Battery Enclosure with Thermal Insulation for Autoclavable Surgical Tools
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Solution Overview
Problem
Battery cells in surgical tools are at risk of damage due to high sterilization temperatures, as they can be degraded or permanently damaged when exposed to temperatures above 70°C, and existing solutions either exclude batteries during sterilization or require specialized infrastructure.
Innovation Solution
A sealed battery enclosure with a low thermal conductivity gas atmosphere and a partial vacuum, combined with a composite plastic outer wall and standoffs, allows for autoclaving while minimizing heat transfer to the batteries, using inert gases like krypton or xenon and a partial vacuum to reduce thermal conductivity to less than 0.018 watts per meter per degree Celsius.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery enclosure is sterilized using conventional autoclaving methods, then the surgical tool achieves sterilization, but the battery cells are exposed to temperatures above 70°C causing performance degradation or permanent damage
Solution Approach 1:
The battery enclosure is divided into separate compartments: a sterile field compartment that undergoes autoclaving and a battery compartment that is thermally isolated. This segmentation allows the sterile components to be sterilized while the battery remains protected from high temperatures.
Solution Approach 2:
A vacuum barrier acts as an intermediary between the high-temperature autoclave environment and the battery cells. The vacuum layer (thermal insulation) blocks heat transfer, allowing the enclosure to be sterilized while maintaining a safe temperature environment for the battery.
2Object-affected harmful factors
If the battery is excluded from the sterilization process by using shields and sealable covers, then the battery cells are protected from thermal damage, but the sterilization process becomes more complex and requires additional components
Solution Approach 1:
The battery is extracted from the sterile field compartment and placed in a separate, thermally isolated compartment. This extraction eliminates the need for complex shields and sealable covers, simplifying the overall sterilization process while maintaining battery protection.
Solution Approach 2:
The vacuum barrier serves multiple functions: it provides thermal insulation to protect the battery, maintains the sterile barrier, and simplifies the enclosure design. This multi-functionality reduces the need for additional protective components.
3Object-affected harmful factors
If chemicals or gases are used to sterilize the battery enclosure with the battery cells inside, then the battery cells are protected from thermal damage, but specialized sterilization infrastructure is required that is not typically present in healthcare settings
Solution Approach 1:
The sterilization method is changed from chemical/gas-based approaches to thermal autoclaving. By implementing thermal insulation (vacuum barrier), the system enables the use of conventional autoclave parameters (steam at 121°C or 132°C) without damaging the battery, eliminating the need for specialized sterilization infrastructure.
4Object-affected harmful factors
If insulation materials such as microporous silicate or silica aerogel are used to insulate the battery cells, then thermal protection is achieved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The vacuum barrier provides effective thermal insulation without requiring expensive specialized insulation materials like silica aerogel or microporous silicate. The vacuum structure itself serves as the insulating medium, simplifying material selection and reducing manufacturing costs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the sterilization of battery packs without damaging the cells, maintaining performance and safety by preventing temperature extremes during autoclaving cycles, and is cost-effective and easily implementable in healthcare settings.
Implementation Method 1
The thermal conductivity of the gas in the volume of space is less than 0.018 watts per meter per degree Celsius
Implementation Method 2
minimizing heat transfer to the batteries, using inert gases like krypton or xenon and a partial vacuum to reduce thermal conductivity
Implementation Method 3
using inert gases like krypton or xenon and a partial vacuum to reduce thermal conductivity to less than 0.018 watts per meter per degree Celsius
Data Source
AI summary
A battery pack assembly or enclosure comprises one or more batteries having an electrochemical cell and an enclosure having at least an outer wall configured to create a sealed volume of space substantially around the batteries. An atmosphere of the volume of space comprises gas having a thermal conductivity less than 0.018 watts per meter per degree Celsius. This atmosphere of gas provides an insulative layer between the outer wall of the enclosure and the batteries. With this insulative layer, the battery pack assembly can be subjected to autoclaving without damaging the batteries. The battery pack assembly can be used to power surgical tools or other devices that are subjected to autoclaving.