WO2009155046A1

WO2009155046A1 - Power interrupt device

Info

Publication number: WO2009155046A1
Application number: PCT/US2009/045464
Authority: WO
Inventors: Michael Nordmeyer; Eric David Serafin; Glenn William Ruhf; Raymond Louis Nordmeyer
Original assignee: Engineered Medical Solutions Company, Llc
Priority date: 2008-05-30
Filing date: 2009-05-28
Publication date: 2009-12-23

Abstract

A power interrupt device for interrupting power from a power supply to an electrical circuit having a non-conducting body moveable between a first position interposed between a conductor and the power supply and a second position removed from between the conductor and the power supply. A novel illumination device using the interrupt device is also provided. Also provided is a novel means of connecting electrical power to a light emitting diode.

Description

POWER INTERRUPT DEVICE

Field of the Invention

This invention relates to devices for interrupting electrical power, and more particularly to devices for interrupting battery power to an electrical device. Background of the Invention

It is sometimes desirable in electrical devices to interrupt the electrical power to the device. For example, hand operated illumination devices can include a battery wired to a controller for operating a light source. The controller may draw power constantly from the battery, even when not in use. This can affect the life of the battery, and thereby negatively impact the reliability of the illumination device. Opening the circuit between the battery and controller would prevent the drain on the battery, and thus improve the shelf life and reliability of the illumination device.

One known type of interrupt device is a paper or plastic pull tab that is positioned to open the circuit between a battery and the circuitry of a device. For example, the pull tab could be located between a terminal of the battery and an electrical conductor biased to move into contact with the terminal when the tab is removed. To use such a device, the pull tab is removed to allow the conductor to contact the terminal and close the circuit to the battery. Such pull tabs, however, can create waste and may not be suitable for certain uses, such as devices used in surgical settings where such waste can be problematic. Moreover, devices with such pull tab interrupts require openings through the outer housing of the device for the pull tab that make it difficult if not impossible to fully enclose and or hermetically seal such devices as required in many uses. Accordingly, an improved interrupt device would be advantageous.

Although the power interrupt device of the present invention can be used with any suitable electrical device, it will be described herein in reference to an illumination device suitable for use during medical examinations and surgical procedures where the power interrupt device is used to inhibit battery power drain and increase the shelf life of the illumination device. Improvements in surgical illumination devices are also disclosed.

Ambient illumination is often not adequate for medical examinations and surgical procedures. Surgical procedures within body cavities may require a source of illumination which can be positioned within the cavity to properly illuminate its interior, as there is usually no direct line of sight between the ambient source of illumination and the cavity interior.

Illumination devices useful in such environments must also be reliable, capable of being sterilized, capable of operating with other surgical instruments and should be easy for a physician to manipulate with one hand while wearing gloves. There is clearly a need for illumination devices which can provide light that adequately illuminates an examination site or the site of a surgical procedure. Concerns present with illumination devices include brightness of the light, temperature of the light, battery life, shelf life of the device, ease of use with other devices and affordability, among others. For example, a clear bright light of suitable intensity may generate sufficient heat to cause tissue damage to the patient or to members of the medical team. As another example, the illumination device should preferably be useable immediately upon removal from a hermetically sealed packaging. This requires the illumination device to be packaged and shipped to the medical user ready for use, e.g., the illumination device is shipped to the user fully assembled with the battery installed. Batteries have a limited shelf life, particularly when installed in a working device. If the battery is in electrical communication with the circuitry of the device during storage, there will be a small but constant power drain which will decrease the useful life of the device. Thus, it is desirable to have an illumination device with an improved shelf life and which will last as long as possible once use begins. Known illumination devices include those disclosed in U.S. Patent

6,428,180 to Karram et al and U.S. Patent 7,270,439 to Horrell et al., both of which are incorporated by reference herein. Nevertheless, further improvements over these devices and other electrical devices are believed to be advantageous to address various concerns, including those discussed above.

Summary of the Invention The invention concerns a power interrupt device for interrupting power from a power supply to an electrical circuit. The power supply has a terminal. The interrupt device comprises an electrical conductor in electrical communication with the circuit and biased so as to contact the terminal. A non-conducting body is movable between a first position interposed between the conductor and the terminal, and a second position removed from between the conductor and the terminal thereby allowing contact between the conductor and the terminal and providing power to the circuit. A switch actuator is engagable with the body for manually moving the body from the first to the second position. The terminal is mounted within a housing. The conductor is mounted within the housing adjacent to the terminal. The nonconducting body is mounted within the housing adjacent to the conductor and the terminal. The actuator is mounted on the body adjacent to the nonconducting body.

In one embodiment, the conductor comprises a resilient clip having a first leg and a second leg joined to the first leg by a reverse bend therebetween. The first leg is mounted on the housing and the second leg is biased toward the terminal. The body may comprise a first plate pivotably mounted on the housing and a second plate attached to the first plate and oriented perpendicularly thereto. An aperture is positioned between the first and second plates. The aperture receives the second leg of the clip, and when the body is in the first position, the second plate is interposed between the second leg and the terminal. When the body is in the second position, the first plate is pivoted so as to remove the second plate from between the second leg and the terminal. The second leg passes through the aperture and is biased into contact with the terminal.

Preferably, the switch actuator is positioned on the housing adjacent to the first plate. The switch actuator is movable into engagement with the first plate so as to pivot the first plate between the first and the second positions. An opening is positioned in the first plate beneath the switch actuator. A finger projects from the switch actuator toward the opening. A switch is mounted on or within the housing, and preferably on a printed circuit board within the housing beneath the first plate. The switch is aligned with the opening and the finger is engagable with the switch to control the electrical circuit when the switch actuator is moved into engagement with the first plate so as to pivot the first plate into the second position and provide power to the electrical circuit. The conductor is formed with a bend positioned in the second leg. A projection is positioned on the second plate. The projection extends toward and engages the bend in the second leg. The projection interacts with the bend and provides resistance to pivoting motion of the body between the first and the second positions to prevent inadvertent pivoting of the body in response to shock effects on the device.

The device may further include an access port positioned in the housing. The access port is aligned with the second plate and permits the second plate to be engaged and moved from the second position to the first position. In another embodiment, the illumination device may comprise a shroud having first and second ends oppositely disposed. A light emitting diode is mounted within the shroud proximate to the first end. The diode has a substrate and pair of electrical contacts are mounted on the substrate. The electrical contacts are positioned in spaced apart relation from one another. A power supply supplies power to the light emitting diode. A pair of electrical conductors are in electrical communication with the power supply. The electrical conductors extend through the shroud to the light emitting diode. A non-conducting block defines a slot sized to receive the substrate. Ends of each of the electrical conductors are positioned in spaced relation from one another within the slot. Each of the electrical conductors is in contact with one of the contacts on the substrate when the substrate is received within the slot. The illumination device may also include a lens mounted on the first end of the shroud for refracting light from the light emitting diode. Preferably, a heat sink is mounted within the shroud between the light emitting diode and the second end of the shroud. The heat sink is in contact with the light emitting diode. The shroud may be mounted on a flexible boom having first and second ends oppositely disposed. A housing is attached to the second end of the boom, the power supply being located within the housing. The power supply may be a battery, for example. Brief Description of the Drawings Figure 1 is an isometric view of an exemplary illumination device;

Figure 2 is an exploded isometric view of the illumination device shown in Figure 1;

Figure 2A is an exploded view of a portion of the device shown in Figure 2 on an enlarged scale; Figure 3 is a longitudinal sectional view taken at line 3-3 of Figure 1;

Figure 4 is a cross-sectional view taken at line 4-4 of Figure 1;

Figure 4A is a longitudinal sectional view taken at line 4A of Figure 4;

Figure 5 is an exploded view of a kit and a package according to the invention; Figure 6 is an isometric view of an illumination device combined with a retractor having suction according to the invention;

Figure 7 is an isometric view of an illumination device and one type of mounting cradle;

Figure 7A is a enlarged top isometric view of a single retaining element shown in Figure 7;

Figure 8 is a detailed isometric view of a base portion of another type of a mounting cradle shown on an enlarged scale;

Figure 9 is a cross-sectional view of an arming pin formed as a shear tab in the container bottom and which is used as an electrical interrupt; Figure 10 is an exploded isometric view of another embodiment of an illumination device in accordance with the present invention; Figure 11 is an exploded partial isometric view of the embodiment shown in Figure 10;

Figure 12 is a partial plan view of the embodiment shown in Figure 10; Figure 13 is a longitudinal sectional view taken at line 13-13 of Figure

U;

Figure 14 is a cross-sectional view taken at line 14-14 of Figure 13; Figure 15 is a longitudinal sectional view taken at line 13-13 of Figure

11; Figure 16 is a cross-sectional view taken at line 16-16 of Figure 15;

Figure 17 is a partial sectional view on an enlarged scale taken from Figure 15;

Figure 18 is an exploded partial isometric view of another embodiment of an illumination device; Figure 19 is a longitudinal sectional view of a portion of the illumination device shown in Figure 18; and

Figure 20 is a longitudinal sectional view of a portion of the illumination device taken at line 20-20 of Figure 19. Detailed Description of the Embodiments The illumination device of Figures 1 through 9 illustrate a surgical illumination device. This device is fully described in co pending US patent application serial number 12/029829 filed February 12, 2008 and which is hereby incorporated herein by reference. An illumination device in accordance with the present invention is described with reference to Figures 10 to 20. The illumination device in accordance with the present invention incorporates many of the features of the device shown in Figures 1 through 9 and thus this device will be described first followed by a description of the device of Figures 10 through 20 to illustrate the invention in detail.

Figures 1 and 2 show an embodiment of an illumination device 10 which does not have an interrupt device in accordance with the present invention. Device 10 comprises an electrically powered light source 12 mounted on the end of a flexible boom 14. A housing 16 is mounted on the opposite end of the boom 14. The housing 16 holds an electrical battery 18 and has a switch actuator 20 for turning the device on and off by supplying electrical power from the battery to the light source 12.

The housing 16 can be made of any suitable material for medical use, and in the illustrated embodiment is made of an acrylic material such as Cyrolite G20 Hiflow™ formed in an injection molded process in two sections 16a, 16b as seen in Figure 2. With further reference to Figures. 4 and 4A, the switch actuator 20 is formed in an opening 22 in housing 16 of the same material and preferably as part of the molding process for the housing 16, suspended within the opening by two attachment members 24 having a flexure bend as shown to allow the switch actuator 20 to be depressed relative to the housing 16. As best seen in Figure 2, the housing sections include internal press-fit interference connection pins, ribs and other support members as known in the art to provide support for the various components to be mounted within, and to provide for an interference press-fit connection of the two housing sections. Some adhesive can be provided to at least the front two pins (LED side of housing 16) to prevent the housing halves 16a, 16b from separating when the boom 14 is flexed.

A skin layer 26 of a resilient material such as GLS Versaflex OM 1040XTM is molded over a top section of the housing 16 and in the opening 22 around the switch actuator 20 (see also Figure 4). The skin layer 26 is flexible and resilient to allow depressing of the switch 20 and helps return the switch actuator to its initial position while supporting and maintaining a sealed connection thereto, and which provides a comfortable easy to grip feel (the opening 22 is filled in and covered by the over mold skin layer 26). A skin layer 26 of similar material can be provided along a section of the underside of the lower housing section 16b to add an easy to grip feel there as well (Figure 4).

In the embodiment 10, the light source 12 comprises a light emitting diode (LED) 28, best shown in Figures 2A and 3. A preferred LED is provided by Luxeon, part # LXHL-PW09. Diode 28 has a metal base 30 which is in contact with a metal heat sink 32 (e.g., aluminum) mounted on the end of boom 14 to conduct heat away and prevent overheating of the LED during operation. The heat sink 32 has a channel 34 which receives contacts 36 on the diode. The contacts 36 are connected to conductors 38 which supply electrical energy to the diode from the battery 18 when the 5 switch actuator 20 is used to turn on the device 10. Proper orientation of the diode 28 ensuring that the contacts are positioned within the channel and not in contact with the heat sink is provided by notches 40 on the diode which receive registration pins 42 extending from the heat sink 32. By maintaining proper orientation between the diode 28 and heat sink 32 witho the registration pins 42, short circuiting of the diode is prevented.

As best shown in Figure 3 a lens 44 is positioned overlying the light emitting diode 28. The lens is configured to focus or spread the light from the diode as desired. In the illustrated embodiment, the lens 44 focuses the light from the LED 28 to provide a concentrated beam. For example, in ones preferred embodiment, the beam may encompass an angle up to 27° and concentrate the light over a 1.875 inch area (substantially square shape) at a distance of 4 inches from the lens. In another possible arrangement, the beam may encompass an angle up to 14° and concentrate the light over a 1.5 square inch area at a distance of 6 inches from the lens. Other suitable0 configurations may be used. In this illustrated embodiment, the lens 44 is formed of a clear plastic material such as Cyrolite G20 Hiflow™.

With reference to Figure 3, the heat sink 32 preferably is attached to boom 14 by swaging the end of the boom, i.e., expanding the diameter of the boom at 46 to engage the inside surface of a bore 48 extending a set5 distance into the heat sink, thereby making a tight connection to fixedly hold the two members together and allow good heat conduction. The lens 44 and diode 28 are captured and held against the heat sink 32 by an elongated shroud 50 that surrounds the lens and diode and engages an end cap 52 positioned on the boom 14 adjacent to the heat sink. The shroud 50 can beo made of any suitable biocompatible material, such as a random copolymer polypropylene. Shroud and end cap preferably interference snap fit together making a water tight connection, although other joining means are also feasible.

Boom 14 is preferably formed of a hollow aluminum tube that is readily bendable into a desired shape to allow the position and orientation of 5 the light source 12 to be adjusted for convenient pointing when held in the hand, or relative to its target area when on a fixed mounting. The boom is yieldably adjustable so that it maintains the shape into which it is bent. In the illustrated embodiment, the boom is formed of annealed aluminum tubing having about a .125 inch outer diameter and about 25 thousandths ofo an inch wall thickness. The annealed aluminum is sufficiently soft to be malleable with minimal kinking or breakage. The boom 14 may be covered with a protective coating 53 as shown, for example, a heat shrink material such as a medical grade high temperature fluoropolymer which protects the aluminum and affords advantage when the illumination device is sterilized.s It is seen that that the protective coating 53 is sealed onto an end lip 55 of the heat sink 32. It is seen that the end lip 55 is tapered, creating an opening smaller than the outer diameter of the swaged section of the boom 14 and thereby helping to hold the boom tightly to the heat sink 32.

As best shown in Figure 2, the housing 16 is mounted on the oppositeo end of the boom 14 from the light source 12 and provides a convenient handle for manual manipulation of the device. The end of the boom opposite the LED includes a connection collar 54, having tabs 54a, that is held within the receiving recess 56, having tab receiving openings (not shown), configured to cooperate with the collar 54. The collar 54 can be5 made of any suitable material, such as an acrylic material such as Cyro G20 Hiflow™. A boot 58, preferably made of a resilient material such as GLS Versaflex OM 1040XTM, is provided on the end of the boom 14 where the boom meets the housing 16 as shown to prevent the boom from excessive bending at that position which could break the boom. The housing 16 mayo include a slot 60 that does not extend completely through the housing wall, but which is shaped to receive a tool, such as non sharp end of a scalpel, to separate the two housing halves 16a 16b from one another. This can be used for removal of the battery for recycling after use of the illumination device 10.

In addition to the battery 18, the housing 16 also contains a circuit board 62 with an electronic controller 64. The controller may comprise, for example, an integrated circuit which is programmed to control the operation of the illumination device as described below. As shown in Figure 4, the switch actuator 20, mounted on the housing, interfaces with a switch 66 on the circuit board for manually turning the illumination device on and off. The switch 66 can be formed of any device and in any configuration capable of signaling the controller, such as the momentary pushbutton switch device as used in the preferred embodiment, and which is surface mounted on the circuit board. The preferred pushbutton is provided by Panasonic, part # EVQ-Q2F02W. In the illustrated embodiment, the switch actuator does not directly turn the illumination device on and off, but sends a signal to the controller via the micro switch 66, which controls the device according to its programming as described below. As indicated, wires 38 connect the LED to the controller, and wires 38a connect the battery to the controller. A CR123 lithium battery providing about 3V is electrically connected to the controller with wires in the illustrated embodiment. Figure 5 illustrates a kit 68 encompassed by the invention. Kit 68 includes, along with the illumination device 10, one or more additional components 70 such as the instrument (retractor and suction device as shown), a mounting cradle 72 with a mounting strap 74, as well as a mounting cradle 76 having an adhesive layer 78 (see Figure 8). The kit may be provided in a package 80 comprising a container 82 having a lid 84. The container and lid may be made of any suitable material such as Pentamed MD E678 Copolyester film material. The container and lid may be placed in a sterile enclosure, such as a TYVEK® pouch which allows a sterilizing gas to penetrate and then maintains the sterile environment within the pouch. As shown in Figure 6, in one form the instrument is a retractor 70 that has a base portion 86 which receives and retains the housing 16 for mounting the retractor onto the illumination device 10. The retractor 70 is preferably removably mounted and is retained by retaining elements 88, here formed of tabs that engage slots 90 integral with the housing 16 in a similar manner as does the retaining elements 88 of the cradle 72 further described below. The retractor 70 may be made from a plastic material such as Cyrolite G20 Hiflow™ which may be readily deformed to engage and disengage the housing and the base portion. A projecting portion 92 is attached to the base portion 86 and extends adjacent to the boom 14. In the illustrated embodiment, the instrument also forms a suction device 94 comprising a duct 96 that extends along and through the base and projecting portions of the retractor. The duct has an inlet 98 positioned at the end of the retractor projecting portion 92 and an outlet 100 positioned at the base portion 86. The outlet is connectable to a source of suction (not shown) during operation. The retractor need not have suction, and any suitable surgical tool can be modified to be attachable with the illumination device 10. This instrument 70 could also be a suction device by itself, without the retractor capability.

Figure 7 illustrates in detail the mounting cradle 72 with a mounting strap 74. Cradle 72 is also formed of a suitable material such as Cyrolite G20 Hiflow™ and can include a skin layer on its bottom made of GLS Verseflex OM 1040XTM. The cradle 72 receives the housing 16 therein and has retaining elements 88, such as longitudinal tabs as shown that extend upwardly to engage the longitudinal housing slots 90, permitting easy engagement and removal of the device 10 from the cradle 72. With further reference to Figure 7A, it is seen that the retaining elements 88 for the cradle 72 include small ribs 89 formed on tabs 91 to provide a sufficient interference fit in the slot 90 to hold the housing 16 thereto. It is believed that there may be a slight deforming of the ribs and tab and/or the slot 90 to hold the two together. This is one possible configuration as any suitable arrangement or ribs, dots or other shapes and forms for creating the interference fit can be used. In this example, the adjustable strap 74 has ratchet teeth 102 which engage a pawl 104 to mount the cradle on an item, such as another surgical instrument, allowing the illumination device to be used with the item without the need for another hand to hold the device 10.

Figures 5 and 8 illustrate another mounting cradle 76, which also is capable of receiving the housing 16 of the device 10, and further has a base 106 to which is attached the adhesive layer 78. The adhesive layer allows the cradle 76 to be attached to a surface, such as the draperies used during an examination or surgery. This permits the illumination device 10 to be positioned for maximum effectiveness during the examination or operation. The adhesive layer 78 is protected by a release sheet 110 which does not adhere strongly to the adhesive and is removed to expose the adhesive layer before use. As best seen in Figure 5, each of the two mounting cradles 76 is detachable from the base 106 by cutting or breaking the area adjacent to openings 112 in the base 106. The base 106 in its entirety can be attached to a surface, such as a surgical drape, if additional adhesive surface is needed to support the illumination device 10 in one of the cradles 76. The openings 112 also allow the base 106 to be bent to match the contour of a surface as needed. Here, the cradles 76 have retaining elements 88 formed of two resilient arms 114 having a retaining tab 116 disposed at the distal end of each arm 114. As the housing 16 of the illumination device 10 is pressed into the cradle 76, i.e., two opposing latch tabs 87 are pushed into the cradle 76, the resilient arms 114 move away from one another to allow the tabs 87 to pass, then returning to their original position whereby the retaining tabs 116 engage the top face 118 of the tabs 87 to hold the housing 16 in place. To remove the illumination device 10 from the cradle, a simple twisting of the housing 16 will move the arms 114 sufficiently to release the latches 116.

With reference to Figure 8, a further advantage of the present invention is described. As discussed above, the base 106 includes a release sheet 110 that is removed to expose the adhesive layer 78 on the underside of the base 106. An adhesive layer 120 on sheet tab 122 can be provided on the underside of the release sheet 110 to adhere the release sheet to the bottom of the container 82. This allows removal of the base 106 from the container 82 and the automatic removal of the release liner 110 which stays adhered to the container, keeping the waste in the tray. A release sheet 124 on the adhesive layer 120 can be peeled to expose the adhesive when the base 106 is placed into the container 82 during assembly. It is appreciated that the device 10 provides a universal quick connect means for quick attachment, detachment and reattachment to another device as needed to change location or position of the illumination device 10. For example, the device 10 could be quickly docked to any cradle 72, 76, then adhered to a surgical drape, removed and re-docked to another cradle attached to a surgical instrument, attached to the retractor, etc.

In operation, the switch actuator 20 is manually depressed to turn on the illumination device 10. The switch actuator actuates the switch 66 on controller 64. As discussed previously, the switch 66 of the present device is a pushbutton device. In the preferred embodiment, the switch actuator and switch 66 do not directly control the flow of electricity from the battery 18 to the light emitting diode 28. Instead, the switch 66 communicates with the controller by providing a signal to the controller which controls the flow of electrical energy according to the controller's programming. Pressing the switch actuator 20 turns the diode 28 on when it is off and off when it is on. Since the full current of the device does not flow through the switch 66, a smaller and less expensive switch can be used as compared to a switch through which the full electrical load of the illumination device would pass. Such switch devices, however, such as push buttons, may produce false signals immediately (microseconds) after being actuated due to "bouncing" of the contacts within the switch before the switch returns to a steady state. These false signals can be neutralized or filtered out in the illustrated embodiment with de-bounce programming, e.g., after a signal is received by the controller indicating that the state of the LED is to be changed (turned on or off), the controller is programmed to wait a predetermined number of program cycles to ensure that the switch 66 has returned to steady state before carrying out the desired action. In the present embodiment, the controller waits five program cycles before carrying out the desired action. If a change in state of the switch contacts is detected before the end of the five cycles, the counter starts over again to count five cycles. This continues until the program counts five cycles without detecting a change of state of the switch contacts. In practice, this event happens in microseconds and prevents the bounces from operating the light. Without such de-bounce means, one could press the switch and not be sure which state the light would end up, on or off. An alternative means of de-bouncing would be to program the controller to ignore signals received from the switch 66 for a predetermined time after the switch was activated, e.g., the typical time it takes the switch contacts to return to a steady state.

When the LED 28 is turned on, the controller is programmed to pulse current through the diode between high and low current levels. Pulsing the diode extends battery life and reduces the amount of heat produced. The LED is pulsed at a rate that is undetectable by the human eye so as to appear substantially continuous and bright. Here, the LED is electrically coupled to an LED driver circuit that outputs current to the LED at a predetermined level. The LED driver circuit is also electrically coupled to external resistors that are used to control the value of the current output from the driver circuit to the LED. By the controller switching the effective value of the external resistors from a first resistance to a second resistance, the current output from the driver circuit to the LED is varied from a predetermined high current level to a second predetermined lower current level at which the LED will have a lower brightness than when powered at the higher current level. The LED driver circuit is powered by a DC voltage source, for example, a 3 Volt DC battery as discussed above. LED driver circuits such as this are known in the art. One example of an LED driver circuit is disclosed in a brochure published by Linear Technology for the LTC 3215 70OmA Low Noise High Current LED Charge Pump (LT 0306 REV A), which is hereby incorporated herein by reference. The effective resistance of the external resistors is controlled according to a pulse train with a predetermined duty cycle. While the device is on, the pulse train continuously oscillates between a logic high level and a logic low level, with each logic high level lasting for about 36 microseconds and each logic low level lasting for about 50 microseconds. While the pulse train is at a logic high level, the effective resistance is set to the first resistance at which the LED has a lower brightness level. While the pulse train is at a logic low level, the effective resistance is set to the second resistance at which the LED has a higher brightness level. Therefore, as the pulse train oscillates from logic high to logic low, the brightness of the LED oscillates from a corresponding lower level to brighter level. Because the period of the pulse train is only 86 microseconds, the changes in the brightness of the LED are not discernable to the human eye. Thus, the LED appears to have a continuous level of brightness. Because the current output from driver circuit to the LED is reduced during each logic-high portion of each cycle of the pulse train, the power consumption of the device is thereby reduced. The controller may also include a timer circuit. The timer works in conjunction with a battery interrupt feature programmed into the controller which permanently disables the illumination device 10 after a predetermined duration has elapsed (as measured by the timer) after a designated event has occurred. The time period of the predetermined duration may vary, but will be shorter than the battery life. This disabling feature prevents the illumination device from being used on more than one patient, and helps mitigate cross contamination and infection of patients.

In another embodiment illustrated in Figure 9, the event which starts the timer is initially supplying electrical energy to the controller. This is effected by having a non-conducting arming pin 126 positioned between two electrical contacts 128 and 130. Contact 128 is in electrical communication with the battery 18. Contact 130 is in electrical communication with the controller 64. The arming pin keeps the contacts apart, preventing electrical energy from flowing to the controller. When the arming pin is removed, the contacts 128 and 130 engage one another and electrical energy is supplied to the controller. The timer begins to time the predetermined duration during which the illumination device 10 will be useable. At the end of the time period, the controller 64 will disable the device and prevent further use. In this example embodiment, the arming pin is part of the package 80 in which the kit 68 is provided, so removal of the illumination device from the package will start the timer which, along with the controller, determines the length of time which the illumination device will be operable.

Figure 10 shows an exploded isometric view of another embodiment of an illumination device 150 according to the present invention. It incorporates the elements of the device shown in Fig.l with like elements having the same reference numbers, and the differences, such as the inclusion of an interrupt device, being further described below. As with the previously described embodiment, device 150 has battery 18 as its power supply. The battery is contained within housing 16 and is electrically connected to the controller 64 on circuit board 62 using two electrical conductors, preferably in the form of resilient copper alloy spring clips 152 and 154, a preferred material being beryllium copper. In this example, clip 152 has a tab 156 at one end which engages a contact 158 on the circuit board 62 in electrical communication with the controller 64. The other end of clip 152 has a tab 160 which engages a terminal of the battery 18. Similarly, clip 154 has a tab 162 at one end which engages a contact 164 on circuit board 62 which is also in electrical communication with the controller 64. Clip 154 comprises a second tab 166 which engages another terminal 168 of the battery 18.

Preferably, clip 154 comprises a first leg 170 attached to the tab 162 and a second leg 172 joined to the first leg 170 by a reverse bend 174. The second leg 172 forms the second tab 166 which engages the battery terminal 168. By constructing the clip 154 from a resilient copper alloy and joining the legs 170 and 172 by reverse bend 174, the second leg 172 (tab 166) may be biased into contact with the terminal 168 when the battery 18 is contained within the housing between the clips 152 and 154 as shown in Figure 12.

Illumination device embodiment 150 includes a non-conducting power interrupt device 176 for extending the shelf life of the device prior to use. When the power source, namely, battery 18, is in electrical contact with the controller 64 on circuit board 62, there is a constant drain of power which is dissipated within the controller. This results in reduced useful life of the illumination device which, in an extreme case, may come off the shelf with a dead battery and no useful life. The interrupt device isolates the power supply from the circuit until the device is used, thereby ensuring that each illumination device has a working light with a known and certain useful life regardless of how long it remained on the shelf.

Power interrupt device 176 comprises a first plate 178 which is pivotably mounted within housing 16. In this example, the pivoting motion is effected by two legs 180 which extend from one end of the plate 178, the legs having notches 182 adapted to engage a stiffening rib or bulkhead 184 in the housing 16 (see also Figure 11) and permit pivoting motion relative to the bulkhead. Other pivoting means are also feasible, for example, gudgeons may extend transversely from the plate and mount in bearings on the housing. A second plate 186 is attached to and extends from the first plate 178. In the present embodiment, the second plate 186 extends substantially perpendicularly to the first plate and forms a body which may be interposed between the second leg 172 and the battery terminal 168 upon pivoting of the power interrupt device 176 as described below. The interrupt device 176 can be made of any suitable material, and in the preferred embodiment is made of Nylon formed in an injection molded process.

As shown in Figure 13, power interrupt device 176 is shown in a first position wherein the second plate 186 is interposed between the second leg 172 of the second clip 154 and the terminal 168 of battery 18. Because the power interrupt device is non-conducting, imposition of the second plate isolates the battery from the controller 64 and prevents the battery from being drained by dissipating energy therein. This is the configuration of the power interrupt device when the illumination device 150 is in storage. The illumination device may be made operational by pivoting the power interrupt device 176 from the first position to a second position as shown in Figure 15. Pivoting of the device 176 is effected by depressing the switch actuator 20 on the housing 16. As shown in Figures 14 and 16, the switch actuator 20 has laterally extending ears 188 which engage raised ribs 190 on the first plate 178 as the switch actuator is depressed. The motion of switch actuator 20 causes the power interrupt device 176 to pivot on legs 180 about the bulkhead 184. This causes the second plate 186 to slide from between second leg 172 of clip 154 and the terminal 168. Note that the second clip is received within and passes through an aperture 192 positioned between the first plate 178 and the second plate 186. The second leg 172 is biased toward the terminal 168 by the reverse bend 174, which acts as a spring. The spring biasing forces the second leg against the terminal when the second leg 172 is moved from between the clip 154 and the terminal. Engagement between the second leg and the terminal completes an electrical circuit and provides power to the controller 64. The illumination device 150 is now ready for operation.

Further depression of the switch actuator 20 allows the illumination device 150 to be turned on and off. Switch actor includes a finger 193 which projects through an opening 194 in the first plate 178. The opening 194 is aligned with the switch 66 which communicates with the controller 64 to turn the light source 12 on and off as described above for other embodiments.

It is desired to prevent the interrupt device 176 from inadvertently pivoting, either from the first position to the second position or from the second position to the first position. This may occur, for example, if the illumination device is subjected to shock, such as might occur if it is dropped. To prevent inadvertent pivoting of the interrupt device 176, a projection 196 is positioned on the second plate 186 as shown in Figure 17. Projection 196 extends toward and engages a bend portion 198 on the second leg 172 of clip 154. Interaction between the projection 196 and the bend portion provides resistance to motion of the second plate 186 relative to the second leg 172 of clip 154 sufficient to prevent undesired pivoting of the interrupt device 176. However, the force applied to the first plate by the switch actuator 20 will readily overcome the resistance and allow the interrupt device to be pivoted as described above.

It may be desired to test the illumination device 150 by temporarily pivoting the interrupt device 176 into the second position (Figure 15) to provide power to controller 64 and then turn the light source on and off via switch 66. Once tested, it may then be desired to again interrupt power to the controller so that the illumination device may be stored without draining the battery 18. To this end, an access port 200 is provided in housing 16. As shown in Figure 17, access port 200 is aligned with the second plate 186, thereby allowing a tool (not shown) to be inserted into the housing to engage the second plate and pivot the interrupt device from the second position (shown) back into the first position (see Figure 13) wherein the second plate is interposed between the clip 154 and the terminal 168. A skin layer of resilient material such as GLS Versaflex OM 1040XTM is molded over the underside of the lower housing 16b to sealingly cover the access port 200. The skin layer 26 is sufficiently flexible to permit a tool to engage the interrupt device 176 without breaking the seal over the port 200.

From the above description, it is appreciated that a novel and advantageous device for interrupting power is provided. For example, the interrupt device 176 of the illustrated embodiment is self contained within the housing of the illumination device and invisible to users. It has no external components, does not create any waste, and allows the handle of the device to be fully (hermetically) sealed as required. This provides numerous advantages over prior art devices. Other advantages may become evident from specific use of the device.

Figures 18, 19 and 20 illustrate another embodiment 202 of an illumination device according to the invention. This invention features a means for attaching conductors, such as wires 204, 206, to the LED 28 which is a preferred light source for the illumination device. The wires are in electrical communication with the power supply, such as the battery 18, through the controller 64 as described above and shown in previous figures. The wires 204 and 206 pass through the boom 14 and then through a heat sink 208 which is swaged to the boom 14. A port 210 is provided in the heat sink which permits the wires to travel along a longitudinal groove 212. The LED 28 comprises a substrate 214 mounted on the end of heat sink 208. As shown in Figure 20, two electrical contacts 216, 218 are positioned on the substrate and connect respectively to wires 204 and 206 thereby providing power to operate the LED. Connection between the wires 204 and 206 and the electrical contacts 216, 218 on the substrate 214 is provided by a nonconducting block 220 which receives the wires 204 and 206 within a slot 222 defined by the block. Here the slot is enclosed or fully bounded by the block 220 as shown, but could include other configurations. The wires are positioned in spaced apart relation with one another corresponding to the spacing of the electrical contacts on the substrate. As best shown in Figure 20, the slot 222 is sized to receive and grip the substrate 214, forcing and holding the wires 204 and 206 into contact with the electrical contacts 216, 218. As best shown in Figures 18 and 19, the heat sink 208 and the LED 28 are surrounded by a shroud 224. A lens 226 is mounted on the end of shroud 224 adjacent to the LED for refracting the emitted light. Use of the block 220 provides for a quick connection between the wires 204, 206 and the contacts 216, 218, avoiding the need to solder the connections, which is more time consuming.

The LED used in this embodiment is smaller than the one used in the embodiment of Fig. 1. This smaller LED allows the secondary lens 226 to be placed much closer to the LED, thereby allowing more light to pass through the lens and thus providing a brighter light. In the design shown in Fig.l, the lens was further away from the LED so that light from the periphery of the LED may not have reached the lens and thereby was lost. In the present design, more of the light from the periphery of the LED reaches the lens to provide a brighter light. The LED 28 of the present embodiment has a circuit board 214 and heat conducting material 215 attached to the underside of the circuit board (substrate) 214 as shown and which is in contact with the heat sink 208 to transfer heat thereto. A preferred LED is the Luxeon Rebel. It is seen that this method for connecting the LED to the device for electrical power is advantageous. The connector block 220 allows electrical connection directly to the LED substrate without soldering thereby negating the need for an additional circuit board on which the LED is mounted for electrical connection. Eliminating the extra circuit board and connecting the wires directly to the LED's own substrate provides a more compact construction that uses less space and is quicker and less costly to assemble. In the case of the surgical light disclosed herein, this compactness allows for the use of the high intensity LED in a very small form which, when placed close to the lens 226, allows for more light to reach the lens. The compactness also permits the LED to be mounted remotely such as at the end of the boom as illustrated.

It is understood that the above-identified arrangements are merely illustrative of the many possible specific embodiments which represent applications of the present invention. Numerous and varied other arrangements can readily be devised in accordance with the principles of the invention without departing from the spirit and scope of the invention.

Claims

CLAIMSWhat is claimed is:

1. A power interrupt device for interrupting power from a power supply to an electrical circuit, said power supply having a terminal, said interrupt device comprising: an electrical conductor in electrical communication with said circuit and positioned to be moveable into contact with said terminal; a non-conducting body movable between a first position interposed between said conductor and said terminal, and a second position removed from between said conductor and said terminal thereby allowing contact between said conductor and said terminal and providing power to said circuit; and a switch actuator engagable with said body for manually moving said body from said first to said second position.

2. A device in accordance with claim 1 wherein said electrical conductor is biased so as to contact said terminal.

3. A device according to Claim 2, further comprising a housing, said terminal being mounted within said housing, said conductor being mounted within said housing adjacent to said terminal, said non-conducting body being mounted within said housing adjacent to said conductor and said terminal, said actuator being mounted on said body adjacent to said nonconducting body.

4. A device according to Claim 3, wherein said conductor comprises a resilient clip having a first leg and a second leg joined to said first leg by a reverse bend therebetween, said first leg being mounted on said housing and said second leg being biased toward said terminal.

5. A device according to Claim 4, wherein said body comprises: a first plate pivotably mounted on said housing; a second plate attached to and extending from said first plate; an aperture positioned between said first and second plates, said aperture receiving said second leg of said clip; and wherein when said body is in said first position, said second plate is interposed between said second leg and said terminal, and when said body is in said second position, said first plate is pivoted so as to remove said second plate from between said second leg and said terminal, said second leg passing through said aperture and being biased into contact with said terminal.

6. A device according to Claim 5, wherein said switch actuator is positioned on said housing adjacent to said first plate, said switch actuator being movable into engagement with said first plate so as to pivot said first plate between said first and said second positions.

7. A device according to Claim 6, further comprising: an opening in said first plate positioned beneath said switch actuator; a finger projecting from said switch actuator toward said opening; a switch mounted on said housing beneath said first plate, said switch being aligned with said opening, said finger being engagable with said switch to control said electrical circuit when said switch actuator is moved into engagement with said first plate so as to pivot said first plate into said second position and provide power to said electrical circuit.

8. A device according to Claim 5, further comprising : a bend positioned in said second leg; and a projection positioned on said second plate, said projection extending toward and engaging said bend in said second leg, said projection interacting with said bend and providing resistance to pivoting motion of said body between said first and said second positions.

9. A device according to Claim 5, further comprising an access port positioned in said housing, said access port being positioned to permit said second plate to be engaged and moved from said second position to said first position.

10. A power interrupt device for interrupting power from an electrical battery to an electrical circuit, said battery having a terminal, said interrupt device comprising: a housing holding said battery and said circuit; an electrical conductor mounted within said housing and in electrical communication with said circuit, said conductor being biased so as to contact said terminal; a non-conducting body movably mounted in said housing, said body being movable between a first position interposed between said conductor and said terminal and a second position removed from between said conductor and said terminal thereby allowing contact between said conductor and said terminal and providing power to said circuit; and an actuator mounted on said housing and engagable with said body for manually moving said body from said first to said second position.

11. A device according to Claim 10, wherein said conductor comprises a resilient clip having a first leg and a second leg joined to said first leg by a reverse bend therebetween, said first leg being mounted on said housing and said second leg being biased toward said terminal.

12. A device according to Claim 11, wherein said body comprises: a first plate pivotably mounted on said housing; a second plate attached to said first plate and oriented perpendicularly thereto; an aperture positioned between said first and second plates, said aperture receiving said second leg of said clip; and wherein when said body is in said first position, said second plate is interposed between said second leg and said terminal, and when said body is in said second position, said first plate is pivoted so as to remove said second plate from between said second leg and said terminal, said second leg passing through said aperture and being biased into contact with said terminal.

13. A device according to Claim 12, wherein said switch actuator is positioned on said housing adjacent to said first plate, said switch actuator being movable into engagement with said first plate so as to pivot said first plate between said first and said second positions.

14. A device according to Claim 13, further comprising: an opening in said first plate positioned beneath said switch actuator; a finger projecting from said switch actuator toward said opening; and a switch mounted on said housing beneath said first plate, said switch being aligned with said opening, said finger being engagable with said switch to control said electrical circuit when said switch actuator is movable into engagement with said first plate so as to pivot said first plate into said second position and provide power to said electrical circuit.

15. A device according to Claim 13, further comprising: a bend positioned in said second leg; and a projection positioned on said second plate, said projection extending toward and engaging said bend in said second leg, said projection interacting with said bend and providing resistance to pivoting motion of said body between said first and said second positions.

16. A device according to Claim 12, further comprising an access port positioned in said housing, said access port being aligned with said second plate, said access port permitting said second plate to be engaged and moved from said second position to said first position.

17. An illumination device, comprising: a shroud having first and second ends oppositely disposed; a light emitting diode mounted within said shroud proximate to said first end, said diode having a substrate and pair of electrical contacts mounted on said substrate, said electrical contacts being positioned in spaced apart relation from one another; a power supply supplying power to said light emitting diode; a pair of electrical conductors in electrical communication with said power supply, said electrical conductors extending through said tube to said light emitting diode; and a non-conducting block defining a slot sized to receive said substrate, ends of each of said electrical conductors being positioned in spaced relation from one another within said slot, each of said electrical conductors being in contact with one of said contacts on said substrate when said substrate is received within said slot.

18. An illumination device according to Claim 17, further comprising a lens mounted on said first end of said tube for refracting light from said light emitting diode.

19. An illumination device according to Claim 17, further comprising a heat sink mounted within said tube between said light emitting diode and said second end of said tube, said heat sink being in contact with said light emitting diode.

20. An illumination device according to Claim 17, further including a flexible boom having first and second ends oppositely disposed, said tube being mounted on said first end of said boom.

21. An illumination device according to Claim 20, further comprising a housing attached to said second end of said boom, said power supply being located within said housing.

22. An illumination device according to Claim 21, wherein said power supply comprises a battery located within said housing.

23. An illumination device according to Claim 21, further comprising a controller electrically connected to said power supply and said pair of electrical conductors for controlling electrical power provided to said light emitting diode.

24. An illumination device according to Claim 23 further comprising a switch positioned within said housing and in electrical communication with said controller so as to provide a signal to said controller when said switch is actuated, said controller being actuated by said switch to control electrical power to said light emitting diode.

25. A device for connecting electrical power to a light emitting diode (LED) having a substrate with electrical contacts; comprising: a non-conducting block; a slot formed within said block configured for receiving said substrate therein; and at least one electrical conductor disposed within said slot so as to contact one of the electrical contacts of said substrate when said substrate is received within said slot.

26. The device of claim 25 further comprising two conductors disposed within said slot spaced from one another so as to contact electrical contacts of said substrate when said substrate is received within said slot.

27. The device of claim 26 wherein said slot is sized to grippingly hold said substrate.

28. The device of claim 26 wherein said two conductors comprise two wires held within said slot spaced from one another and positioned to electrically contact said electrical contacts of said substrate when said substrate is received within said slot.

29. The device of claim 28 wherein said block includes grooves formed along an inner surface of said slot for receiving said conductors therein and which are positioned to be adjacent said electrical contacts of said substrate when said substrate is received within said slot.

30. The device of claim 29 wherein said grooves are sized so that said conductors, when lying within said grooves, are at least partially exposed above said surface of said inner surface to securely contact said electrical contacts of said substrate when said substrate is received within said slot.

31. The device of claim 27 wherein said slot is configured so that said substrate friction fits into said slot.

32. The device of claim 28 wherein said wires extend from said block through openings formed in said block.

33. An apparatus for providing electrical power to a light emitting diode, comprising: said LED includes a substrate having at least two electrical contacts; a non-conducting block connectable to said substrate; a slot formed within said block configured for receiving said substrate therein; and at least two electrical conductors disposed within said slot so as to contact said electrical contacts of said substrate when said substrate is received within said slot.

34. The apparatus of claim 33 wherein said two conductors comprise two wires held within said slot spaced from one another and positioned to electrically contact said electrical contacts of said substrate when said substrate is received within said slot.