selectively cover at least one of the first and second outer
terminals.
[0024] In yet another aspect of this disclosure, the sterile
terminal cap may be puncturable such that at least one of the first
or second outer terminals may be accessed by piercing or removing a
portion of the sterile terminal cap.
[0025] In yet another aspect of this disclosure, a battery
autoclaving system may include a battery pack having a housing, a
battery cell disposed within the housing, and an isolation region
disposed between the housing and the battery cell, wherein the
isolation region is formed at least in part from at least one of a
thermal insulating material, a phase change material, or any
combination thereof, a temperature sensor adapted to sense at least
one of a temperature of the battery cell temperature of the
isolation region, and an autoclave configured to receive a
temperature indication from the temperature sensor and to inhibit
autoclaving when the temperature indication exceeds a predetermined
value.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] Embodiments according to the present disclosure are
described, by way of example only, with reference to the
accompanying drawings, wherein:
[0027] FIG. 1 illustrates an embodiment of a rechargeable battery
pack in accordance with the present disclosure;
[0028] FIG. 2 illustrates another embodiment of a rechargeable
battery pack in accordance with the present disclosure;
[0029] FIG. 3 illustrates yet another embodiment of a rechargeable
battery pack in accordance with the present disclosure; and
[0030] FIG. 4 illustrates an embodiment of a system for autoclaving
a battery in accordance with the present disclosure.
DETAILED DESCRIPTION
[0031] Particular embodiments of the present disclosure are
described hereinbelow with reference to the accompanying drawings;
however, the disclosed embodiments are merely examples of the
disclosure and may be embodied in various forms. Well-known
functions or constructions are not described in detail to avoid
obscuring the present disclosure in unnecessary detail. Therefore,
specific structural and functional details disclosed herein are not
to be interpreted as limiting, but merely as a basis for the claims
and as a representative basis for teaching one skilled in the art
to variously employ the present disclosure in virtually any
appropriately detailed structure.
[0032] Like-referenced numerals may refer to similar or identical
elements throughout the description of the drawings. As shown in
the drawings and described throughout the following description, as
is traditional when referring to relative positioning on a surgical
instrument, the term "proximal" refers to the end of the apparatus
that is closer to the user and the term "distal" refers to the end
of the apparatus that is farther away from the user. The term
"clinician" refers to any medical professional (e.g., doctor,
surgeon, nurse, or the like) who may perform a medical procedure
involving the use of embodiments described herein.
[0033] In accordance with at least one aspect of the present
disclosure, a battery pack for use with a portable surgical
instrument is disclosed. Referring to FIG. 1, the battery pack 100
may include an isolation region 105 disposed between at least one
battery cell 101 and at least one housing 107, thereby sealing the
at least one battery cell 101 and the isolation region 105
inside.
[0034] The battery cell 101 may be any suitable battery, including,
but not limited to, rechargeable batteries for surgical devices now
or in the future known. Non-limiting examples of such a battery
cell may include a Li-ion battery, a NiMH battery, a NiCd battery,
and the like. The at least one battery cell 101 may include a first
terminal 103a and a second terminal 103b.
[0035] The housing 107 may be made from at least one of any rigid
or semi-rigid material suitable to form a protective layer over the
isolation region 105 and/or battery cell 101, including, but not
limited to plastic, ceramic, metal, and the like. The housing 107
may further take any desired shaped such that the battery pack 100
may fit into a desired portable surgical device and/or
autoclave.
[0036] The housing 107 may be selectively sealable and openable
such as to allow for removal of the at least one battery cell 101
if desired.
[0037] A first outer terminal 109a and a second outer terminal 109b
may be disposed on the housing 107, and are configured to conduct
electricity. The outer terminals 109a, 109b may form part of the
housing 107.
[0038] The first outer terminal 109a and a second outer terminal
109b may be connected to the first terminal 103a and second
terminal 103b via a first electrical connection 111a and a second
electrical connection 111b, respectively.
[0039] In some embodiments, the isolation region 105 is formed at
least partially from at least one of a thermal insulating material,
a phase change material and/or any combination thereof. The
isolation region 105 may be formed from an insulating material such
as, without limitation, silica aerogel with reinforcing fibers,
e.g., Spaceloft.TM. insulation manufactured by Aspen Aerogel of
Northborough, Mass., USA.
[0040] In some embodiments, a phase change material is used in
addition or alternatively to the insulation material to protect the
battery from damaging heat. For example, and without limitation,
the phase change material may include sodium sulfate decahydrate
(e.g., Glauber's salt) or a similar material whose phase change
temperature is below the damage threshold temperature of the
battery cell 101.
[0041] This isolation region 105 is sized to maintain the
temperature of the battery cell (or cells) below its temperature
limit when the case is subjected to the known time and temperature
profile of an autoclave sterilization cycle.
[0042] The battery pack 100 may further include at least one
temperature sensor configured to sense the temperature of at least
one of the housing 107, the isolation region 105, or the battery
cell 101. For example, there may be at least one isolation region
temperature sensor 113 and/or at least one battery cell temperature
sensor 115.
[0043] Referring to FIG. 2, a battery pack 200 may include a
battery cell 201, a housing 207, a first outer terminal 209a and a
second outer terminal 209b, a first terminal 203a and second
terminal 203b, a first electrical connection 211a and a second
electrical connection 211b, and an isolation region 205, all
similar to the embodiments as described above with respect to FIG.
1.
[0044] In some embodiments, and as shown in FIG. 2, battery pack
200 may further include a sterile terminal cap 217 configured to
selectively cover at least one of the first outer terminal 209b and
second outer terminal 209a. The sterile terminal cap 217 may be
puncturable such that access to at least one of the first outer
terminal 209b and second outer terminal 209a may be gained by
piercing or removing a portion of the sterile terminal cap 217.
This allows sterility of the terminals to be maintained underneath
the sterile terminal cap 217 after autoclaving and during
storage/installation into a surgical device.
[0045] Referring to FIG. 3, a battery pack 300 may include a
battery cell 301, a housing 307, a first outer terminal 309a and a
second outer terminal 309b, a first terminal 303a and second
terminal 303b, a first electrical connection 311a and a second
electrical connection 311b, and an isolation region 305, all
similar to the embodiments as described above with respect to FIG.
1.
[0046] In some embodiments, and as shown in FIG. 3, the isolation
region 305 may further include at least two layers, each layer
being formed from at least one of a phase change material as
described above or an insulation material as described above. In
some embodiments where multiple layers include at least one phase
change material, the phase change materials of each layer may be
selected to have different phase change temperatures. For example,
an outer layer 306a may have a lower phase change temperature such
that it melts at a first temperature and absorbs heat before an
inner layer 306b melts.
[0047] The battery pack 300 may further include at least one
temperature sensor configured to sense the temperature of at least
one of the housing 307, the isolation region 305, or the battery
cell 301. For example, there may be at least one isolation region
temperature sensor 313 and/or at least one battery cell temperature
sensor 315. In embodiments where there are multiple layers in the
isolation region 305, there may be additional temperature sensors
314 for any combination of layers as desired.
[0048] An embodiment of a battery pack as described herein may
protect a battery cell during a heating procedure. For example,
during autoclaving, the heat of fusion of the phase change material
enables the material to absorb a great deal of thermal energy, thus
keeping heat from accumulating in the battery cell and thereby
maintaining the cell (or cells) at a safe temperature.
[0049] Referring to FIG. 4, further disclosed is a battery
autoclaving system 400 that may include a battery pack 500 as
described herein, a temperature sensor as described above, and an
autoclave 401 configured to receive a temperature indication from
the temperature sensor and to inhibit autoclaving (e.g.,
sterilization) when the temperature indication exceeds a
predetermined value.
[0050] The autoclave may have a controller module designed to
periodically or constantly monitor temperature indications from one
or more temperature sensors. The controller module 705 may include
a processor, memory, and/or interface elements configured to
communicate with one or more temperature sensors, an autoclave, and
the like. The controller module may further be configured to shut
down autoclaving or modify the temperature of autoclaving to avoid
battery cell failure. The autoclave may alternatively be manually
controlled based on a temperature display wherein the temperature
information may be displayed on a text display 407 located on the
autoclave 401, the housing, or through any other manner of
indication such as audible means or visual display.
[0051] In some embodiments, a temperature sensor 513 is operatively
associated with the battery pack 500 to enable a user to determine
whether it is safe to autoclave the battery pack 500. This may be
beneficial in situations such as where heat from a prior, recent
autoclaving procedure remains in the phase change material or the
battery cell. In one scenario, the phase change material may be
fully or partially liquefied (having already undergone a phase
change during the previous autoclaving session) and thus not be
able to fully absorb the necessary heat from another autoclaving
session until it necessarily cools. The temperature information may
be displayed on a text display located on the housing or through
any other means such as audible means or visual display.
[0052] In some embodiments, the temperature sensor 513 may be in
operative communication with an autoclave 401 that is configured to
receive a temperature signal from the temperature sensor 513
indicative of an internal temperature of the battery pack, e.g.,
the temperature of the battery cell and/or the phase change
material. The autoclave may be further configured to inhibit the
autoclaving process in the case that one or more battery cells
indicate that an internal temperature thereof exceeds a safe
threshold for autoclaving. In an embodiment, the autoclave 401 may
automatically determine the condition of any battery placed therein
prior to initiating an autoclaving cycle. The autoclave 401 may
communicate with the battery by any suitable manner of
communication, e.g., by electrical connection (e.g., via mating
terminals on the battery and autoclave), by wireless connection
(e.g., active or passive RFID tags), and/or or any other suitable
communication link between the battery and the autoclave. The
autoclave 401 may even have an emergency door release feature to
open door 403 and release heat quickly in the event of a near
critical temperature reading inside the battery. The autoclave 401
may even have an emergency vent feature to open one or more vents
and release heat quickly in the event of a near critical
temperature reading inside the battery.
[0053] Further disclosed is a method for autoclaving a battery
pack. The method may include providing the battery pack as
described above.
[0054] The method may further include inserting the battery pack
into an autoclave, sterilizing the battery pack in the autoclave,
and removing the battery pack from the autoclave after sterilizing.
The battery pack may be moved from the autoclave to a sterile
storage area or into a sterile surgical device to maintain
sterility.
[0055] The method may further include providing an autoclave
configured to accept the battery pack and to sterilize the battery
pack.
[0056] The method may further include monitoring the temperature of
at least one of the housing, the battery cell, and the isolation
region. The method may further include modifying the temperature of
the autoclave or shutting down the autoclave in response to the
monitored temperature.
[0057] The method may further include providing a sterile terminal
cap and placing the sterile terminal cap over at least one of the
first or second outer terminals.
[0058] The method may further include providing an autoclave
configured to accept the battery pack and to sterilize the battery
pack, wherein the autoclave is configure to read the at least one
temperature sensor and provide an indication of temperature.
* * * * *