Patent Description:
Medical environments such as hospitals, surgery centers, urgent care centers, clinical care centers, and others utilize batteries to power devices such as scopes, cameras, surgical tools, and various powered tools and accessories. Often these devices need to be cleaned, sanitized, or sterilized prior to use or between uses. Recharging the batteries in these devices presents a challenge in medical environments. The remainder of this disclosure addresses solutions in this field. <CIT> describes a battery pack device including a housing, a plurality of electrical contacts, a plurality of electrical connectors, a moveable control device, and a battery. <CIT> battery charging system that includes a battery charging chute that comprises a housing configured to receive a battery via an insertion slot and configured to dispense a battery through a dispensing slot.

These embodiments are not intended to limit the scope of the disclosure. Aspects of the invention are in accordance with the appended independent claims. Various optional features are the subject of the dependent claims.

There is described a wireless charging system for recharging batteries in a medical environment includes a charging station. The charging station includes a housing that may comprise a rear plate, a slidable front cover, and a base; an inlet for depleted batteries at a top of the housing, wherein the inlet comprises an opening between the rear plate and the slidable front cover an outlet for charged batteries below the inlet, wherein the outlet comprises a slot in the front slidable cover; a vertical channel extending between the inlet and outlet; a wireless power transmitter inside the rear plate, wherein the wireless power transmitter comprises a transmitting antenna; a status light on the housing; and a power supply connected to the housing. The wireless charging system also includes at least two rechargeable batteries in different orientations inside the vertical channel, each battery having a wireless power receiver which comprises a receiving antenna, and each battery sealed inside a sterile barrier, wherein the transmitting antenna has a vertical length that is longer than a horizontal width, and wherein the horizontal width increases in a middle section of the transmitting antenna to create a bulged shape, the transmitting antenna sized to charge the at least two rechargeable batteries simultaneously in the different orientations.

There is described a charging station for recharging batteries in a medical environment includes a housing comprising an inlet for batteries at atop of the housing, an outlet for charged batteries below the inlet, and a vertical channel extending between the inlet and outlet; a wireless power transmitter inside the housing, wherein the wireless power transmitter comprises a transmitting antenna configured to wirelessly charge a plurality of rechargeable batteries simultaneously by transmitting wireless power to a wireless power receiver of each of the plurality of batteries, and wherein the transmitting antenna, in operation, is configured to charge the plurality of batteries independent of orientation in the charging station; a status light on the housing; and a power supply connected to the housing.

A method for wirelessly recharging batteries inside a sterile barrier includes the steps of receiving a first battery through an inlet at a top of a charging station as claimed herein, the first battery sealed inside a first sterile barrier; receiving a second battery through the inlet and onto the first battery to form a stack of batteries inside the charging station, the second battery sealed inside a second sterile barrier; transmitting power wirelessly to the first battery through the first sterile barrier and simultaneously transmitting power wirelessly to the second battery through the second sterile barrier; providing the first battery in a charged state through an outlet at a bottom of the charging station; and subsequently, providing the second battery in a charged state through the outlet.

Advantages of the disclosed techniques may become apparent upon reading the following detailed description and upon reference to the drawings in which:.

The present disclosure relates generally to medical devices and, more particularly, to a battery charging system for wirelessly charging batteries across a sterile barrier in a medical environment. A wireless charging system <NUM> according to an embodiment is depicted in <FIG>. The wireless charging system <NUM> includes a charging station <NUM> and several rechargeable batteries <NUM>. Each battery is sealed inside a sterile barrier <NUM>. However, the wireless charging system <NUM> is also capable of charging batteries <NUM> that are not sealed within a sterile barrier <NUM>. The charging station <NUM> transmits power wirelessly to the batteries <NUM> across the sterile barrier <NUM>, so that the batteries do not need to be sterilized again after charging. The batteries enter the charging station through an inlet <NUM> at the top and then exit the charging station at an outlet <NUM> at the bottom in a first-in first-out order, such that the battery that entered first exits first. This ordering dispenses batteries <NUM> in order of the amount of time they have spent inside the charging station <NUM>, to reduce the chance that a battery <NUM> is removed from the station <NUM> before it has had time to charge.

As shown in <FIG>, the batteries <NUM> are oriented generally horizontally inside the charging station, forming a vertical stack of batteries that move from the inlet <NUM> toward the outlet <NUM> as batteries at the outlet are taken for use. The batteries <NUM> can receive power wirelessly regardless of their orientation inside the charging station <NUM>; charging a battery <NUM> inside the charging station <NUM> is not dependent on any particular orientation (turned, tilted, rotated, etc.) of the battery <NUM>. The stacked batteries <NUM> can all have a same general orientation within the charging station <NUM>, or some or all of the batteries <NUM> can have different orientations relative to other batteries <NUM>. Regardless, the charging station <NUM>, in operation, charges the batteries independent of their orientation within the charging station <NUM>. In addition, the charging station <NUM> can be mounted or arranged in other orientations and charge the batteries <NUM>.

The charging station <NUM> is shown in <FIG> in an empty or unloaded state without any batteries <NUM> that are being charged. In an embodiment, the charging station <NUM> includes a housing <NUM> with a rear plate <NUM>, a front cover <NUM>, and a base <NUM>. The base <NUM> includes or is attached to a power supply such as a battery, a power generator, or a power cord <NUM> (which attaches to an external power supply such as a wall outlet). The inlet <NUM> is an opening formed between the front cover <NUM> and the rear plate <NUM>. The outlet <NUM> is formed as a horizontal slot in the front cover, below the inlet <NUM> and above the base <NUM>. The top of the base <NUM> can also serve as a tray <NUM> on which the batteries rest. The housing <NUM> also includes an indicator light <NUM>, such as a vertical or horizontal light bar or shaped light indicator (e.g., circle, star, triangle), LED light or strip, illuminated surface, or other suitable visible indicator. In <FIG>, the indicator light <NUM> is a horizontal light bar at the bottom of the base <NUM>.

<FIG> also shows some internal components of the charging station <NUM>. A wireless power transmitter <NUM> is located inside the rear plate <NUM>. In an embodiment, the wireless power transmitter <NUM> includes a transmitting antenna formed on a printed circuit board (PCB). The charging station <NUM> also includes a main board <NUM> in the base <NUM>. The main board <NUM> includes a processor, memory, and other components for operating the charging station <NUM>.

The power transmitter <NUM> transmits power wirelessly to the batteries <NUM> inside the charging station. As shown in more detail in <FIG> (and described below), each battery includes a power receiver <NUM> such as a receiving antenna, that receives the wirelessly-transmitted power and stores it in a battery cell <NUM>. The power transmitter <NUM> is designed to send power wirelessly to multiple batteries <NUM> at the same time. Referring to <FIG>, in an embodiment the charging station <NUM> can charge at least four batteries <NUM> simultaneously. The charging station <NUM> has a shape that is large enough to contain at least four batteries <NUM> inside the charging station, and the power transmitter <NUM> is sized to transmit power to these four batteries simultaneously, so that the four batteries are all receiving power at the same time. This is accomplished by the relative sizing and orientation of the power transmitter <NUM> and the power receivers <NUM>. In an embodiment, both the power transmitter <NUM> and the power receivers <NUM> are elongated, meaning that they have one dimension longer than the other. The power transmitter <NUM> is oriented inside the rear plate <NUM> such that the longer dimension 136a is vertical, and the shorter dimension 136b is horizontal. This shape and orientation of the power transmitter <NUM> creates a charging field (such as a magnetic field) inside the charging station, and the batteries <NUM> pass through the charging field as they pass through the charging station. In an embodiment, the batteries are oriented such that their longer dimension is generally horizontal (see <FIG>). This enables at least four batteries <NUM> to fit inside the charging field created by the power transmitter <NUM>. However, the batteries <NUM> receive charge in any orientation inside the charging field.

Although four batteries are shown in <FIG>, in other embodiments, different numbers of batteries can be charged simultaneously, such as two, three, five, six, seven, eight, nine, ten, or more batteries.

Referring again to <FIG>, the power transmitter <NUM> has a rectangular shape, taller than wide, with a bulge <NUM> in the middle. The shorter dimension 136b of the power transmitter widens in the center, to create the bulge <NUM>. This bulged shape compensates for the loss in strength of the charging field along the long dimension of the rectangle. The charging field is relatively stronger at the corners of the rectangle (of the power transmitting antenna), and the field is relatively weaker along the longer ends. Thus, a rectangular charging antenna creates a charging field with an hourglass shape (narrower in the middle). The bulge <NUM> is a reverse hourglass shape, which compensates for the shape of the charging field and creates a more uniform charging field along the length of the charging antenna.

In an embodiment, the transmitting antenna on the power transmitter <NUM> has a horizontal length 136b that is longer than the longest dimension of the receiving antenna <NUM> in the battery <NUM>. This shape creates a charging field that is bigger than the battery's receiving antenna, and the battery <NUM> can receive charge in any orientation inside the charging station. The battery <NUM> can be rotated or turned in any orientation inside the charging station <NUM> and still effectively receive power to charge the battery. As shown in <FIG>, the batteries <NUM> in the stack of batteries are tilted in different directions, away from horizontal, and they are all receiving power simultaneously. The batteries <NUM> do not need to be aligned in a particular way in order to receive charge in the charging station <NUM>. They can face in toward the plate <NUM> or out toward the cover <NUM>. In an embodiment, the charging station is sized and shaped to receive the batteries in a generally horizontal orientation so that the batteries rest in a vertical stack inside the charging station and arrive at the outlet in a first-in first-out order. However if a battery moves through the charging station in a different orientation (vertical, or tilted), it will still receive power. The battery can be dropped into the charging station quickly and easily, without needing to be precisely aligned.

An example of a wireless charging system <NUM> in use is shown in <FIG>. In <FIG>, a first battery <NUM> in a depleted state is deposited into the charging station <NUM> through the inlet <NUM> at the top. If the charging station <NUM> is empty, the first battery <NUM> passes through the charging station to the base <NUM>, where it rests on the tray <NUM>. If the charging station <NUM> is turned on and operating, it transmits power wirelessly to the first battery <NUM>.

In <FIG>, additional batteries <NUM>, <NUM>, <NUM>, <NUM> are inserted into the charging station through the inlet <NUM>, forming a vertical stack of batteries. In this example, the charging station is large enough to contain at least five batteries, and to simultaneously charge at least four batteries at the same time.

In <FIG>, the first battery <NUM> is being removed from the charging station through the outlet <NUM>, which is formed a horizontal slot above the base <NUM>. The battery <NUM> entered the charging station first (before batteries <NUM>, <NUM>, <NUM>, and <NUM>) and exits first (ahead of batteries <NUM>, <NUM>, <NUM>, <NUM>). The shape of the housing <NUM> orients the batteries in this order, such that the batteries arrive at the outlet in the same order that they entered the inlet. This means that the battery that has spent the longest time in the charging station, and thus had the longest amount of time to receive charge, is the first one available to be taken for use.

In an embodiment, the housing <NUM> of the charging station is formed as a cabinet or bin that receives depleted batteries into the housing. The housing accepts the batteries through the inlet one at a time and keeps them in that order as they pass through the housing to the outlet.

<FIG> show an embodiment in which the front cover <NUM> is slidable vertically along the housing <NUM>. In <FIG>, the front cover <NUM> slides up to expose the base <NUM>, and in <FIG> the front cover <NUM> slides down to expose the top of the rear plate <NUM>. In this embodiment, the front cover <NUM> includes an open top and an open bottom, so that it can slide in either direction. This sliding motion can be helpful to access either end of the housing <NUM> (such as the base <NUM> or the plate <NUM>) for inspection or cleaning. In an embodiment, the front cover <NUM> is fully or partially transparent, so that the batteries <NUM> inside the charging station are visible through the front cover <NUM>. As shown in <FIG>, in an embodiment, the outlet <NUM> is formed as a cutout edge that creates a horizontal slot in the front cover <NUM>.

A top view of the cover <NUM> and plate <NUM> is shown in <FIG>. The cover <NUM> has a bracket shape with rear wings <NUM> that hook around the plate <NUM>, to hold the cover <NUM> in place. <FIG> also shows the space formed between the rear plate <NUM> and the front cover <NUM>, to accept the batteries <NUM> into the charging station. The space between the rear plate <NUM> and the front cover forms a channel <NUM> through the charging station. The channel <NUM> is sized and shaped to receive the batteries <NUM> in a horizontal orientation, so that multiple batteries can fit inside the charging station, forming a vertical stack of batteries along the channel <NUM>. In an embodiment, the channel <NUM> is a vertical channel that extends along the vertical plate <NUM>.

In an embodiment, the housing <NUM> includes a contoured surface <NUM> along the channel <NUM>. In an example, the contoured surface <NUM> is the front surface of the rear plate <NUM>. In this example, the contoured surface <NUM> widens in the middle, to accommodate the width of the batteries <NUM>. The contoured surface <NUM> includes a recessed center, where the depth of the channel <NUM> increases. In an embodiment, the channel comprises has a vertical length, a horizontal width, and a depth perpendicular to the width, and the vertical length is longer than the horizontal width, and the horizontal width is longer than the depth. The depth of the channel increases in the recessed center. As shown in <FIG>, this recess helps guide the batteries <NUM> into the channel <NUM> in a generally horizontal orientation.

The charging station <NUM> can be used to charge batteries <NUM> that are in sterile barrier <NUM> or that are not sterile and, therefore, have a smaller footprint. <FIG> shows a first arrangement of a configurable charging station <NUM> with a first cover 124a that is sized to accommodate the larger sealed batteries <NUM> within respsetive sterile barriers <NUM>. The cover 124a fits over the base <NUM>, which is generally smaller (narrower) than the cover 124a such that the first cover 124a extends beyond the lateral edges of the base <NUM>. That is, a width <NUM> of the base <NUM> is less than a width <NUM> of the cover 124a. Removal of the larger cover 124a and replacement with a smaller cover 124b (<FIG>) transitions the charging station <NUM> to a second arrangement that is sized to better accommodate nonsterile batteries <NUM> that are not within sterile barriers <NUM>. In an embodiment, the second cover 124b is about as wide as the width <NUM> of the base <NUM>. The configurable charging station <NUM> can be provided as a kit with different covers 124a, 124b to be removed and replaced as desired by the user, depending on whether sterile or nonsterile batteries <NUM> are generally charged. It should be understood that both sterile and nonsterile batteries <NUM> fit within the cover 124a of the first arrangement.

<FIG> show different states of the indicator light <NUM>. In <FIG>, the indicator light <NUM> is illuminated in a first state, such as a solid first color. This first color can be white, green, blue, or other colors, and the solid state means the color is not blinking. This state of the indicator light means the charging station <NUM> is turned on and operating normally. In <FIG>, the indicator light <NUM> has changed to a second color (such as red, orange, yellow, or other colors) and is flashing. This can indicate an error state, to alert users that the charging station <NUM> is not operating correctly. When the indicator light <NUM> is dark (not turned on), then that means that the charging station <NUM> is not powered on. Different combinations of colors, blinking patterns, and visible indications (brightness, etc.) correspond with various system states, to communicate information to the user.

In an embodiment, the batteries <NUM> also include an indicator light <NUM>. This is a visible indicator that shows the state of charging of the batteries <NUM>. A first state of the indicator <NUM> (color, blinking pattern, brightness, or combinations of visual indications) indicates that the battery is depleted and receiving power. A second state (different color, etc.) indicates that the battery is fully charged. A third state indicates that the battery is malfunctioning, or not charging correctly. A dark state indicates that the battery is not currently charging.

<FIG> show two options for mounting the charging station <NUM> in a medical environment. <FIG> shows a wall mount <NUM> including a bracket <NUM> that attaches the housing <NUM> to a wall. <FIG> shows an upright stand or rack <NUM> that supports the housing <NUM> and can be placed on a horizontal surface such as a table or counter. These are two options for placing the charging station <NUM> in a medical environment such as a hospital, operating room, surgery centers, urgent care centers, clinical care centers, and others. While disclosed embodiments show a generally vertical mounting arrangement and with the channel <NUM> being oriented vertically (perpendicular to the floor), the charging station <NUM> may be mounted in other orientations, e.g., angled or horizontally. For example, in a horizontal mounting arrangement, the batteries <NUM> can be pushed through the channel <NUM>.

<FIG> shows an exploded view of a chargeable battery <NUM>, according to an embodiment. In an embodiment, the battery <NUM> is re-chargeable, meaning it can be charged again after is has been depleted. The battery <NUM> includes a power receiver <NUM> such as a printed circuit board with a power receiving antenna. The power receiver <NUM> is coupled to a battery cell <NUM>, which stores the received power. In an embodiment, the battery cell <NUM> is a lithium cell. The battery <NUM> also includes a top case or cover <NUM>, a main printed circuit board <NUM>, a flex circuit <NUM>, and a rear case or cover <NUM>, among other components. In an embodiment, the indicator light <NUM> is an LED (light emitting diode) carried by the flex circuit <NUM> and visible through the front case <NUM>.

<FIG> shows a method for wirelessly charging batteries for a medical device, in this case a video laryngoscope. At number <NUM>, a battery <NUM> is removed from the outlet of the charging station (also referred to as the power transmitting unit, PTU). At number <NUM>, the battery <NUM> is removed from the sterile barrier <NUM>, for insertion into a medical device. In the example of <FIG>, the battery <NUM> is a battery 112for a video laryngoscope <NUM>. At number <NUM>, the battery <NUM> is inserted or plugged into the medical device (such as the video laryngoscope <NUM>), and the medical professional (such as a doctor, therapist, nurse, or other practitioner) uses the medical device in a medical procedure (such as an intubation - inserting an endotracheal tube or other airway device into a patient's airway passages such as the trachea). In number <NUM>, the battery <NUM> is decontaminated after use. In an example, the battery <NUM> is cleaned with a cleaning solution or is sterilized. In number <NUM>, the cleaned battery <NUM> is placed inside a sterile barrier <NUM> and sealed. In number <NUM>, the depleted battery <NUM> is placed back into the top of the charging station, where it passes through the charging field in the vertical stack of batteries <NUM> and receives power from the charging station <NUM>. The battery <NUM> emerges at the outlet in a charged state, back at numeral <NUM> in <FIG>, and the cycle repeats.

Batteries <NUM> can be received into the inlet in any state - charged, partially charged, or depleted. Depending on the particular environment where they are used, the batteries <NUM> may be fully depleted before they are decontaminated and returned to the charging station <NUM>, or they may be only partially depleted. In the example of <FIG>, an intubation performed with a video laryngoscope <NUM> may deplete the battery <NUM> only partially, and the battery <NUM> is then moved through steps <NUM>, <NUM>, and <NUM> and charged back to full in the charging station <NUM>. If a particular video laryngoscopy <NUM> procedure takes a longer amount of time, for example, the battery <NUM> in use may be depleted further or fully depleted. The charging station <NUM> can accept batteries <NUM> in any of these conditions, for charging back to full.

In an embodiment, the sterile barrier <NUM> is a plastic or paper pouch that is sealed around the battery <NUM> such as by vacuum or heat sealing, creating a sterile single or double barrier with the battery inside. The barrier <NUM> is compatible with sterilization methods (such as chemical, temperature, or radiation methods) and does not block the magnetic charging field from the power transmitter <NUM>.

According to an embodiment, a method is provided for wirelessly recharging batteries (e.g., batteries <NUM>) inside a sterile barrier (e.g., sterile barrier <NUM>). The method includes receiving a first battery in a depleted state through an inlet at a top of a charging station (e.g., charging station <NUM>). The first battery is sealed inside a first sterile barrier. The method includes receiving a second battery in a depleted state through the inlet and onto the first battery to form a vertical stack of batteries inside the charging station. The second battery is sealed inside a second sterile barrier. The method includes transmitting power wirelessly to the first battery through the first sterile barrier and simultaneously transmitting power wirelessly to the second battery through the second sterile barrier, such that both batteries are charging at the same time. The method includes providing the first battery in a charged state through an outlet at a bottom of the charging station, and subsequently, providing the second battery in a charged state through the outlet.

The charging station <NUM> can be mounted as provided herein to a stand, surfaces or walls, or to equipment in a medical environment. <FIG> shows a charging station system <NUM> in which the charging station <NUM> is mounted on (e.g., mounted directly on, coupled to) a medical cabinet <NUM>. The charging station <NUM> may be close to or in direct contact with a metal surface <NUM> of the medical cabinet <NUM>, and the metal surface <NUM> can act as a power drain on the charging field generated by the power transmitter <NUM> (<FIG>) of the charging station <NUM>. <FIG> show examples of shielding arrangements for the charging station <NUM> that prevent or reduce power drains away from charging batteries <NUM> that may be caused by metallic mounting surfaces positioned close to a power transmitter.

<FIG> is a cross-sectional view of a mounted charging station <NUM> of the system <NUM>. The metal surface <NUM> is directly coupled to the housing <NUM> of the charging station <NUM>. However, it should be understood that other mounting arrangements may involve intervening mounting brackets or structures positioned between the housing <NUM> and the metal surface <NUM>. To facilitate transmission of the charging field of the power transmitter <NUM> towards any inserted batteries <NUM>, shown by the arrows, one or more shielding layers are positioned between the power transmitter and the metal surface <NUM> to form a shielded power transmitter assembly <NUM>. The shielding arrangement prevents a drain of the charging field in the direction of the metal surface <NUM>, or a drain in a direction opposite the desired direction of the charging field. Therefore, the charging field is emitted in the direction of the inserted batteries <NUM>.

In an embodiment, the shielded power transmitter assembly <NUM> includes a non-ferromagnetic layer <NUM> separated from the power transmitter <NUM> by a ferrite or ferromagnetic layer <NUM>. The non-ferromagnetic layer <NUM> may be a non-ferromagnetic metal, such as gold, silver, platinum, aluminum, copper, nickel, zinc, titanium, or combinations thereof. The non-ferromagnetic layer <NUM> may be a graphite layer. The ferrite or ferromagnetic layer <NUM> may be a ferrite or ferrous iron, cobalt, or nickel. The ferrite or ferromagnetic layer <NUM> may be in direct contact with a surface of the power transmitter opposing the direction of the charging field.

<FIG> is view of an embodiment of the shielded power transmitter assembly <NUM> that includes a curved non-ferromagnetic layer <NUM>. The assembly <NUM> also includes a first ferrite or ferromagnetic layer 226a and a second ferrite or ferromagnetic layer 226b separated by an air gap <NUM>. The power transmitter <NUM> is, in the depicted embodiment, adjacent to the second ferrite or ferromagnetic layer 226b.

Claim 1:
A charging station for recharging batteries in a medical environment, comprising:
a housing (<NUM>) comprising an inlet (<NUM>) for batteries at a top of the housing (<NUM>),
an outlet (<NUM>) for charged batteries below the inlet (<NUM>), and a vertical channel (<NUM>) extending between the inlet (<NUM>) and outlet (<NUM>);
a wireless power transmitter (<NUM>) inside the housing (<NUM>), wherein the wireless power transmitter (<NUM>) comprises a transmitting antenna configured to wirelessly charge a plurality of rechargeable batteries (<NUM>) simultaneously by transmitting wireless power to a wireless power receiver (<NUM>) of each of the plurality of batteries (<NUM>), wherein the transmitting antenna, in operation, is configured to charge the plurality of batteries (<NUM>) independent of orientation in the charging station (<NUM>), and wherein the transmitting antenna has a vertical length that is longer than a horizontal width, and wherein the horizontal width increases in a middle section of the transmitting antenna to create a bulged shape, the transmitting antenna sized to charge at least two batteries simultaneously in the different orientations;
a status light (<NUM>) on the housing (<NUM>); and
a power supply connected to the housing (<NUM>).