USRE40681E1 - Combination rechargeable, detachable battery system and power tool - Google Patents

Abstract

A cordless drive assembly for driving various orthopedic surgical instruments is described. The drive assembly is battery powered and includes tracks in the handle portion of its housing for receiving the battery. A latch locks the battery to the housing.

A combination of a rechargeable, detachable battery system and a power tool. The battery slides onto the power tool through a complementary groove and flange structure.

Description

This application isThis reissue patent application is a continuation of U.S. reissue patent application Ser. No.09/954,526, filed Mar.5,2001, which is a continuation of U.S. reissue patent application Ser. No.09/637,339, filed Aug.11,2000, now abandoned, which is an application for reissue of U.S. patent application Ser. No.08/692,886, filed Jul.24,1996, now U.S. Pat. No.5,792,573, issued Aug.11,1998, which application is a divisional of U.S. patent application Ser. No. 08/258,338, filed Jun. 10, 1994, now U.S. Pat. No. 5,553,675, issued Sep. 10, 1996.

Notice: More than one reissue application has been filed for the reissue of U.S. Pat. No.5,792,573. The reissue applications are: U.S. Reissue application Ser. No.11/129,760 filed May16,2005 (the present application), which is a continuation of U.S. Reissue application Ser. No.09/954,526 filed Mar.5,2001(pending), which is a continuation of U.S. Reissue application Ser. No.09/637,339 filed Aug.11,2000(now abandoned).

TECHNICAL FIELD

The present invention is directed to cordless rechargeable battery powered drive assemblies for driving orthopedic surgical instruments.

BACKGROUND

Orthopedic drive assemblies are well known in the art. Such drive assemblies may be adapted for various orthopedic procedures such as drilling, screwing, reaming, wire driving, pinning and sawing (both reciprocating and sagittal). Typically a drive assembly is powered by either a rechargeable battery system (e.g. a cordless system) or by a pneumatic system which utilizes compressed fluid to power the device.

The art is replete with cordless rechargeable battery powered drive assemblies for driving orthopedic surgical instruments. Typically, such instruments comprise generally pistol-shaped devices having elongate handle and drive portions. Examples of such drive assemblies comprise: (1) the Orthopower 90 cordless instruments available from Stryker of Kalamazoo, Mich.; (2) the Cordless 200 Reamer, Cordless 800 Wire Driver, Cordless Sagittal Saw or Cordless 450 Orthopedic Drill available from Dyonics of Andover Md., (3) the Maxion™ orthopedic drive device, previously sold by the Minnesota Mining and Manufacturing Co. (3M) of St. Paul, Minnesota; (4) the Hall Versipower orthopedic instruments available from Hall Surgical of Carpinerina California (associated with Zimmer); and (5) the product known as the 200 Reamer, previously sold by Black & Decker. Cordless battery powered drive assemblies for driving orthopedic surgical instruments are described in U.S. Pat. Nos. 3,734,207; 4,050,528; 4,091,880; 4,441,563; 4,641,076; 4,728,876 and 5,080,983.

Because the batteries in an orthopedic drive device are preferably rechargeable, releasable attachment means are provided in some prior art devices for releasably attaching a battery pack to the rest of the device. Typically, a battery pack is attached to and removed from the handle portion of the device in a direction that is substantially parallel to the axis of elongation of the handle portion. Individual batteries are placed in a housing creating the battery pack which is then attached to the device by being slid in a direction generally parallel to the elongate axis of the handle portion of the device. The battery pack typically includes electrical circuit connection means for connecting the battery pack to electronic circuitry in the device. A device typically secures the battery pack to the rest of the device.

While such releasable attachment means are generally acceptable, they leave room for improvement. One drawback of such a releasable attachment means is that gravity tends to continuously operate on the battery pack to urge it out of the device. Another drawback for some prior devices is that, because of the significant vibration forces encountered during use of the orthopedic drive assembly (particularly during sagittal sawing), the electrical circuit connection means tend to corrode. This type of corrosion is known as fretting corrosion. As used herein, the phrase “fretting corrosion” means surface degradation occurring at the interface of mating electrical contacts which results in the reduction or even loss of electrical continuity.

Fretting corrosion is found in components forming contacts which are allowed to move independently with respect to each other during current flow. This independent movement is believed to cause mechanical abrasion which will wear the surfaces. Gaping between the electrical contacts during electrical flow may result in electrical arcing with attendant generated heat potentially sufficient to melt the surface of the contacts. Pitting, welding and burning may also result. Also, a physical change in the material forming the contacts may occur. Plating for enhanced electrical contact may be lost and carbon deposits may accumulate resulting in reduced electrical continuity.

Because orthopedic drive assemblies are used in surgical procedures which require delicate yet physically demanding tasks, the balance and maneuverability of an orthopedic drive device is also important to surgeons. Hand fatigue is a problem associated with many existing drive assemblies as well as a general difficulty in maneuvering the device during some surgical procedures. Weight distribution and size considerations are believed to contribute to these problems, as the typical cordless rechargeable battery powered drive assembly may be cumbersome to hold and use, particularly during a delicate orthopedic procedure where only the height quality is tolerated. Size and weight considerations involved in the placement of elements such as the batteries, transmission, electronic control circuitry and motor typically render an existing device to maneuver.

Other prior art drive assemblies are excessively large. Oversized drive assemblies may be difficult to maneuver, particularly during a surgical procedure at a cramped or remote location.

BRIEF DESCRIPTION OF THE INVENTION

According to the present invention there is provided a drive assembly for driving orthopedic surgical instruments which (1) affords excellent balance and maneuverability for a user which offers enhanced handling characteristics and convenience during use, (2) affords attachment and removal of a battery pack in a direction other than the direction of elongation of the handle portion of the device, (3) includes a connection between the battery pack and the electronic circuitry of the device which resists fretting corrosion, (4) includes an ergonomically designed handgrip shape that fits a surgeon's hand comfortably, and (5) is sized for convenient maneuvering during an orthopedic surgical procedure.

According to the present invention, there is provided a drive assembly for driving various orthopedic surgical instruments, such as, but not limited to, drills, screws, reamers, wires, pins and saws (both reciprocating and sagittal). The drive assembly comprises a housing having elongate drive and handle portions with the handle portion projecting from the drive portion. A drive is present comprising an motor preferably mounted within the drive portion. The motor has a motor shaft, and the drive includes a transmission for transmitting power of the motor shaft to the surgical instrument. The transmission includes a drive member. Preferably the drive portion has surfaces defining a wire receiving chamber adapted to receive an orthopedic wire adapted to be driven during an orthopedic surgical procedure.

The drive assembly also includes a trigger assembly movable relative to the handle portion; and electrical circuit means operatively associated with the trigger assembly for controlling the motor.

The handle portion comprises a releasably attachable battery having at least one cell (preferably eight), a battery housing, and a pair of battery contacts. The handle portion also has a battery receiving portion having battery terminals adapted to engage the battery contacts; and releasable attachment means for releasably attaching the battery to the battery receiving portion in a direction other than the direction of elongation of the handle portion. Preferably, the direction is a direction substantially parallel to the axis of the drive portion.

In the preferred embodiment, the releasable attachment means comprises a) the handle portion having a pair of tracks defining flanges that are elongate in a direction substantially parallel to the longitudinal axis of the drive portion, b) the battery having a pair of grooves adapted to receive the flanges of the tracks, and a pair of flexible, resilient cantilever members, and c) the battery receiving portion having surfaces defining a cantilever member cavity for receiving the pair of flexible, resilient cantilever members in an interface fit so that the battery is frictionally held in place relative to the battery receiving portion. A latch for releasably securing the battery to the battery receiving portion is also preferably present.

The drive assembly also includes a novel floating battery terminal assembly comprising biasing means for biasing the battery terminals toward a rest position, and mounting means for mounting the battery terminals for deflection from the rest position. In one embodiment, each of the battery terminals comprises a substantially flat plate member having opposite side surfaces, and each of the battery contacts comprise a pair of flexible, resilient arcuate members which are adapted to engage opposite side surfaces of a battery terminal.

Also preferably, the handle portion comprises a handgrip portion having outer surfaces that are sized and shaped to be grasped by a user without touching the battery, and inner surfaces defining a handgrip cavity. The handgrip cavity is free of the transmission, the motor and any cells of the battery when the battery is received in the battery receiving portion. Preferably, the cells of the battery are spaced on an opposite end of the handgrip portion than the motor and transmission.

Alternatively, the present invention may be described as a rechargeable battery adapted to be repeatedly and releasably attached to an orthopedic drive assembly. In this aspect of the invention, the orthopedic drive assembly has elongate drive and handle portions, a battery receiving portion having a pair of tracks defining flanges, a pair of battery terminals, and surfaces defining a cantilever member receiving cavity.

The battery comprises an autoclave battery housing having opposite top and bottom portions, at least one cell within the battery housing and a pair of battery contacts mounted adjacent the top portion of the housing and adapted to engage the battery terminals of the orthopedic drive assembly. Releasable attachment means are present for releasably attaching the battery to the battery receiving portion in a direction other than the direction of elongation of the handle portion. The releaseable attachment means and battery terminals comprise the preferred versions as discussed above.

In this aspect of the invention, the battery contacts each include a first end fixedly attached to the top portion of the battery housing and a second end adapted to abut a support shoulder of the top portion of the battery housing. The battery housing comprises opposite, substantially flat front and rear walls constructed from a material suitable for protecting the cell(s) during an autoclave procedure. The battery comprises eight substantially cylindrical cells having longitudinal axes. The eight cylindrical cells are arranged in: a) a front row of three cells substantially adjacent a front wall of the battery housing, b) a rear row substantially adjacent a rear wall of the battery housing, and c) a middle row of two cells between the front and rear rows.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be further described with reference to the accompanying drawings wherein like reference numerals refer to like parts in the several views, and wherein:

FIG. 1 is a perspective view of a drive assembly for driving orthopedic surgical instruments according to the present invention;

FIG. 2 is an enlarged sectional view of the drive assembly ofFIG. 1, illustrating a battery pack of the device removed from the device in solid lines, and illustrating the position of the battery pack when attached to the drive assembly in phantom lines;

FIG. 3 is an enlarged perspective view of the battery pack for use in the drive assembly ofFIG. 1;

FIG. 4 is an enlarged rear view of the drive assembly ofFIG. 1;

FIG. 5 is a top view of the battery pack ofFIG. 3;

FIG. 6 is a sectional view of the battery pack ofFIG. 3;

FIG. 6A is a bottom view of portions of the drive assembly ofFIG. 2 with the battery pack removed which illustrates battery terminals that are adapted to be connected to the battery contacts of the battery pack ofFIG. 3;

FIG. 7 is an enlarged side view of the drive assembly ofFIG. 1;

FIG. 8 is a top view of the orthopedic drive assembly ofFIG. 7;

FIG. 9 is a front view of the drive assembly ofFIG. 7;

FIG. 10 is a side view of the battery pack ofFIG. 3;

FIG. 11 is an enlarged bottom view of a handle portion of a drive assembly with the battery pack removed to illustrate details of a second embodiment of battery terminals according to the present invention and with portions of a battery pack receiving cavity illustrated with dashed lines;

FIG. 12 is a partial sectional view of a battery receiving portion of the drive assembly and cantilever arms of the battery pack showing the position of the cantilever arms when the battery pack is attached to the rest of the orthopedic drive assembly;

FIG. 13 is a top view of one of a pair of preferred battery contacts for a battery pack according to the present invention, which battery pack is adapted to be connected to a drive assembly having the battery terminals ofFIG. 11;

FIG. 14 is a side view of the battery contact ofFIG. 13;

FIG. 15 is an enlarged bottom view of portions of the handle portion of the drive assembly ofFIG. 11 which illustrates details of a pair of floating battery terminal assemblies including a battery terminal of one of the assemblies shown offset relative to the axis of the drive portion of the housing of the device;

FIG. 16 is a sectional view of a floating battery terminal assembly ofFIG. 15 which illustrates details of a battery terminal in a rest position;

FIG. 17 is a sectional view of portions of the drive assembly ofFIG. 16 taken approximately alonglines17—17 ofFIG. 16 except that one battery terminal and connector are removed to illustrate details of a hole for receiving the battery terminal;

FIG. 18 is a sectional view similar toFIG. 16 except that the floating battery terminal assembly is slightly offset from its rest position, as may occur during vibration of the orthopedic drive device;

FIG. 19 is a sectional view of the floating battery terminal ofFIG. 17 with the battery terminal offset laterally with respect to its longitudinal axis in a rest position and with other portions omitted to illustrate details;

FIG. 20 is a sectional view of the floating battery terminal assembly ofFIG. 17 with the battery terminal illustrated in a rest position and with other portions omitted to illustrate details;

FIG. 21 is a schematic illustration of a switch mechanism for use in the drive assembly according to the present invention;

FIG. 22 is a top view of another embodiment of battery contact for use with a drive assembly having the battery terminals ofFIG. 11;

FIG. 23 is a side view of the battery contact ofFIG. 22; and

FIG. 24 is a perspective view of a battery with the battery contacts of FIGS.13 and14.

DETAILED DESCRIPTION

Referring now toFIGS. 1 through 10 of the drawing there is shown an embodiment of a cordless rechargeable battery powered drive assembly for driving orthopedic surgical instruments according to the present invention, generally designated byreference character10. Thedrive assembly10 includes a housing comprisingelongate drive4 and handle6 portions defining drive D and handle H portion longitudinal axes. Thedrive portion4 and a significant portion of thehandle portion6 are constructed by assembling two large housing pieces (seeFIG. 7) to afford convenient disassembly of the device for repair.

Referring now toFIG. 2, thedrive assembly10 includes a motor assembly having a D.C. electric poweredmotor12 including arotor14 and amotor shaft16. A drive is also present comprising a transmission for transmitting the power of themotor shaft16 to the surgical instrument. The illustrated transmission includes a drive member orspindle18, aring gear19, and a gear pin andplanetary gear assembly21.

Preferably, themotor12 is mounted within thedrive portion4. As used in this application, when it is said that the motor is within thedrive portion4, it is meant that therotor14 andmotor shaft16 are substantially completely located within the structure of the housing defining thedrive portion4, as opposed, for example, to one of the rotor or motor shaft being located in thehandle portion6 or a substantial portion of the motor being located in thehandle portion6, of course some wires and electronic circuitry associated with the motor may be present outside thedrive portion4, and yet the motor will nevertheless be within thedrive portion4 as understood in the present invention. Also preferably, the transmission (e.g.18,19 and21) is mounted within thedrive portion4.

A connector is provided for attaching a chuck or other such holder or instrument that may be driven by thedrive assembly10. The connector comprises anose insert26 having a socket into which a cylindrical portion of the surgical instrument can project with a splined central rotatable driven collar engaged withmating splines17 on the inner surface of thedrive member18, and with pins (not shown) projecting radially of the cylindrical portion engaged in longitudinally extendingslots15 opening through the end of the housing. A helix pin/collar assembly25 is rotatable about the axis D of the drive portion and is biased bytorsion spring27 so that circumferentially projecting hooks nearslots15 on thecollar25 can engage the pins on the surgical instrument to maintain the pins within theslots15 and thereby the surgical instrument in driven engagement with thedrive assembly10.

The surgical instrument may comprise any instrument suitable for use in an orthopedic surgical procedure, including but not limited to, drills, screws, reamers, pins and saws (both reciprocating and sagittal) or a suitably designed chuck or adapter for use with any of the previously mentioned instruments.

As a particular example, the surgical instrument may comprise the chuck described in U.S. Pat. No. 4,728,876, the entire contents of which are herein expressly incorporated by reference. Alternatively, for example, an appropriate wire driving attachment adapter may be attached to thedrive assembly10 so that it may be used as an orthopedic wire driver, optionally, but not preferably, engagement between the orthopedic wire and thespindle18 may afford operation of thedevice10 as a wire driver.

Astationary member22 extends from a proximal end1 of the housing toward itsdistal end3. Preferably, thestationary member22 includes a through chamber so that a surgical wire may be passed through thestationary member22 from the proximal end1 of thedevice10 toward thedistal end3. The through chamber in thestationary member22 forms a portion of a wire receiving chamber in thedrive portion4 between the proximal end1 and thedistal end3. Threading a surgical wire through the wire receiving chamber affords use of thedevice10 as a wire driver.

O-rings64 and65 restrict internal contamination of thedrive assembly10 from ambient contaminants. O-ring66 is compressed againstmember22 to restrict themember22 from rotating relative to thehandle6 and drive4 portions of the housing.

Thedrive assembly10 also includes a rechargeable battery orbattery pack30 that is adapted to provide a rechargeable source of power for themotor12. Unique mounting means (described in greater detail below) attach thebattery30 to the rest of theassembly10.

Atrigger assembly40 is movable relative to thehandle portion6. The trigger assembly includes abutton member45 adapted to be engaged by a user's digits, a trigger shaft46, an O-ring seat41 for fixedly connecting thebutton member45 to the trigger shaft46, a coil spring42 andmagnet44 that is rigidly attached to the trigger shaft46. Thetrigger assembly40 is movable between a released or extended position (FIG. 2) and a depressed or inner position relative to thehandle portion6.

Thedrive assembly10 also includes electrical circuit means operatively associated with thetrigger assembly40 for controlling themotor12. The illustrated electrical circuit means comprises an on/offhall sensor52 and a speedcontrol hall sensor54.

The on/offhall sensor52 is a digital hall sensor having an output signal with two levels corresponding to an on state and an off state. The on/offhall sensor52 senses the presence of a magnetic field from themagnet44 on thetrigger assembly40. When thetrigger assembly40 is released, themagnet44 is positioned directly over the on/off hall sensor52 (FIG.2). The magnetic field of themagnet44 causes the on/offhall sensor52 to produce an output signal corresponding to an off state. As thetrigger assembly40 is depressed, themagnet44 moves away from the on/offhall sensor52. The on/offhall sensor52, no longer sensing the presence of a magnetic field, produces an output signal corresponding to an on state.

The output signal from the on/offhall sensor52 is conditioned by electrical circuitry which provides a standby signal when the on/offhall sensor52 produces an off signal. The standby signal disables motor drive circuitry and the speedcontrol hall sensor54. The standby signal therefore ensures that themotor12 is off whenever thetrigger assembly40 is in a released position (FIG.2). An added benefit of disabling the motor drive circuitry and the speedcontrol hall sensor54 is that the electrical power required by thedevice10 is significantly reduced during periods when thetrigger assembly40 is not depressed. This current reduction during a standby mode improves energy efficiency of thedevice10. In this manner, thedevice10 may optionally include a battery saver feature.

The speedcontrol hall sensor54 is a linear ball sensor which provides a speed control signal having a range of levels based upon the strength of the magnetic field that the variablespeed hall sensor54 detects. As the strength of the magnetic field increases, the speedcontrol hall sensor54 produces a speed control signal with a higher level. As thetrigger assembly40 is depressed, themagnet44 moves towards the speedcontrol hall sensor54 and increases the magnetic field across it. The speed control signal from the speedcontrol hall sensor54 is conditioned and drives the motor control circuit to provide motor speeds proportional to the speed control signal. Therefore, as thetrigger assembly40 is further depressed, the motor control circuitry increases the motor speed of thedrive assembly10. In this manner, thedrive assembly10 may optionally comprise a variable speed device.

The circuit has a 25 amp current limit to protect the batteries, motor and electronics. The electrical circuit means may optionally include directional drive circuitry which is discussed in greater detail below.

As best seen inFIGS. 2 and 6A, thedevice10 also comprisesbattery terminals39. Each of thebattery terminals39 have three generally flat surfaces including two end surfaces situated at an angle relative to a middle surface. The function of thebattery terminals39 will be described in greater detail below.

Thebattery terminals39 may be constructed from any suitable material appropriate for use to construct orthopedic surgical tools. For example, the battery terminals may be constructed from copper, brass, bronze, beryllium copper, stainless steel, steel and aluminum. One or more platings may be present to enhance the electrical conducting and corrosion resisting properties of thebattery terminals39. Examples of such platings include, but are not limited to copper, nickel, gold, silver, tin, electroless nickel, rhodium, sulfamate, nickel, cadmium and zinc.

Thehandle portion6 of thedevice10 projects (downwardly inFIG. 2) from thedrive portion4 of thedevice10. Thehandle portion6 of the housing comprises thebattery30 and ahandgrip portion5. Thehandgrip portion5 has manually engageable or graspable surfaces and top T and bottom B ends (see FIG.2). Preferably, thehandgrip portion5 is sized and shaped so that, during use of thedevice10, the user does not need to grasp any portion of thebattery30. For example, thehandgrip portion5 may have a height from its bottommost point to the bottom of thedrive portion4 of less than approximately 6 inches (preferably about 4.5 inches), a width of its neck portion of less than about 2.8 inches (preferably about 1.1 inches), and a length of its neck portion of less than about 2.5 inches (preferably about 1.3 inches).

Thehandgrip portion5 includes specially shaped surfaces that result in a handle that is comfortably held in the head of a surgeon. A middle part of thehandgrip5 includes an curved front surfaces to form a conveniently held handle. Alip portion51 is situated adjacent thebutton member45 to restrict the chance that a surgeon's glove may be caught between thehandle portion6 and thebutton45 when thebutton45 is depressed.

As shown in the figures, the width and length of thehandgrip portion5 vary along its height to afford convenient grasping of thedevice10. The bottom of thehandgrip portion5 includes abattery receiving portion48 having thebattery terminals39 adapted to engage battery contacts33 (described in greater detail below) when thebattery30 is attached to thebattery receiving portion48.

A battery housing31 (FIGS. 2 and 3) preferably comprises opposite, substantiallyflat front201 and rear203 walls constructed from an autoclavable material. An autoclavable material is a material suitable for protecting battery cell(s) during repeated autoclave procedures. Examples of suitable materials are described below.

Thebattery30 comprises at least onerechargeable cell32 and preferably eight substantiallycylindrical cells32 as shown in FIG.2. Because thecells33 are located in a position below or remote from where a user is expected to grasp thedrive assembly10, the handgrip portion is free to be used for mounting other electrical and/or mechanical components such as an electronic printed circuit board forming a portion of the electrical circuit means discussed above.

Thebattery30 preferably comprises eight substantiallycylindrical cells32 having longitudinal axes. The axes of the cells are preferably substantially parallel to the front andrear walls201 and203. The eightcylindrical cells32 are arranged in a front row F of three cells substantially adjacent thefront wall201, a rear row R of three cells substantially adjacent therear wall203, and a middle row M of two cells between the front andrear rows201 and203. All of the rows F, M and R are enclosed within thebattery housing31 so that the cells are protected during an autoclave or other sterilization procedure.

The weight distribution of thedevice10 is substantially balanced about thehandgrip portion5 as the relatively heavier elements such as the battery cells and the motor/transmission assemblies of thedevice10 are spaced on opposite ends (top T and bottom B) of thehandgrip5. Ahandgrip cavity53 is formed within the inner portions thehandgrip5. As opposed to prior art devices which include a battery or motor within the portion of its housing that is designed to be manually grasped, thecavity53 is free of batteries or motors or transmission or gear assemblies. Since battery cells30 (described in greater detail below) are situated below the battery receiving portion of thehandle portion6, some of the electronic control circuitry mentioned above may be placed in thehandgrip cavity53 of thehandle portion6. This is believed to further contribute to the beneficial balance and handling characteristics of thedevice10.

Thecells32 are preferably stacked in the manner shown inFIG. 2, with a distal row of three cells placed at the front of thebattery30, a proximal row three cells at the rear of thebattery30, and a middle row of two cells placed between the front and rear cells. The axes of the cells are perpendicular to the axis D of the drive portion of the housing. Thecells32 may comprise, for example, nickel-cadmium secondary (rechargeable) sub “C” size cells with a 22 mm diameter and a 34 mm length in a nickel-plated steel case. Such cells are expected to provide a capacity of about 1.4 amp hours at 9.6 volts, D.C. Suitable cells may be obtained from Saft of Valdosta. Ga.; Panasonic of Japan; Sanyo Electric Co. Ltd. of Sumoto-City, Hyogo Japan or Gates available from DC Battery Products of St. Paul, Minn.

Thecells32 are enclosed in an autoclave proof (saturated stream @ 280 degrees Fahrenheit, @ 30 pounds per square inch, and vacuum @ 26 inches of mercury) housing orcasing31. Thecasing31 preferably is designed to withstand other sterilization techniques and remain suitable to protect thebattery cells32. Thecasing31 includes a poppet or umbrella valve8 (e.g. the #VL2491-102 Vernay valve generally available from Vernay of Calif.) to relieve any pressure, such as pressure generated by thecells32. Optionally, thebattery housing31 may include a power terminal (not shown) for a power cord so that thedrive assembly10 may be powered without discharging thecells32.

The particular material used to construct thecasing31 may comprise any suitable material for use in an orthopedic device. Specific examples include, but are not limited to, poly-ether-imide (PET) including Ultem (e.g. GE grades 1000 Black #7101, 1000 Black #1000, 2100 muddled natural #1000 10% glass fill, 2200 muddled natural 20% glass fill, 3452 muddled natural #1000 45% short glass and mineral, or 6200 muddled natural #1000 20% glass fill high temperature); poly-phenyl-sul-fone (PPSU) (e.g. Amoco Radel R, grades R5100 Black #935 or #937, or R 5000, natural); polysulfone (PSU) (e.g. Amoco Udel P, grade P 1700, natural #11); polyaryletherketone (PAEK) (e.g. BASF Ultrapek, grade KR4176, natural); liquid crystal polymer (LCP) (e.g. Vectra grades A950 natural, A530 muddled natural moderately mineral filled, or A130 muddled natural 30% glass fill); and polyketone (PEK) (e.g. Amoco Kadel E grade 1000 natural).

Themotor12 of thedrive assembly10 is designed to: (1) operate between about 9.6 volts and a reduced voltage which is the output range the battery will produce under load, and (2) have very low internal resistance to restrict internal losses when handling the high current flow by which it is powered. Since themotor12 and transmission are relatively heavy elements of the device10 (e.g. the motor may weight about 0.82 pounds), themotor12 and transmission are preferably located within thedrive portion4 of the housing. Locating themotor12 and transmission in a position spaced from thehandgrip cavity53 frees thehandgrip cavity53 for use to store the electronic circuitry of thedevice10. The location of themotor12 and transmission also contribute to the beneficial balance and weight distribution of thedevice10 and improves its handling characteristics. These improvements are believed to reduce hand fatigue for some users.

Thebattery30 shown inFIGS. 1-7,9 and10 comprises the battery housing orcasing31, and a pair ofbattery contacts33, one of which is an electrically positive terminal, the other of which is an electrically negative terminal. Thebattery contacts33 comprise thin, arcuate contact members. Thearcuate contact members33 are connected at one end to thehousing31 and are in electrical communication with the cells32 (which are connected in series by electrically conductive strips). The other end of thecontact members33 is free to float along the top of thecasing31. Preferably, thecontacts33 are constructed from a flexible, resilient electrically conductive material, such as a material selected from the group comprising copper, brass, bronze, beryllium copper, nickel, stainless steel, aluminum or steel. Optionally, one or more materials may be plated to the contacts to enhance their performance and corrosion resistance. Plating materials include, but are not limited to gold, copper, nickel, silver, tin electroless nickel rhodium, sulfamate nickel, cadmium and/or zinc. The shape of the arcuate contact/members33 afford their resilient deflection in a direction substantially parallel to the axis H of thehandle portion6 of the housing upon abutment with thebattery terminals39.

Referring now toFIGS. 11,13-14,15-16,18-20 and24 of the drawings, there is shown a second embodiment of cooperable battery terminals and battery contacts according to the present invention with the battery contacts designated withreference character33A and the battery terminals designated byreference character39A.

As best seen inFIG. 16,handgrip5 has a portion constructed from an electrically insulatingmaterial106. Thebattery terminals39A are each attached to the insulatingmaterial106 byscrew87. A crimp-onconnector107 is situated between thescrew87 and thebattery terminal39A. The crimp-onconnector107 places thebattery terminal39A in electrical communication with the rest of the electrical circuit means by virtue ofinsulated wire108.

Thebattery terminals39A are mounted on the manuallygraspable portion5 of the housing to float relative to the rest of the housing (including the insulating portion106). This feature is particularly useful when thedevice10 generates vibration as the floatingbattery terminals39A tend to retain electrical communication between thebattery30 and the rest of the electronics of thedevice10.

Thebattery terminal39A is placed in anoblong hole88 in thehandgrip portion5 of the housing. Theoblong hole88 preferably affords side to side float (movement in a direction that is substantially perpendicular to both axes H and D) of thebattery terminal39A (see FIG.19), but restricts float of thebattery terminal39A in a direction substantially parallel to the axis D so that thebattery terminal39A is not unduly deflected upon insertion and removal of thebattery30 from thedevice10.

Acoil spring89 is provided to afford float of thebattery terminal39A and to bias thebattery terminal39A toward a rest position (see FIGS.16 and20). Thecoil spring89 has a pair of ends, one of which abuts the crimp-onconnector107, and the other of which abuts the insulatingportion106 of the housing. A rest position ofbattery terminals39A is shown in FIG.16. When thebattery terminal39A is deflected from its rest position (such as when thedevice10 vibrates during an orthopedic surgical procedure), thespring89 deflects in compression from its rest position and biases thebattery terminal39 toward its rest position. Alternatively, thespring89 may be designed to deflect in tension from its rest position to bias thebattery terminal39 toward its rest position.

Thescrew87, crimp-onconnector107,coil spring89 and portions of thebattery terminals39A are situated withincavity109 in thehandgrip5. Thecavity109 has a diameter at least slightly larger than the diameter of thescrews87 to afford float of thebattery terminals39A. Unlike thebattery terminals39A, thebattery terminals39A comprise a substantially flat, rectangular contact member having a pair ofopposite sides91 and92 for contacting thebattery contacts33A.

Battery contacts33A for use with thebattery terminals39A is shown inFIGS. 13,14 and24. Each of thebattery contacts33A include a pair of flexible, resilient deflectingmembers81 and82. The flexible, resilient deflectingmembers81 and82 each have a first end rigidly affixed to thebattery housing31, and a second end, opposite the first end. The second end of themembers81 and82 is free to slide along the top of thecasing31 when themembers81 and82 are deflected. Asupport shoulder surface115 of the top portion of thebattery housing31 receives the second end of themembers81 and82 and affords sliding movement of the second ends of themembers81 and82.

Thebattery terminal39A is designed to be sandwiched between the flexible, resilient deflectingmembers81 and82 and to deflect themembers81 and82 in a direction that is substantially perpendicular to both of the axes H and D during vibration of thebattery terminals39A. Preferably,side91 of thebattery contact33A is in electrical communication with deflectingmember81, andside92 of the battery contact is in electrical communication with deflectingmember82.

Thebattery contacts33A are constructed from a flexible, resilient, electrically conductive material. Any of the materials and platings mentioned above for use in constructing thebattery contacts33 may be used to construct thebattery contacts33A. Particular examples include beryllium copper,Brush Wellman alloy 25, 0.0159 (26 Ga) thick, ¼ H temper, or equivalent UNS No. C17200, (ASTM temper TD01) heat treated 2 hours @ 600 degrees fahrenheit (ASTM TH01), R/C 38-43. As an example not intended to be limiting, thecontacts33A may have an overall height inFIG. 14 of about 0.17 inches, a overall length (FIG. 13) of about 1.44 inches and an overall width of approximately 0.32 inches.

FIGS. 22 and 23 illustrate another embodiment ofbattery contact33B for use with a drive assembly having the battery terminals of FIG.11. Thebattery contact33B is similar to thebattery contact33A except in that thecontact33B has a slightly different shape when viewed in the top view.

Thehandle portion6 of the housing has a releasable attachment means for releasably attaching thebattery30 to thebattery receiving portion48 in a direction other than the direction of elongation of thehandle portion6. In the illustrated embodiment, that means comprises surfaces on thebattery receiving portion48 definingtrack portions49 with flanges that are elongate in a direction substantially parallel to the longitudinal axis D of the drive portion. Thebattery30 has a pair of opposite mountinggrooves35 adapted to cooperably receive the flanges of the track portions49 (see FIGS.4 and6).

Thebattery pack30 also has a pair of flexible,resilient cantilever members37 having opposite ends. Each of thecantilever members37 has a first end attached to thebattery housing31 and an enlargeddistal end38. Thecantilever members37 project from the structure defining thegrooves35 in a direction other than direction of elongation of the handle portion6 (preferably in a direction substantially parallel with the top of the battery and the drive portion axis D). Referring now toFIG. 11, thebattery receiving portion48 of the housing includes a cantilevermember receiving cavity77 formed in part by a relatively thin shelf. The cantilevermember receiving cavity77 includes radiused side walls75 (see FIG.12).

The flexible,resilient cantilever members37 are shown mounted in the cantilevermember receiving cavity77 in FIG.12. When thebattery30 is mounted on thebattery receiving portion48, the flexible,resilient cantilever members37 interfere with the surfaces defining the cantilevermember receiving cavity77 to resist movement of thebattery30 relative to the rest of thedevice10, particularly movement in the D axis direction. The flanges of thetrack49 cooperably engage thegrooves35 and prevent thebattery30 from separating from the rest of thedevice10.

The distal ends38 of the flexible,resilient cantilever members37 have abevel78 to allow them to ramp onto the shelf forming thecavity77. The engagement between thebevel78 and the shelf forming thecavity77 forces the flexible,resilient cantilever members37 upwards in the H axis direction (inFIG. 2) when thebattery30 is mounted in thebattery receiving portion48. Consequently, thebattery30 is forced into abutment with the manually graspingportion5. When thebattery30 is fully mounted in the battery receiving portion48: (1) portion71 (seeFIG. 3) of thebattery housing31 is preferably in contact with the bottom side of the shelf forming thecavity77, and (2) the flexible,resilient cantilever members37 are in engagement with the side surfaces forming thecavity77 which results in a pinching interference fit that tends to resist transmission of vibration to thecontacts33 or33A. The pinching interference holds the flanges of thetrack portions49 in engagement with thegrooves35 of thebattery housing31 to retain thebattery30 attached to thehandgrip5.

The enlarged distal ends38 of the flexible,resilient cantilever members37 have an outwardbiased radius28. When thebattery30 is inserted into the receivingportion48 of thehandle portion6, the outward biasedradius28 contacts the radiused side wall75 (FIG.12). The width between the outermost portions of the two distal end outward biasedradiuses28 is greater than the width of theradiused side walls75. With this difference in widths, the flexible,resilient cantilever members37 are forced inward when thebattery30 is received in thebattery receiving portion48 thereby generating a resistance to movement. For example, the interference is preferably less than about 0.1 inches and is more preferably less than about 0.02 inches. This slight interference causes theresilient members37 to deflect and to provide excellent frictional contact with thecavity77 in thebattery receiving portion48. In the manner described above, thecantilever members37 stabilize the front end of thebattery30. This is especially effective in resisting movement when using the instrument is used for oscillating sawing where side to side forces (perpendicular to the axis H) are generated.

Preferably, the flexible,resilient cantilever members37 comprise a single, unitary, integral monolithic piece with thebattery housing31. Thus, the material for thebattery housing31 should be sufficiently durable for forming a battery housing (e.g. it should be able to withstand autoclaving procedures), and yet resilient flexible to accomplish the repeated interference fit of the flexible,resilient cantilever members37 andcavity77. Any suitable materials may be used including the materials discussed above as suitable for use to construct thecasing31. Alternatively, the flexible,resilient cantilever members37 may be constructed from a material different than the material used to construct thecasing31.

When thedrive assembly10 is held in the position referenced inFIG. 2, the mountinggrooves35 and flanges of thetrack portions49 are cooperable to resist the effect of gravity on thedevice10 which, in prior art devices, tends to urge the battery away from contact with the rest of the device. Alatch56 is provided for releasably securing thebattery30 to thebattery receiving portion48, and for retaining the electrical contact betweencontacts33 of thebattery30 and the battery terminals39 (or theterminals39A with thecontacts33A) of thebattery receiving portion48. Thelatch56 comprises a blockingmember57 mounted on the lower portion of thehousing6 for movement between a latched (FIG. 4) and a release position. Acoil spring58 biases the blockingmember57 toward the latched position. Thelatch56 also includes thebattery housing31 havingsurfaces defining slot34 for receiving achamfered end55 of the blockingmember57.

In the latched position, (1) the mountinggrooves35 of thebattery30 are received in the track portions49 (seeFIG. 4) in thebattery receiving portion48, and (2) thechamfered end55 of the blockingmember57 is biased into engagement with theslot34 of thebattery30 to lock thebattery30 to thebattery receiving portion48 of the housing.Indicia59 may be present to provide user information such as how to unlatch thebattery30.

Thelatch56 also includes means for automatically moving the blockingmember57 from the latched toward the release position as thebattery30 is mounted to thebattery receiving portion48. That means comprises thebattery housing31 having aramp surface36 adapted to engage thechamfered end55 on the blockingmember57.

Referring toFIG. 2, as thebattery30 is slid into thetrack portions49 of thebattery receiving portion48, theramp surface36 engages thechamfered end55 of the blockingmember57 and cams the blockingmember57 toward the release position, thereby enabling the flanges of thetrack portions49 to be slid into the corresponding,cooperable grooves35 of thebattery housing31. Once thebattery30 is fully mounted on thebattery receiving portion48, thechamfered end55 of the blockingmember57 is biased into engagement with theslot34 of thebattery housing31 as described above. The side of the blockingmember57 oppositechamfered end55 is not chamfered to resist inadvertent release of thebattery30.

As a portion of the electrical circuit means mentioned above, thedrive assembly10 also includes a convenient rotary switch means, operated by ribbedmember72 on the proximal end1 of thedrive housing4 oppositedrive member18, for causing themotor12 to rotate thedrive member18 either in forward or reverse (clockwise or counterclockwise) directions, or to prevent any rotation by themotor12 even when thetrigger40 is moved to its inner position.Indicia73 indicate when the device is in the forward, reverse or stop modes.

FIG. 21 is a schematic illustration of the switch means. The motor control switch with forward, off and reverse positions is preferably mounted behind the motor. The motor control switch includes arotatable knob72 with an attachedmagnet62 and adetent mechanism63 with three positions that correspond to the forward, off and reverse positions. When the knob is rotated fully clockwise, themagnet62 by its magnetic field, activates one of twohall sensors61 to run the motor counter-clockwise when facing the output shaft. When the knob is rotated fully counter-clockwise, it will reverse the motor. A center, neutral (off) position is also included.

The present invention has now been described with reference to several embodiments thereof. It will be apparent to those skilled in the art that many changes or additions can be made in the embodiments described without departing from the scope of the present invention. Thus, the scope of the present invention should not be limited to the structures described in this application, but only by structures described by the language of the claims and the equivalents of those structures.

Claims (36)

1. A rechargeable battery adapted to be repeatably and releasably attached to an orthopedic drive assembly, the orthopedic drive assembly having elongate drive and handle portions, a battery receiving portion having a pair of tracks defining flanges, a pair of battery terminals, and a blocking member movable between latched and release positions;

said battery comprising:

an autoclavable battery housing having top and bottom portions, at least one cell within the battery housing and a pair of battery contacts adjacent the top portion of the housing and situated to engage the battery terminals of the orthopedic drive assembly,

releasable attachment means for releasably attaching the battery to the battery receiving portion in a direction other than the direction of elongation of the handle portion,

said releasable attachment means comprising:

a) the battery having a pair of grooves adapted to receive the flanges of the tracks, and

b) a slot for receiving the blocking member when the blocking member is in the latched position.

2. A rechargeable battery according toclaim 1 wherein each of the battery terminals comprise a substantially flat plate member having opposite side surfaces, and

each of said battery contacts comprise a pair of flexible, resilient arcuate members which are adapted to engage opposite side surfaces of a battery terminal.

3. A rechargeable battery according toclaim 1 wherein said battery contacts each include a first end fixedly attached to said top portion of said battery housing and a second end adapted to abut a support shoulder of the top portion of the battery housing.

4. A rechargeable battery according toclaim 1 wherein said battery housing comprises opposite, substantially flat front and rear walls constructed from a material suitable for protecting the cell(s) during an autoclave procedure,

said battery comprises eight substantially cylindrical cells having longitudinal axes, said eight cylindrical cells being arranged in:

a) a front row of three cells substantially adjacent said front wall within the battery housing,

b) a rear row of three cells substantially adjacent said rear wall within the battery housing, and

c) a middle row of two cells between said front and rear rows wherein all eight cells are within the battery housing.

5. A rechargeable battery according toclaim 1 wherein the slot is sized and shaped to engage the blocking member to lock the battery to the battery receiving portion when the blocking member is in the latched position.

6. A rechargeable battery according toclaim 1 wherein the battery further includes means for automatically moving the blocking member from the latched toward the release position as the battery is mounted to the battery receiving portion.

7. A rechargeable battery according toclaim 6 wherein the means for automatically moving the blocking member comprises a ramped surface on the top portion of the battery housing.

8. A rechargeable battery adapted to be repeatably and releasably attached to an orthopedic drive assembly, the orthopedic drive assembly having elongate drive and handle portions, a battery receiving portion having a pair of tracks defining flanges, a pair of battery terminals, and a blocking member movable between latched and release positions;

said battery comprising a battery housing having top and bottom portions, at least one cell within the battery housing, and a pair of battery contacts adjacent the top portion of the housing and situated to engage the battery terminals of the orthopedic drive assembly when the battery is fully received by the orthopedic drive assembly,

releasable attachment means for releasably attaching the battery to the battery receiving portion, said releasable attachment means comprising:

a) the battery having a pair of grooves adapted to receive the flanges of the tracks, and

b) a slot for receiving the blocking member when the blocking member is in the latched position, wherein the slot is sized and shaped to engage the blocking member to lock the battery to the battery receiving portion when the blocking member is in the latched position.

9. A rechargeable battery according toclaim 8 wherein the battery further includes means for automatically moving the blocking member from the latched toward the release position as the battery is mounted to the battery receiving portion.

10. A rechargeable battery according toclaim 9 wherein the means for automatically moving the blocking member comprises a ramped surface on the top portion of the battery housing.

11. A rechargeable battery according toclaim 8 wherein each of the battery terminals comprise a substantially flat plate member having opposite side surfaces, and

each of said battery contacts comprise a pair of flexible, resilient arcuate members which are adapted to engage opposite side surfaces of a battery terminal.

12. A rechargeable battery according toclaim 8 wherein said battery contacts each include a first end fixedly attached to said top portion of said battery housing and a second end adapted to abut a support shoulder of the top portion of the battery housing.

13. A powered device with a detachable, rechargeable battery comprising:

a housing having an electric motor associated therewith, an elongate handgrip portion, and a battery receiving portion attached to a bottom end of the handgrip portion, the battery receiving portion including battery terminals, the battery terminals being electrically connected to the electric motor via a power switch for delivering electric power to the electric motor;

a battery comprising a battery casing, at least one rechargeable battery cell housed inside of the battery casing, and battery contacts adapted to contact the battery terminals formed on the housing when the battery is attached to the housing, the at least one rechargeable battery cell being electrically connected to the battery contacts; and

wherein one of the housing or the battery casings has a pair of flange formed thereon, and the other of the housing or the battery casing has a pair of mounting grooves formed thereon which engage the pair of flanges in a direction of engagement other than the general direction of elongation of the handgrip portion when the rechargeable battery is mounted to the housing; and

wherein the handgrip portion does not house any part of the electric motor.

14. The tool ofclaim 13 wherein a drill chuck is operatively connected to the electric motor to drive a drill.

15. The tool ofclaim 13 further comprising means for releasably securing the battery to the battery receiving portion.

16. The tool ofclaim 13 wherein the rechargeable battery cell comprises at least two electrically connected, individual, rechargeable, cylindrical battery cells arranged in a plurality of rows and housed inside of the battery casing.

17. The tool ofclaim 13 wherein the pair of flanges or the pair of mounting grooves that is formed on the battery casing is at least one-third the length of a top portion of the battery casing.

18. The tool ofclaim 13 wherein the rechargeable battery cell comprises at least five series electrically connected, individual, rechargeable, cylindrical battery cells arranged in a plurality of rows and housed inside of the battery casing; and

the pair of flanges or the pair of mounting grooves that is formed on the battery casing is at least one-third the length of a top portion of the battery casing.

19. The tool ofclaim 16 wherein the battery casing comprises two halves joined together, and each of the halves formed approximately a half of a top portion of the battery casing and a half of a bottom portion of the battery casing.

20. The tool ofclaim 16 wherein the pair of flanges is a pair of parallel flanges, and the pair of mounting grooves is a pair of parallel mounting grooves.

21. The tool ofclaim 13 wherein the housing further comprises a motor portion attached to a top end of the handgrip portion opposite the handgrip portion's bottom end, and wherein a longitudinal axis of the handgrip portion intersects the motor portion and the battery receiving portion and the battery casing when the battery is attached to the housing.

22. The tool ofclaim 21 wherein the rechargeable battery cell comprises at least five electrically connected, individual, rechargeable, cylindrical battery cells arranged in a plurality of rows and housed inside of the battery casing.

23. The tool ofclaim 22 wherein the pair of flanges or the pair of mounting grooves that is formed on the battery casing is formed on a top portion of the battery casing opposite a bottom portion with a generally flat bottom surface.

24. The tool ofclaim 22 wherein the battery contacts are positioned on the top portion of the battery casing between the pair of flanges or the pair of mounting grooves that is formed on the battery casing.

25. The tool ofclaim 13 wherein the battery casing further comprises a top portion and an opposite bottom portion, the bottom portion having a substantially flat bottom surface that is parallel to the direction of engagement, and wherein the pair of flanges or the pair of mounting grooves that is formed on the battery casing is formed on the top portion of the battery casing.

26. The tool ofclaim 25 wherein the battery contacts are positioned between the pair of flanges or the pair of mounting grooves that is formed on the battery casing.

27. The tool ofclaim 26 wherein the battery contacts and the battery terminals comprise a substantially flat plate member having opposite side surfaces, and resilient deflecting members which engage the opposite side surfaces of the plate member.

28. A powered device with a detachable, rechargeable battery comprising:

a housing having an electric motor associated therewith, an elongate handgrip portion, and a battery receiving portion attached to a bottom end of the handgrip portion, the battery receiving portion including battery terminals, the battery terminals being electrically connected to the electric motor via a power switch for delivering electric power to the electric motor;

a battery comprising a battery casing, at least one rechargeable battery cell housed inside of the battery casing, and battery contacts adapted to contact the battery terminals formed on the housing when the battery is attached to the housing, the at least one rechargeable battery cell being electrically connected to the battery contacts; and

a drill chuck operatively connected to the electric motor to drive a drill;

wherein one of the housing or the battery casing has a pair of flanges formed thereon, and the other of the housing or the battery casing has a pair of mounting grooves formed thereon which engage the pair of flanges in a direction of engagement other than the general direction of elongation of the handgrip portion when the rechargeable battery is mounted to the housing.

29. The tool ofclaim 28 wherein the electric motor drives a planetary gear transmission, and the planetary gear transmission drives a drive spindle adapted to mount the drill chuck.

30. The tool ofclaim 28 wherein the rotary axis of the electric motor is parallel to the direction of engagement.

31. The tool ofclaim 28 wherein the rechargeable battery cell comprises at least five electrically connected, individual, rechargeable, cylindrical battery cells arranged in a plurality of rows in a single plane and housed inside of the battery casing.

32. The tool ofclaim 31 wherein the longitudinal axes of all of the battery cells are parallel to each other and perpendicular to the single plane.

33. A powered device with a detachable, rechargeable battery comprising:

a housing having an electric motor associated therewith, an elongate handgrip portion, and a battery receiving portion attached to a bottom end of the handgrip portion, the battery receiving portion including battery terminals, the battery terminals being electrically connected to the electric motor via a power switch for delivering electric power to the electric motor; and

a battery comprising a battery casing, at least five electrically connected, individual, rechargeable, cylindrical battery cells arranged in a plurality of rows in a single plane and housed inside of the battery casing, and battery contacts adapted to contact the battery terminals formed on the housing when the battery is attached to the housing, the battery cells being electrically connected to the battery contacts;

wherein one of the housing or the battery casing has a pair of flanges formed thereon, and the other of the housing or the battery casing has a pair of mounting grooves formed thereon which engage the pair of flanges when the rechargeable battery is mounted to the housing.

34. The tool ofclaim 33 wherein a drill chuck is operatively connected to the electric motor to drive a drill.

35. The tool ofclaim 33 further comprising a saw blade mounted for reciprocating motion and driven by the electric motor.

36. The tool ofclaim 33 wherein the pair of flanges is a pair of parallel flanges, and the pair of mounting grooves is a pair of parallel mounting grooves.

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