Battery pack with thermal protection

Abstract

A battery pack protects the internal battery pack components from the heat, e.g., heat generated during a sterilization process of an autoclave. The battery pack prevents the heat of the autoclave from damaging the battery cells and other electronic components within a battery pack housing. The battery pack may include a multi-layer thermal protection portion lining an inside surface of the walls of the battery pack housing with a combination of materials designed to limit the amount of heat to which the internal components of the battery will be exposed for the duration of a traditional autoclave sterilization cycle. Additionally, the battery pack may include a thermal protection casing around connection elements, such as wires and contacts, between a battery pack contact and the battery cells, to limit the heat rise from the heat of the autoclave in or on the connection elements of the battery pack.

I/We claim: 
     
         1 . A battery pack configured to prevent overheating of internal components when the battery pack is exposed to a sterilization cycle of an autoclave and configured to electrically power an end device, the battery pack comprising:
 a battery cell holder to hold a plurality of battery cells, each battery cell of the plurality of battery cells fixed within the battery cell holder, wherein the plurality of battery cells is arranged in the battery cell holder in a configuration to form a battery block;   a battery pack housing that includes a housing cover and a housing base to hold the battery block and internal components of the battery pack, the housing base comprising four outer walls extending perpendicularly from a base;   a plurality of battery pack contacts electrically connected to a circuit board with a connection element;   a thermal protection casing in contact with and enclosing the connection element, wherein the thermal protection casing is configured to limit a heat rise across the connection element; and   a thermal protection portion that comprises a multi-layer portion that encloses the battery block and includes a first layer, a second layer, and an air gap between the second layer and the battery block, wherein the thermal protection portion is configured to prevent overheating of the internal components when the battery pack is exposed to the sterilization cycle for the autoclave,   wherein the first layer includes a ceramic fiber paper applied to an inner surface of the four outer walls, the base, and the housing cover, and wherein the second layer includes a phase change material layer applied to the first layer opposite the inner surface of the battery pack housing.   
     
     
         2 . The battery pack of  claim 1 , wherein the connection element includes a plurality of wires connecting the plurality of battery pack contacts and the circuit board. 
     
     
         3 . The battery pack of  claim 1 , wherein the connection element includes a plurality of clip contacts extending outside the battery pack and connecting the plurality of battery pack contacts and the circuit board. 
     
     
         4 . The battery pack of  claim 1 , wherein the connection element includes a plurality of contact pins that penetrate a wall internal to the battery pack housing, the plurality of contact pins connecting the plurality of battery pack contacts and the circuit board. 
     
     
         5 . The battery pack of  claim 1 , wherein the housing base and the housing cover create a hermetic seal for the battery pack to prevent ingress of steam of the autoclave during the sterilization cycle. 
     
     
         6 . The battery pack of  claim 1 , wherein the second layer includes a plurality of pouches to hold the phase change material layer and the plurality of pouches are applied to the first layer opposite the inner surface of the battery pack housing. 
     
     
         7 . The battery pack of  claim 1 , wherein the plurality of battery pack contacts are configured to electrically connect to power the end device or electrically connect to charge the battery pack. 
     
     
         8 . The battery pack of  claim 1 , wherein the thermal protection casing comprises at least one selected from: a phase change material, a heat sinking material, and a thermally conductive potting compound. 
     
     
         9 . A battery pack configured to prevent overheating of internal components when the battery pack is exposed to a sterilization cycle of an autoclave and configured to electrically power an end device, the battery pack comprising:
 a battery cell holder to hold a plurality of battery cells, each battery cell of the plurality of battery cells fixed within the battery cell holder, wherein the plurality of battery cells is arranged in the battery cell holder in a configuration to form a battery block;   a battery pack housing that includes a housing cover and a housing base to hold the battery block and internal components of the battery pack, the housing base comprising four outer walls extending perpendicularly from a base;   a plurality of battery pack contacts electrically connected to a circuit board with a connection element, the plurality of battery pack contacts configured to electrically connect to power the end device or electrically connect to charge the battery pack;   a thermal protection casing in contact with and enclosing the connection element, wherein the thermal protection casing is configured to limit a heat rise across the connection element, wherein the thermal protection casing comprises at least one selected from: a phase change material, a heat sinking material, and a thermally conductive potting compound; and   a thermal protection portion that comprises a multi-layer portion that encloses the battery block and includes a first layer, a second layer, and an air gap between the second layer and the battery block, wherein the thermal protection portion prevents overheating of the internal components when the battery pack is exposed to a sterilization cycle for the autoclave.   
     
     
         10 . The battery pack of  claim 9 , wherein the connection element includes a plurality of wires connecting the plurality of battery pack contacts and the circuit board. 
     
     
         11 . The battery pack of  claim 9 , wherein the connection element includes a plurality of clip contacts extending outside the battery pack and connecting the plurality of battery pack contacts and the circuit board. 
     
     
         12 . The battery pack of  claim 9 , wherein the connection element includes a plurality of contact pins that penetrate a wall internal to the battery pack housing, the plurality of contact pins connecting the plurality of battery pack contacts and the circuit board. 
     
     
         13 . The battery pack of  claim 9 , wherein the housing base and the housing cover create a hermetic seal for the battery pack to prevent ingress of steam of the autoclave during the sterilization cycle. 
     
     
         14 . The battery pack of  claim 9 , wherein the second layer includes a plurality of pouches to hold a phase change material and the plurality of pouches are applied to the first layer opposite an inner surface of the battery pack housing. 
     
     
         15 . The battery pack of  claim 9 , wherein the housing base comprises four outer walls extending perpendicularly from a base. 
     
     
         16 . The battery pack of  claim 15 , wherein the first layer includes a ceramic fiber paper applied to an inner surface of the four outer walls, the base, and the housing cover. 
     
     
         17 . The battery pack of  claim 16 , wherein the second layer includes a phase change material layer applied to the first layer opposite the inner surface of the battery pack housing. 
     
     
         18 . A method for assembling a battery pack configured to prevent overheating of internal components when the battery pack is exposed to a sterilization cycle of an autoclave and configured to electrically power an end device, the method comprising:
 applying a first layer of a thermal protection portion to a plurality of inner surfaces of a battery pack housing that includes a housing cover and a housing base to hold a battery block and internal components of the battery pack, wherein the first layer includes a ceramic fiber paper, wherein the battery block includes a battery cell holder to hold a plurality of battery cells, each battery cell of the plurality of battery cells fixed within the battery cell holder, wherein the plurality of battery cells is arranged in the battery cell holder in a configuration to form the battery block, wherein the thermal protection portion prevents overheating of the internal components when the battery pack is exposed to a sterilization cycle for the autoclave;   applying a second layer of the thermal protection portion to the first layer opposite the plurality of inner surfaces of the battery pack housing, wherein the second layer includes a phase change material layer;   applying a thermal protective casing in contact with and enclosing a connection element that electrically connects the plurality of battery cells to a plurality of battery pack contacts configured to electrically connect to power the end device or electrically connect to charge the battery pack, wherein the thermal protective casing comprises at least one selected from: a phase change material, a heat sinking material, a thermally conductive potting compound, and a combination thereof; and   adding the plurality of battery cells, the battery block, and the internal components to the battery pack housing; and   hermitically sealing the battery pack housing to prevent ingress into the battery pack of steam of the autoclave during a sterilization cycle.   
     
     
         19 . The method of  claim 18 , wherein the connection element includes a plurality of wires connecting the plurality of battery pack contacts and the plurality of battery cells. 
     
     
         20 . The method of  claim 18 , wherein the connection element comprises at least one selected from: a plurality of clip contacts extending outside the battery pack and connecting the plurality of battery pack contacts and the plurality of battery cells; and a plurality of contact pins that penetrate a wall internal to the battery pack housing and connect the plurality of battery pack contacts and the plurality of battery cells.