Battery

Claim 2

A battery comprising a casing having walls defining at least one battery cell, aqueous fluid electrolyte in the cell, an electrode assembly in the cell including positive and negative electrodes normally immersed in the electrolyte, and a vent tower extending inwardly from a wall of the casing into the cell and terminating at a free end, the vent tower having: a passageway opening inwardly through the free end of the vent tower and opening outwardly through the casing for venting gases and pressure from the cell; a porous, hydrophobic filter in the passageway adjacent the free end of the vent tower permitting movement of gas through the passageway while restricting movement of liquid through the passageway; and pressure-relief means in the passageway for allowing gas in the cell above a predetermined pressure to escape through the passageway while sealing the passageway against the escape of gas below the predetermined pressure; the free end of the vent tower being spaced sufficiently from any wall defining the battery cell that any void defined by a horizontal plane along the free end of the vent tower and the walls of the casing below the horizontal plane is greater than the volume of free electrolyte regardless of the orientation of the battery.

Claim 3

A battery according to claim 1 wherein the free end of the vent tower is configured so as to facilitate movement of electrolyte away from the passageway.

Claim 4

A battery according to claim 2 wherein the free end of the vent tower has a generally conical, frustoconical or hemispherical configuration with the surface of the free end generally sloping away from the passageway to facilitate movement of electrolyte away from the passageway.

Claim 5

A battery according to claim 3 wherein the filter has an inner end portion adjacent the free end of the vent tower, the inner end portion having a generally conical, frustoconical or hemispherical end surface extending slightly outwardly from the free end of the vent tower to facilitate movement of electrolyte away from the passageway.

Claim 6

A battery according to claim 4 wherein the filter has an outer end portion having a larger cross-sectional area than the inner end portion of the filter, and a shoulder formed along a surface of the filter between the inner end portion and the outer end portion of the filter, the inner end portion of the filter being tapered from the shoulder to its end surface, and the passageway of the vent tower having a configuration complementary to the configuration of the inner and outer end portions and shoulder of the filter, the vent tower further comprising an elastomeric filter seal positioned along the shoulder of the filter for sealing between the filter and the passageway.

Claim 7

A battery according to claim 5 wherein the outer end portion of the filter is generally cylindrical, and the inner end portion of the filter is generally conical or frustoconical, the cross-sectional area of the inner end portion across the passageway being approximately twenty percent smaller along its end surface than adjacent the outer end portion of the filter, the inner end portion of the filter being force fit within the passageway of the vent tower, and the cross-sectional area of the inner end portion across the passageway being approximately 35-50 percent smaller than the cross-sectional area of the outer end portion across the passageway.

Claim 8

A battery according to claim 5 wherein the pressure-relief means comprises: a valve housing mounted in the vent tower or casing having a tapered valve seat defining a portion of the passageway through the vent tower; a poppet movable within the passageway relative to the valve seat between a sealing position wherein the poppet seals against the valve seat and a pressure-relief position wherein the poppet does not seal against the valve seat; resilient spring means for biasing the poppet against the valve seat, the resilient spring means being sufficiently stiff to prevent the escape of gas below the predetermined pressure outwardly through the passageway and sufficiently flexible to allow the escape of gas above the predetermined pressure outwardly through the passageway; and an elastomeric valve-housing/filter seal for sealing between the valve housing and filter along the walls of the passageway.

Claim 9

A battery according to claim 3 wherein the filter is formed of a porous, hydrophobic polymeric material containing fluorine.

Claim 10

A battery according to claim 8 wherein the filter is formed of porous polytetrafluoroethylene material.

Claim 11

A battery according to claim 9 wherein the filter is formed of porous polytetrafluoroethylene material having an average pore size of approximately 10-40 micrometers, the filter having a porosity at least sufficient to permit passage of gas generated during charging of the battery.

Claim 12

A battery-powered drive assembly for driving surgical instruments in various orientations without leakage during operation or sterilization, the drive assembly comprising an electric motor for driving surgical instruments, connecting means for holding surgical instruments in operative engagement with the electric motor, and a handle connected to the electric motor; the handle including manually actuated means for controlling the electric motor, and a battery comprising a casing having walls defining at least one battery cell, aqueous fluid electrolyte in the cell, an electrode assembly in the cell including positive and negative electrodes normally immersed in the electrolyte, and a vent tower extending inwardly from a wall of the casing into the cell and terminating at a free end, the vent tower having: a passageway opening inwardly through the free end of the vent tower and opening outwardly through the casing for venting gases and pressure from the cell; a porous, hydrophobic filter in the passageway adjacent the free end of the vent tower permitting movement of gas through the passageway while restricting movement of liquid through the passageway; and pressure-relief means in the passageway for allowing gas in the cell above a predetermined pressure to escape through the passageway while sealing the passageway against the escape of gas below the predetermined pressure; the free end of the vent tower being spaced sufficiently from any wall defining the battery cell that any void defined by a horizontal plane along the free end of the vent tower and the walls of the casing below the horizontal plane is greater than the volume of free electrolyte regardless of the orientation of the battery.

Claim 13

A battery-powered drive assembly for driving surgical instruments in various orientations without leakage during operation or sterilization, the drive assembly comprising an electric motor for driving surgical instruments, connecting means for holding surgical instruments in operative engagement with the electric motor, and a handle connected to the electric motor; the handle including manually actuated means for controlling the electric motor, and a battery comprising a casing having walls defining at least one battery cell, aqueous fluid electrolyte in the cell, an electrode assembly in the cell including positive and negative electrodes normally immersed in the electrolyte, and a vent tower extending inwardly from a wall of the casing into the cell and terminating at a free end, the vent tower having: a passageway opening inwardly through the free end of the vent tower and opening outwardly through the casing for venting gases and pressure from the cell; a porous, hydrophobic filter in the passageway adjacent the free end of the vent tower permitting movement of gas through the passageway while restricting movement of liquid through the passageway; and pressure-relief means in the passageway for allowing gas in the cell above a predetermined pressure to escape through the passageway while sealing the passageway against the escape of gas below the predetermined pressure; the free end of the vent tower being spaced sufficiently from any wall defining the battery cell that any void defined by a horizontal plane along the free end of the vent tower and the walls of the casing below the horizontal plane is greater than the volume of free electrolyte regardless of the orientation of the battery.

Claim 14

A drive assembly according to claim 11 wherein the free end of the vent tower is configured so as to facilitate movement of electrolyte away from the passageway.

Claim 15

A drive assembly according to claim 12 wherein the free end of the vent tower has a generally conical, frustoconical or hemispherical configuration with the surface of the free end generally sloping away from the passageway to facilitate movement of electrolyte away from the passageway, the filter having an inner end portion adjacent the free end of the vent tower, the inner end portion having a generally conical, frustoconical or hemispherical end surface extending slightly outwardly from the free end of the vent tower to facilitate movement of electrolyte away from the passageway.

Claim 16

A drive assembly according to claim 13 wherein the filter has an outer end portion having a larger cross-sectional area than the inner end portion of the filter, and a shoulder formed along a surface of the filter between the inner end portion and the outer end portion of the filter, the inner end portion of the filter being tapered from the shoulder to its end surface, and the passageway of the vent tower having a configuration complementary to the configuration of the inner and outer end portions and shoulder of the filter, the vent tower further comprising an elastomeric filter seal positioned along the shoulder of the filter for sealing between the filter and the passageway.

Claim 17

A drive assembly according to claim 14 wherein the outer end portion of the filter is generally cylindrical, and the inner end portion of the filter is generally conical or frustoconical, the cross-sectional area of the inner end portion across the passageway being approximately twenty percent smaller along its end surface than adjacent the outer end portion of the filter, the inner end portion of the filter being force fit within the passageway of the vent tower, and the cross-sectional area of the inner end portion across the passageway being approximately 35-50 percent smaller than the cross-sectional area of the outer end portion across the passageway.

Claim 18

A drive assembly according to claim 15 wherein the pressure-relief means comprises: a valve housing mounted in the vent tower or casing having a tapered valve seat defining a portion of the passageway through the vent tower; a poppet movable within the passageway relative to the valve seat between a sealing position wherein the poppet seals against the valve seat and a pressure-relief position wherein the poppet does not seal against the valve seat; resilient spring means for biasing the poppet against the valve seat, the resilient spring means being sufficiently stiff to prevent the escape of gas below the predetermined pressure outwardly through the passageway and sufficiently flexible to allow the escape of gas above the predetermined pressure outwardly through the passageway; and an elastomeric valve-housing/filter seal for sealing between the valve housing and filter along the walls of the passageway.

Claim 19

A drive assembly according to claim 15 wherein the filter is formed of a porous, hydrophobic polymeric material containing fluorine.

Claim 20

A drive assembly according to claim 17 wherein the filter is formed of porous polytetrafluoroethylene material.

Claim 21

A drive assembly according to claim 18 wherein the filter is formed of porous polytetrafluoroethylene material having an average pore size of approximately 10-40 micrometers, the filter having a porosity at least sufficient to permit passage of gas generated during charging of the battery.

Claim 22

A drive assembly according to claim 19 wherein the casing includes a cell cover defining one wall of the cell and an elastomeric seal for sealing between the cell cover and other walls of the casing, the vent tower extending inwardly into the cell from the cell cover, the cell cover and vent tower being integrally formed of polysulfone material filled with glass; the filter having a thickness longitudinally along the passageway of approximately 10-20mm, and the pressure-relief means is positioned within the passageway outwardly of the filter, the outer end portion of the filter having a cross-sectional area across the passageway of approximately 28-50mm 2 , the inner end portion having a cross-sectional area across the passageway of approximately 3-13mm 2 , and the end surface of the inner end portion being convex and having a radius of approximately 2-4mm; and the pressure-relief means comprising: a valve housing mounted in the vent tower or casing having a tapered valve seat defining a portion of the passageway through the vent tower; a poppet movable within the passageway relative to the valve seat between a sealing position wherein the poppet seals against the valve seat and a pressure-relief position wherein the poppet does not seal against the valve seat; resilient spring means for biasing the poppet against the valve seat, the resilient spring means being sufficiently stiff to prevent the escape of gas below the predetermined pressure outwardly through the passageway and sufficiently flexible to allow the escape of gas above the predetermined pressure outwardly through the passageway; and an elastomeric valve-housing/filter seal for sealing between the valve housing and filter along the walls of the passageway.