BATTERY PACK WITH THERMAL PROTECTION
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.
Aspects described herein generally relate to rechargeable batteries and battery packs. More specifically, aspects of this disclosure relate to rechargeable battery packs and battery systems with thermal protection for a plurality of battery packs/cells inside that may be used in an autoclave and/or other heating vessel.
BACKGROUNDBattery technology has evolved from the nascent era of automation when vehicle batteries were typically large and heavy affairs using lead-acid technology. Battery technology has evolved to provide more electrical energy with less space. For example, Lithium-ion (Li-ion) batteries are quickly replacing regular zinc carbon and lead batteries because Li-ion batteries are smaller and lighter than traditional batteries and can hold charge for up to three times longer than big, heavy traditional batteries. Consequently, Li-ion batteries are finding applications for powering tools, appliances, and vehicles including forklifts, cars, trucks, and so forth. Additionally, Li-ion batteries may be used with medical devices that might be separately sterilized in an autoclave or other heating vessel. In general, Li-ion batteries are susceptible to damage when exposed to excessive heat. Because of this potential for damage, Li-ion batteries have not been readily used in heat sterilization environments. Further, because battery packs use metal wires and/or terminals, exposure of those wires and/or terminals to heat may heat the Li-ion batteries as well, causing further damage to an Li-ion cells in the battery pack.
SUMMARYA battery pack may comprise a plurality of battery cells. Each battery pack may support battery cells (often Li-ion). As described herein, a battery pack with Li-ion battery cells may limit the heating of the Li-ion battery cells and/or battery modules inside the battery pack's enclosure. Additionally, the battery pack may be configured to limit the heat rise of wires, contact pins, or nickel tabs that connect the battery pack's electrical contacts with a circuit board inside the battery pack enclosure.
In a first aspect, a battery pack may be 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 may comprise: a battery cell holder to hold a plurality of battery cells; a battery pack housing; a plurality of battery pack contacts; a thermal protection casing for the battery pack contacts; and a thermal protection portion. Each battery cell of the plurality of battery cells may be fixed within the battery cell holder. The plurality of battery cells may be arranged in the battery cell holder in a configuration to form a battery block. The battery pack housing may include a housing cover and a housing base to hold the battery block and internal components of the battery pack. The housing base may comprise four outer walls extending perpendicularly from a base. The plurality of battery pack contacts may be electrically connected to a circuit board with a connection element. The thermal protection casing may be in contact with and enclosing the connection element. The thermal protection casing may be configured to limit a heat rise across the connection element. The plurality of battery pack contacts may be configured to electrically connect to power the end device or electrically connect to charge the battery pack. The thermal protection casing may comprise at least one selected from: one of the following: a phase change material, a heat sinking material, a thermally conductive potting compound, and a combination thereof. The thermal protection portion may comprise a multi-layer portion that encloses the battery block. The thermal protection portion may include a first layer, a second layer, and an air gap between the second layer and the battery block. The first layer may include a ceramic fiber paper applied to an inner surface of the four outer walls, the base, and the housing cover. The second layer may include a phase change material layer applied to the first layer opposite the inner surface of the battery pack housing. The thermal protection portion may prevent overheating of the internal components when the battery pack is exposed to a sterilization cycle for the autoclave.
With another aspect, 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 may comprise: 1) 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; 2) applying a second layer of the thermal protection portion to the first layer opposite the plurality of inner surfaces of the battery pack housing; 3) applying a thermal protective casing in contact with and enclosing a connection element that electrically connects a 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; 4) adding the plurality of battery cells, a battery block, and internal components to the battery pack housing; and 5) hermitically sealing the battery pack housing to prevent ingress into the battery pack of steam of the autoclave during a sterilization cycle. The first layer may include a ceramic fiber paper. The second layer may include a phase change material layer. The battery block may include a battery cell holder to hold the plurality of battery cells. Each battery cell of the plurality of battery cells may be fixed within the battery cell holder. The plurality of battery cells may be arranged in the battery cell holder in a configuration to form the battery block. The thermal protection portion may prevent overheating of the internal components when the battery pack is exposed to a sterilization cycle for the autoclave. The thermal protective casing may be configured to limit a heat rise across the connection element. The thermal protective casing may comprise at least one selected from: a phase change material, a heat sinking material, a thermally conductive potting compound, and a combination thereof.
The foregoing summary, as well as the following detailed description of exemplary embodiments, is better understood when read in conjunction with the accompanying drawings, which are included by way of example, and not by way of limitation with regard to the claimed invention.
According to an aspect of the embodiments, a rechargeable battery (e.g., a Li-ion battery) used for powering equipment (such as medical equipment and/or medical tools) used in an autoclave may include features to protect internal battery pack components from the heat of the autoclave. Generally, the features may include a thermal protection portion lining an inside surface of the walls of a battery pack housing with a combination of materials designed to limit the amount of heat that the internal components of the battery will be exposed for the duration of a traditional autoclave cycle. The battery pack with the thermal protection portion results in safer battery packs with more charge/discharge cycles than other battery packs used in similar applications. Prior to adding the battery cells, circuit boards, and other internal components of the battery pack enclosure, precut ceramic fiber paper shapes may be applied to the inside surfaces of the enclosure. Pouches with a phase change material may then be applied to the surfaces of the ceramic fiber paper. The rest of the components required for the battery pack may then be added to the enclosure. The battery pack may be manufactured such that the enclosure and battery pack is hermetically sealed to prevent ingress of the steam of the autoclave during a sterilization cycle.
In the following description of the various embodiments, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration various embodiments in which aspects of the disclosure may be practiced. It is to be understood that other embodiments may be utilized and structural and functional modifications may be made without departing from the scope of the present disclosure. Aspects of the disclosure are capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. Rather, the phrases and terms used herein are to be given their broadest interpretation and meaning. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. While various directional arrows are shown in the figures of this disclosure, the directional arrows are not intended to be limiting to the extent that bi-directional communications are excluded. Rather, the directional arrows are to show a general flow of steps and not the unidirectional movement of information. In the entire specification, when an element is referred to as “comprising” or “including” another element, the element should not be understood as excluding other elements so long as there is no special conflicting description, and the element may include at least one other element. Throughout the specification, expression “at least one of a, b, and c” may include ‘a only’, ‘b only’, ‘c only’, ‘a and b’, ‘a and c’, ‘b and c’, and/or ‘all of a, b, and c’.
The battery pack 100 may include features that protect the internal battery pack components from the heat of the autoclave. The battery pack 100 may prevent the heat of the autoclave from damaging the battery cells 124 and other electronic internal components within a battery pack housing 110. The battery pack 100 may be configured to prevent overheating of internal components when the battery pack 100 is exposed to a sterilization cycle of an autoclave and configured to electrically power an end device. The thermal/heat protection, e.g., that prevents the battery cells 124 and internal components from overheating, may preserve a charge storage capacity of the battery cells 124 of the battery block 120 and/or may promote battery pack safety (e.g., by limiting the likelihood of a catastrophic failure of one or more of the battery cells 124).
When a Li-ion battery cell 124 undergoes a catastrophic failure, the battery cell 124 may emit flaming ejecta under pressure. This is known as “thermal runaway.” The flames from the battery cell 124 undergoing such an energetic failure may be extremely hot and readily damage or destroy other components within the battery pack 100. Furthermore, the flaming ejecta emitted from the battery cell 124 can burn through the walls of the battery pack's 100 plastic enclosure or escape through seams or other openings in a sheet metal enclosure and damage components of the host device. Additionally, when one Li-ion battery cell 124 in a multi-cell battery pack 100 undergoes flaming thermal runaway it can cause other battery cells 124 within the battery pack 100 to rapidly overheat and also experience thermal runaway making the event magnitudes more destructive for both the battery pack 100 and the host device. The invention greatly diminishes the possibility of cell thermal runaway. In other embodiments, the battery pack 100 may be configured to prevent overheating of internal components and the battery cells 124 when the battery pack 100 is exposed to any heat from other sources other than an autoclave, such as sun, electrical heat, fire, etc.
The battery pack 100 may include a battery pack housing 110, one or more battery blocks 120 enclosed in the battery pack housing 110, and a thermal protection portion 130. The thermal protection portion 130 may be a multi-layer portion located between the battery block 120 and the battery pack housing 110. The thermal protection portion 130 may surround at least a portion of the battery block 120 and/or line the internal walls of the battery pack housing 110.
The battery pack housing 110 may include a housing base 112 and a housing cover 114 that engages with the housing base 112. The battery pack housing 110 may house one or more battery blocks 120. The battery pack housing 110 and the housing base 112 may be defined by an outer enclosure that comprises four outer walls 116 extending approximately perpendicularly from a base bottom 118. The battery pack 100 and the battery pack housing 110 may be various sizes and shapes without departing from the invention. The battery pack housing 110 with the housing base 112 and the housing cover 114 may include a hermetic seal. The hermetic seal may include various seals and closures that create a hermitically-sealed battery pack 100 that prevents the ingress of the steam of the autoclave during a sterilization cycle. The steam may be saturated steam, superheated steam or other steams known and used in an autoclave or heating vessel. The hermetic seal may be any type of sealing that makes the battery pack 100 airtight, thereby preventing the passage of air, oxygen, steam, or other gases. The battery pack housing 110 may be a plastic material. Other materials may be utilized for the battery pack housing 110.
Referring to
As illustrated in
As illustrated in
As further illustrated in
Additionally, as illustrated in
According to another aspect of the embodiments as illustrated in
The battery pack 400 may include a battery pack housing 410 and one or more battery blocks 420 enclosed in the battery pack housing 410. The battery pack housing 410 may include a housing base 412 and a housing cover 414 that engages with the housing base 412. The battery pack housing 410 may house one or more battery blocks 420. The battery pack housing 410 and the housing base 412 may be defined by an outer enclosure that comprises four outer walls 416 extending approximately perpendicularly from a base bottom 418. The battery pack housing 410 with the housing base 412 and the housing cover 414 may include a hermetic seal. The hermetic seal may include various seals and closures that create a hermitically-sealed battery pack 400 that prevents the ingress of the steam of the autoclave during a sterilization cycle. The battery pack housing 410 may be a plastic material. Other materials may be utilized for the battery pack housing 410.
As illustrated in
As illustrated in
As further illustrated in
The battery pack 500 may include a battery pack housing 510 and one or more battery blocks 520 enclosed in the battery pack housing 510. The battery pack housing 510 may include a housing base 512 and a housing cover 514 that engages with the housing base 512. The battery pack housing 510 may house one or more battery blocks 520. The battery pack housing 510 and the housing base 512 may be defined by an outer enclosure that comprises four outer walls 516 extending approximately perpendicularly from a base bottom 518. The battery pack housing 510 with the housing base 512 and the housing cover 514 may include a hermetic seal. The hermetic seal may include various seals and closures that create a hermitically-sealed battery pack 500 that prevents the ingress of the steam of the autoclave during a sterilization cycle. The battery pack housing 510 may be a plastic material. Other materials may be utilized for the battery pack housing 510.
As illustrated in
As illustrated in
As further illustrated in
The battery pack 600 may include a battery pack housing 610 and one or more battery blocks enclosed in the battery pack housing 610. The battery pack housing 610 may include a housing base 612 and a housing cover that engages with the housing base 612. The battery pack housing 610 may house one or more battery blocks. The battery pack housing 610 may be a plastic material. Other materials may be utilized for the battery pack housing 610.
As illustrated in
As illustrated in
As further illustrated in
In step 710, a precut ceramic fiber paper of the first layer may be applied to the inside surfaces of the battery pack housing. The precut ceramic fiber paper of the first layer may be applied prior to adding the battery cells, the battery block, and other internal components of the battery pack to the battery pack housing. In step 720, a phase change material in pouches of the second layer may be applied to the surfaces of the precut ceramic fiber paper of the first layer. In step 730, a thermal protective casing may be placed in contact with wires, nickel tabs, or contact pins that connect the battery pack contacts to the circuit board within the battery pack housing. The thermal protective casing may be a phase change material, a heat sinking material, a thermally conductive potting compound, or other heat absorbing material, or any combination thereof. In step 740, the battery cells, the battery block, and other internal components of the battery pack may be added to the battery pack housing. In step 750, the battery pack and the battery pack housing may be hermitically sealed to prevent ingress of the steam of the autoclave during a sterilization cycle.
Many illustrative embodiments are listed below in accordance with one or more aspects disclosed herein. Many of the embodiments listed below are described as depending from various embodiments and the dependencies are not limited and may be depending from any of the embodiments as is described and contemplated by this disclosure. Moreover, that any one or more of the listed embodiments may be incorporated into and/or coalesced and depend from any of embodiments #1, #2, #3 is contemplated by this disclosure.
Embodiment #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 prevents overheating of the internal components when the battery pack is exposed to a 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.
Embodiment #2. 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, a thermally conductive potting compound, and a combination thereof; 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.
Embodiment #3. 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.
Embodiment #4. The battery pack, and/or method for assembling the battery pack of any of the preceding Embodiments, wherein the connection element includes a plurality of wires connecting the plurality of battery pack contacts and the circuit board.
Embodiment #5. The battery pack, and/or method for assembling the battery pack of any of the preceding Embodiments, 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.
Embodiment #6. The battery pack, and/or method for assembling the battery pack of any of the preceding Embodiments, 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.
Embodiment #7. The battery pack, and/or method for assembling the battery pack of any of the preceding Embodiments, 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.
Embodiment #8. The battery pack, and/or method for assembling the battery pack of any of the preceding Embodiments, 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.
Embodiment #9. The battery pack, and/or method for assembling the battery pack of any of the preceding Embodiments, 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.
Embodiment #10. The battery pack, and/or method for assembling the battery pack of any of the preceding Embodiments, wherein the thermal protection casing comprises at least one selected from: a phase change material, a heat sinking material, a thermally conductive potting compound, and a combination thereof.
Embodiment #11. The battery pack, and/or method for assembling the battery pack of any of the preceding Embodiments, wherein the thermal protection casing comprises at least one selected from: a phase change material, a heat sinking material, a thermally conductive potting compound, and a combination thereof.
Embodiment #12. The battery pack, and/or method for assembling the battery pack of any of the preceding Embodiments, wherein the housing base comprises four outer walls extending perpendicularly from a base.
Embodiment #13. The battery pack, and/or method for assembling the battery pack of any of the preceding Embodiments, 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.
Embodiment #14. The battery pack, and/or method for assembling the battery pack of any of the preceding Embodiments, wherein the second layer includes a phase change material layer applied to the first layer opposite the inner surface of the battery pack housing.
Although many of the battery packs described herein reference Lithium ion battery storage chemistry, the disclosure is not so limited. In many instances, a person of ordinary skill in the art will appreciate that other major chemistries for rechargeable batteries may be appropriated substituted without substantially departing from the spirit of the solution: Lithium-ion (Li-ion), Nickel Cadmium (Ni—Cd), Nickel-Metal Hydride (Ni-MH), Lead-Acid, and other chemistries. With some embodiments, the solutions disclosed herein may be included with these technology batteries to provide battery protection, provide improved efficiency, and provide a better user experience than previous battery technologies. Variants of the lithium cobalt cathode, such as nickel cobalt aluminum (NCA) and nickel manganese cobalt (NMC), may be desirable in electric vehicles and other applications. Other new cathode chemistries, such as lithium manganese spinel (LMO) and lithium iron phosphate (LFP), may be used where appropriate.
Claims
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.
Type: Application
Filed: Feb 25, 2022
Publication Date: Aug 31, 2023
Inventors: Chris Turner (Dublin, OH), Steve Wener (Littleton, CO)
Application Number: 17/681,688