Battery pack with thermal protection

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.

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.