Exhaust and filter element encapsulated in thermal insulation material

Abstract

The present disclosure relates to materials and systems for thermal runaway issues in energy storage systems. An exemplary embodiment includes an insulation layer encapsulated to form an insulation barrier. A particle capture layer is included in the insulation barrier. The particle capture layer captures particles released from the insulation barrier during compression of the insulation barrier.

Description

[0001] Cross-references to related applications

[0002] This disclosure claims priority to U.S. Provisional Patent Application No. 63 / 218,205, filed July 2, 2021, entitled “Materials, Systems, and Methods for Mitigating Thermal Events in Electrical Energy Storage,” and U.S. Provisional Patent Application No. 63 / 311,299, filed February 17, 2022, entitled “Exhaust and Filter Elements for Battery Barriers.” Each of these applications is incorporated herein by reference in its entirety. Technical Field

[0003] This disclosure generally relates to materials, systems, and methods for venting and filtering battery modules or battery packs. More specifically, this disclosure relates to materials, systems, and methods for providing filtered vents to allow gases to escape through an insulating barrier while capturing particulate matter in the released gases. Background Technology

[0004] Rechargeable batteries, such as lithium-ion batteries, are widely used in electric drive and energy storage systems. Compared to conventional batteries, lithium-ion batteries (LIBs) are widely used to power portable electronic devices such as mobile phones, tablets, laptops, power tools, and electric vehicles, among other high-current devices, due to their high operating voltage, low memory effect, and high energy density. However, safety is a concern because LIBs are prone to catastrophic failures under "abuse conditions," such as when rechargeable batteries are overcharged (charging beyond their design voltage), over-discharged, or operated or exposed to high temperatures and pressures. Therefore, a narrow operating temperature range and charge / discharge rate limit the use of LIBs, as they may fail due to rapid self-heating or thermal runaway events when encountering conditions outside their design window.

[0005] Thermal runaway can occur when the internal reaction rate increases to the point that the heat generated exceeds the heat that can be dissipated, leading to a further increase in the reaction rate and heat generation. During thermal runaway, high temperatures trigger a series of exothermic reactions within the battery, causing the battery temperature to rise rapidly. In many cases, when one battery cell experiences thermal runaway, the heat generated rapidly heats nearby cells undergoing runaway. Each cell added to the thermal runaway reaction contains additional energy to continue the reaction, causing thermal runaway to propagate within the battery pack, ultimately leading to a fire or explosion. Timely heat dissipation and effectively blocking heat transfer paths are effective countermeasures to reduce the hazards of thermal runaway propagation.

[0006] Based on the understanding of the mechanisms leading to battery thermal runaway, many methods are under investigation aimed at reducing safety hazards through the rational design of battery components. To prevent such cascading thermal runaway events, battery-in-the-wall (LIB) systems are typically designed to keep the stored energy at a sufficiently low level, or to employ thermal insulation materials between the batteries within a battery module or pack to protect them, or combinations thereof, from thermal events that may occur in adjacent batteries. The former severely limits the energy that can be stored in such a device. The latter limits the placement distance of the batteries, thereby limiting the effective energy density.

[0007] Aerogel materials have been used as thermal insulation materials. Aerogel insulation materials offer many advantages over other insulation materials. Some of these advantages include good resistance to heat and fire propagation while minimizing the thickness and weight of the material used. Aerogel insulation materials also exhibit good compressibility, compression resilience, and flexibility. However, some aerogel-based insulation materials, due to their light weight and low stiffness, may be difficult to install between battery cells, especially in large-scale production environments. Furthermore, aerogel insulation materials tend to generate particulate matter (dust) that can be harmful to energy storage systems, thus creating manufacturing problems.

[0008] To mitigate the problems associated with handling aerogel materials, aerogel thermal barriers can be encapsulated. Encapsulation materials used to encapsulate aerogel insulation typically form an hermetically sealed area around the insulation material and prevent particulate matter from being released from it. Summary of the Invention

[0009] The purpose of this disclosure is to eliminate or mitigate at least one of the disadvantages of the aforementioned prior methods and materials. The insulating barrier provided in this disclosure is intended to improve the thermal barrier used in the encapsulation and handling of battery modules or battery packs.

[0010] In one aspect of this disclosure, an insulating barrier for an energy storage system includes: at least one insulating layer; an encapsulation layer at least partially surrounding the insulating layer, the encapsulation layer including one or more openings; and a particle trapping layer coupled to the encapsulation layer. Particles and gases generated during compression of the insulating layer flow to the one or more openings of the encapsulation layer. The particles and gases flow through the particle trapping layer, wherein at least a portion of the particles are retained in the particle trapping layer.

[0011] In one aspect of this disclosure, a particle trapping layer is positioned on the outer surface of an encapsulation layer above one or more openings. Particles generated during the compression of the insulating barrier pass through one or more openings in the encapsulation layer and are at least partially retained within the particle trapping layer.

[0012] In one aspect of this disclosure, the encapsulation layer has an elongated opening. The encapsulation layer partially covers an insulating layer such that the elongated opening in the encapsulation layer is positioned along one side of the insulating layer. A particle trapping layer is coupled to the encapsulation layer such that the particle trapping layer is positioned above the elongated opening in the encapsulation layer.

[0013] In one aspect of this disclosure, the encapsulation layer has a plurality of openings disposed along one or more sides of the insulating layer. A particle trapping layer is coupled to the encapsulation layer such that the particle trapping layer is positioned above the plurality of openings in the encapsulation layer.

[0014] In some aspects of this disclosure, the particle trapping layer is coupled to the encapsulation layer via an adhesive material. The adhesive material is located near an opening in the encapsulation layer, such that it acts as a barrier to particle and gas flow, guiding particles and gas into the particle trapping layer.

[0015] In one aspect of this disclosure, the particle trapping layer is located inside the encapsulation layer. During use, particles and gases generated during the compression of the insulation barrier enter the particle trapping layer before passing through one or more openings in the encapsulation layer and are at least partially retained within the particle trapping layer.

[0016] The particle trapping layer can be made of foam material, woven material, nonwoven material or mesh material.

[0017] In one aspect of this disclosure, the insulating barrier includes one or more polymer membranes coupled to a particle trapping layer. The polymer membranes suppress and / or trap particles during compression of the insulating barrier. The one or more polymer membranes may be in the form of a filter that suppresses particle flow through the polymer membrane and allows gas to pass through it. In one aspect of this disclosure, one polymer membrane covers a portion of the particle trapping layer opposite the insulating layer. In another aspect of this disclosure, one polymer membrane covers both a portion of the insulating layer and the particle trapping layer.

[0018] In one aspect of this disclosure, the insulating layer has a thermal conductivity of less than about 50 mW / m·K in the thickness dimension through the insulating layer at 25°C and less than about 60 mW / m·K at 600°C. In another aspect of this disclosure, the insulating layer comprises an aerogel.

[0019] In one aspect of this disclosure, the insulating layer comprises an aerogel material.

[0020] In one aspect of this disclosure, the encapsulation layer includes a polymeric material. In other aspects of this disclosure, the encapsulation layer includes a polymeric material and a metal layer embedded in the polymeric material.

[0021] In another aspect of this disclosure, the battery module includes a plurality of battery cells and one or more insulating barriers disposed between adjacent battery cells.

[0022] On the other hand, this disclosure provides an apparatus or vehicle comprising a battery module or battery pack according to any of the foregoing aspects. In some embodiments, the apparatus is a notebook computer, PDA, mobile phone, label scanner, audio device, video device, display panel, camera, digital camera, desktop computer, military portable computer, military telephone, laser rangefinder, digital communication device, intelligence gathering sensor, electronic integrated clothing, night vision device, power tool, computer, radio, remote control device, GPS device, handheld and portable television, car starter, flashlight, acoustic device, portable heating device, portable vacuum cleaner, or portable medical tool. In some embodiments, the vehicle is an electric vehicle.

[0023] The insulating barrier disclosed herein offers one or more advantages over existing thermal runaway mitigation strategies. The insulating barrier of this disclosure minimizes or eliminates battery thermal runaway propagation without significantly impacting the energy density and assembly cost of the battery module or battery pack. The insulating barrier of this disclosure provides favorable compressibility, compression resilience, and compliance to accommodate continuous battery expansion throughout battery life, while exhibiting favorable thermal performance under both normal operating and thermal runaway conditions. The insulating barrier of this disclosure is durable and easy to handle, with good resistance to heat and flame propagation, while minimizing the thickness and weight of the materials used, and also possesses excellent compressibility, compression resilience, and compliance. Attached Figure Description

[0024] Having thus broadly described this disclosure, please now refer to the accompanying drawings, which are not necessarily drawn to scale, and in which:

[0025] Figure 1A and 1B A projection diagram of an insulating barrier having a particle trapping layer coupled to the side of an insulating layer;

[0026] Figure 2A and 2B This is a projection diagram of an insulating barrier having a particle trapping layer coupled to one side of the insulating layer that is partially covered by the encapsulation layer;

[0027] Figure 3 This is a projection of an insulating barrier coupled to a particle trapping layer on one side of an insulating layer, where the particle trapping layer is encapsulated by the insulating layer.

[0028] Figure 4 End and side views are shown to depict an insulating barrier with an encapsulated insulating layer, wherein a particle trapping layer is coupled to the sidewall of the insulating layer.

[0029] Figure 5A and 5B A projection diagram depicting an insulating barrier with a polymer membrane filter layer;

[0030] Figure 6 To illustrate the schematic diagram of the insulating barrier, the insulating barrier has one or more openings in a particle trapping layer and an encapsulation layer encapsulated with an insulating layer, the openings allowing gas to escape from the insulating barrier.

[0031] Figure 7 A schematic diagram depicting an insulating barrier with an encapsulation insulating layer, wherein a particle trapping layer is coupled to the encapsulation layer via an adhesive;

[0032] Figure 8 To illustrate an alternative schematic of an insulating barrier with an encapsulating insulating layer, wherein the particle trapping layer is coupled to the encapsulating layer via an adhesive; and

[0033] Figure 9 This is a schematic diagram depicting a battery module with insulating barriers between battery cells.

[0034] While this disclosure may be readily modified and substituted in various ways, particular embodiments thereof are illustrated by way of example in the accompanying drawings and will be described in detail herein. The drawings may not be drawn to scale. However, it should be understood that the drawings and their detailed description are not intended to limit this disclosure to the particular forms disclosed, but rather are intended to cover all modifications, equivalents, and alternatives falling within the spirit and scope as defined by the appended claims. Detailed Implementation

[0035] In the following detailed description of preferred embodiments, reference is made to the accompanying drawings, which form a part of the description, and one of the drawings illustrates, by way of illustration, specific embodiments in which the present disclosure may be implemented. It should be understood that other embodiments and structural changes may be utilized without departing from the scope of the present disclosure.

[0036] This disclosure relates to insulating barriers and systems incorporating insulating barriers to manage thermal runaway problems in energy storage systems. Exemplary embodiments include an insulating barrier comprising at least one insulating layer and an encapsulation layer at least partially surrounding the insulating layer.

[0037] The insulating layer may comprise any kind of insulating layer typically used to separate battery cells or battery modules. Exemplary insulating layers include, but are not limited to, polymer-based thermal insulation materials (such as polypropylene, polyester, polyimide, and aramid), phase change materials, intumescent materials, aerogel materials, mineral-based thermal insulation materials (such as mica), and inorganic thermal barriers (such as barriers containing glass fibers).

[0038] In a preferred embodiment, the insulating layer comprises an aerogel material. Aerogel insulating layers are described in U.S. Patent Application Publication No. 2021 / 0167438 and U.S. Provisional Patent Application No. 63 / 218,205, both of which are incorporated herein by reference.

[0039] The thermal conductivity of the insulating layer, by means of the thickness dimension of the insulating layer, can be about 50 mW / mK or less, about 40 mW / mK or less, about 30 mW / mK or less, about 25 mW / mK or less, about 20 mW / mK or less, about 18 mW / mK or less, about 16 mW / mK or less, about 14 mW / mK or less, about 12 mW / mK or less, about 10 mW / mK or less, about 5 mW / mK or less, or in the range of any two of these values ​​at 25°C and under a load up to about 5 MPa.

[0040] Insulating layers can possess many different physical properties that make them difficult to incorporate into battery modules or battery packs. For example, some insulating layers have very low flexural modulus (e.g., less than 10 MPa), making the material difficult to handle and place between battery cells. Furthermore, low flexural modulus materials can be difficult to process, especially when using automated encapsulation processes. Some insulating layers tend to generate particulate matter (dust) that can be harmful to the energy storage system, thus creating processing problems.

[0041] These problems can be mitigated by using an encapsulation layer. The encapsulation layer surrounds at least a portion of an insulating layer, thereby inhibiting or preventing the release of particulate matter into the battery module or battery pack. The encapsulation layer is typically sealed around the insulating layer, preventing particles and gases from entering or leaving the encapsulation layer. During compression of the encapsulation layer, it may rupture or leak, releasing particles and gases into the battery module. To mitigate this problem, the encapsulation layer can be modified. A first modification is to provide one or more openings in the encapsulation layer. These openings provide a flow path for gases and particles to exit the encapsulation layer. A second modification is to couple a particle trapping layer to the encapsulation layer. Particles and gases generated during compression of the insulating barrier will flow to one or more of the openings in the encapsulation layer, and any particulate matter flowing with the gas will be at least partially retained within the particle trapping layer.

[0042] The encapsulation layer can be a single layer or multiple layers of material. The encapsulation layer can be in the form of a film, envelope, or bag. The encapsulation layer can be made of any material suitable for encapsulating the insulating layer. The material used to form the encapsulation layer can be selected from polymers, elastomers, or combinations thereof. Examples of suitable polymers include polyethylene terephthalate (PET), polyethylene (PE), polyimide (PI), polypropylene, polyamide, rubber, and nylon, which have very low thermal conductivity (less than 1 W / m) and have the effect of reducing the thermal conductivity of the entire system through the plane. In one embodiment, the encapsulation layer comprises a polyethylene terephthalate polymer.

[0043] In another embodiment, the encapsulation layer comprises multiple layers of material. For example, a multilayer material similar to that used to form the casing of a pouch cell battery can be used. In one embodiment, the encapsulation layer includes a laminate comprising three layers: a first polymer layer, a second thermally conductive layer, and a third polymer layer, with the thermally conductive layer sandwiched between the first and third polymer layers. The first and third polymer layers are preferably formed of polymers having very low thermal conductivity (less than 1 W / m). Examples of polymers that can be used for the first and third polymer layers include, but are not limited to, polyethylene terephthalate (PET), polyethylene (PE), polypropylene, polyamide, and nylon. Examples of thermally conductive materials that can be used for the second layer include, but are not limited to, metals (e.g., copper, stainless steel, or aluminum), carbon fibers, graphite, and silicon carbide. When a metal thermally conductive layer is used, the metal may be in the form of a foil sandwiched between the polymer layers.

[0044] In another embodiment, the encapsulation layer comprises a laminate consisting of three layers: a first polymer layer, a second flame-retardant layer, and a third polymer layer, wherein the flame-retardant layer is sandwiched between the first and third polymer layers. As mentioned above, the first and third polymer layers are preferably formed of polymers having very low thermal conductivity (less than 1 W / m). Examples of flame-retardant materials that can be used for the second layer include, but are not limited to, metals (e.g., copper, stainless steel, or aluminum), mica, polybenzimidazole fibers (PBI fibers), coated nylon, melamine, modified acrylic resins, and aromatic polyamides (aramid fibers). When a metal thermally conductive layer is used, the metal may be in the form of a foil sandwiched between the polymer layers.

[0045] Metals are the preferred material for laminated encapsulation layers. Metals provide thermal conductivity and flame retardancy to the encapsulation layer. By using a single material to provide both flame retardancy and thermal conductivity, the thickness of the encapsulation layer can be minimized.

[0046] An implementation scheme for an insulating barrier including a particle trapping layer is as follows: Figure 1A and Figure 1B As shown. The insulating barrier 100 includes an insulating layer 110. The insulating layer 110 is surrounded by an encapsulation layer 120. Figure 1BAs shown, one or more openings 130 may be formed in the encapsulation layer 120. A particle trapping layer 140 is coupled to the encapsulation layer 120. In this embodiment, the particle trapping layer 140 is positioned on the outer surface of the encapsulation layer 120, above one or more openings in the encapsulation layer 120. During insulation barrier compression, particles and gas flow toward one or more of the openings in the encapsulation layer. As particles and gas pass through the openings, gas and particles enter the particle trapping layer, where at least a portion of the particles are retained within the particle trapping layer. In this embodiment and any other embodiment, it should be understood that although the particle trapping layer is depicted as being positioned at one end of the insulation layer, the openings in the particle trapping layer and the encapsulation layer may be positioned along any side of the insulation layer (i.e., top surface, bottom surface, front sidewall, rear sidewall, front end, and rear end).

[0047] As used in this disclosure, a particle trapping layer refers to a layer of material capable of trapping particles impacting a material. Examples of materials used for particle trapping layers include, but are not limited to, foams (open-cell or closed-cell), woven materials, nonwoven materials (e.g., felt, wadding, matte fabric), or mesh materials. Typically, particle trapping layers are made of a material that allows gas to pass through while particles are retained within the particle trapping layer.

[0048] An implementation scheme for an insulating barrier including a particle trapping layer is as follows: Figure 2A and 2B As shown. The insulating barrier 200 includes an insulating layer 210. The insulating layer 210 is surrounded by an encapsulation layer 220. Figure 2B As shown, the encapsulation layer is not completely sealed along one side of the insulating layer. In this way, a single elongated opening 230 is formed along the entire side of the insulating layer. A particle trapping layer 240 is coupled above the elongated opening 230. In this embodiment, the particle trapping layer 240 is positioned on the outer surface of the insulating layer 210. During compression of the insulating barrier, particles and gas flow toward the elongated opening of the encapsulation layer, and as the particles and gas pass through the opening, they enter the particle trapping layer, where at least a portion of the particles are retained within the particle trapping layer.

[0049] Another implementation of an insulating barrier that includes a particle trapping layer is as follows: Figure 3As shown. The insulating barrier 300 includes an insulating layer 310. The insulating layer 310 is surrounded by an encapsulation layer 320. One or more openings 330 may be formed in the encapsulation layer 320. A particle trapping layer 340 is coupled to the encapsulation layer 320. In this embodiment, the particle trapping layer 340 is positioned between the insulating layer 310 and the encapsulation layer 320, and is in fluid contact with one or more openings of the encapsulation layer 320. During compression of the insulating barrier, particles and gas flow toward one or more openings of the encapsulation layer. As the particles and gas pass toward the openings, the gas and particles enter the particle trapping layer, where at least a portion of the particles are retained within the particle trapping layer. The gas continues to flow through the particle trapping layer 340 and out through the openings 330. As the gas passes through the material, the particles are substantially retained in the particle trapping layer.

[0050] Another implementation of an insulating barrier that includes a particle trapping layer is as follows: Figure 4 As shown. The insulating barrier 400 includes an insulating layer 410. The insulating layer 410 is surrounded by an encapsulation layer 420. One or more openings 430 may be formed in the sidewalls of the encapsulation layer 420. A particle trapping layer 440 is bonded to the encapsulation layer 420 using an adhesive 450 (e.g., adhesive strip). In the embodiment described, the particle trapping layer 440 is located above the openings formed in the encapsulation layer. During compression of the insulating barrier, particles and gas flow toward one or more openings in the encapsulation layer. As particles and gas pass through the openings 430, they enter the particle trapping layer 440, where at least a portion of the particles are retained within the particle trapping layer. When gas passes through the material, the particles are substantially retained within the particle trapping layer.

[0051] Another implementation of an insulating barrier that includes a particle trapping layer is as follows: Figure 5A and 5BAs shown. The insulating barrier 500 includes an insulating layer 510. A particle trapping layer 540 is coupled to the insulating layer 510. In some embodiments, a first polymeric membrane 515 is positioned between the insulating layer and the particle trapping layer. The insulating layer 510, the first polymeric membrane 515, and the particle trapping layer 540 are surrounded by an encapsulation layer 520. One or more openings 530 may be formed in the encapsulation layer 520. A second polymeric membrane 550 is coupled to the particle trapping layer 540 and positioned between the insulating layer 510, the particle trapping layer 540, and the openings 530. The first and second polymeric membranes may be in the form of filters, allowing gas to pass through the membrane but inhibiting the progression of particles through the membrane. Examples of polymeric materials that can be used are polyethylene terephthalate (PET) and polypropylene (PP). The first and second polymeric membranes are thin films (e.g., polymeric membranes with a thickness of less than 1 millimeter (mm)). During compression of the insulating barrier, particles and gas flow toward one or more openings in the encapsulation layer. The first and second polymeric membranes act as filters, trapping at least a portion of the particles when they are pushed toward the openings. The gas continues to flow through the particle trapping layer 540 and out through the opening 530. As the gas passes through the material, the particles are essentially retained in the particle trapping layer.

[0052] Another implementation of an insulating barrier that includes a particle trapping layer is as follows: Figure 6 As shown. An insulating barrier 600 includes an insulating layer 610. A particle trapping layer 640 is coupled to the insulating layer 610. A polymer membrane 650 is coupled to the particle trapping layer 640. The insulating layer 610, polymer membrane 650, and particle trapping layer 640 are surrounded by an encapsulation layer 620. One or more openings 630 are formed in the encapsulation layer 620. The polymer membrane 650 is positioned between the particle trapping layer 640 and the one or more openings 630. The polymer membrane 650 may be impermeable to gases and particles. During insulation barrier compression, particles and gases flow toward the one or more openings in the encapsulation layer. The barrier properties of the polymer membrane 650 guide gases and particles entering the particle trapping layer away from the openings and through the particle trapping layer before the gases leave through the openings 630. Particle trapping efficiency is improved by creating an extended flow path through the particle trapping material.

[0053] Another implementation of an insulating barrier including a particle trapping layer is as follows: Figure 7As shown. The insulating barrier 700 includes an insulating layer 710. The insulating layer 710 is surrounded by an encapsulation layer 720. A particle trapping layer 740 is contacted to the encapsulation layer and coupled to the insulating layer 710 using an adhesive 760 (e.g., a strip or pad). A polymer film 750 is coupled to the particle trapping layer 740. One or more openings 730 are formed in the encapsulation layer 720. The polymer film 750 is positioned on the side of the particle trapping layer 740 opposite to the insulating layer 710. The polymer film 750 prevents gas and particles from penetrating. During compression of the insulating barrier, particles and gases flow towards and through one or more openings in the encapsulation layer, such as... Figure 7 As shown. The barrier properties of the polymer film 750 guide gas and particles through the particle trapping layer before they leave. The adhesive 760 provides an additional barrier for the flow of particles and gas. The adhesive 760 guides particles and gas escaping from the encapsulation layer into the particle trapping layer. By creating a directional flow path through the particle trapping material, particle trapping efficiency is improved.

[0054] Another implementation of an insulating barrier that includes a particle trapping layer is as follows: Figure 8 As shown. The insulating barrier 800 includes an insulating layer 810. The insulating layer 810 is surrounded by an encapsulation layer 820. A particle trapping layer 840 is attached to the encapsulation layer and coupled to the insulating layer 810 using an adhesive 860 (e.g., a strip or pad). One or more openings 830 are formed in the encapsulation layer 820. A polymer film 850 is positioned on the side of the particle trapping layer 840 opposite to the insulating layer 810. The polymer film 850 prevents gas and particles from penetrating. During compression of the insulating barrier, particles and gases flow towards and through one or more openings in the encapsulation layer, such as... Figure 8 As shown. The barrier properties of the polymer membrane 850 guide gas and particles through the particle trapping layer before they leave. The binder 860 provides an additional barrier for the flow of particles and gas. The binder 860 further guides particles and gas into the particle trapping layer, providing a longer flow path for particle trapping. By creating a directional flow path through the particle trapping material, particle trapping efficiency is improved.

[0055] As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include multiple indications unless the context clearly specifies otherwise. As used in this specification and the appended claims, the term “or” is generally used to mean “and / or” unless the context clearly specifies otherwise.

[0056] In the context of this disclosure, the terms "aerogel," "aerogel material," or "aerogel matrix" refer to a gel comprising a framework of interconnected structures, having a corresponding network of interconnected pores integrated within said framework, and containing a gas such as air as a dispersed interstitial medium; and wherein the following physical and structural properties (based on nitrogen porosity testing) attributable to the aerogel are: (a) a uniform pore size of about 2 nm to about 100 nm, (b) a porosity of at least 80% or more, and (c) 100 m² / g (m³ / g). 2 / g) or larger surface area.

[0057] The aerogel materials disclosed herein therefore include any aerogel or other open-cell material that satisfies the defining elements set forth in the foregoing paragraphs; including materials that may be further classified as dry gels, cryogels, bigels, microporous materials, etc.

[0058] In the context of this disclosure, references to "thermal runaway" generally refer to a sudden, rapid increase in battery temperature and pressure due to various operating factors, which in turn causes excessive temperature to propagate throughout the relevant module. Potential causes of thermal runaway in such systems may include: battery defects and / or short circuits (internal and external), overcharging, battery perforation or rupture (e.g., an accident), and excessively high ambient temperatures (e.g., temperatures typically above 55°C). During normal use, batteries generate heat due to internal resistance. Under normal power / current loads and ambient operating conditions, the temperature within most lithium-ion batteries can be relatively easily controlled within the range of 20°C to 55°C. However, stress conditions such as high battery power consumption / ambient temperatures, as well as defects within individual cells, can dramatically increase localized heat generation. In particular, above critical temperatures, exothermic chemical reactions within the battery are activated. Furthermore, chemical heating typically increases exponentially with temperature. As a result, the heat generated far exceeds the available heat dissipation. Thermal runaway can lead to battery venting and internal temperatures exceeding 200°C.

[0059] In the context of this disclosure, the terms "thermal conductivity" and "TC" refer to the ability of a material or composition to transfer heat between two surfaces on either side of the material or composition, having a temperature difference between the two surfaces. Thermal conductivity is specifically measured as the amount of heat transferred per unit time and per unit surface area divided by the temperature difference. It is typically recorded in SI units as mW / m*K. The thermal conductivity of a material can be determined by test methods known in the art, including but not limited to test methods for steady-state heat transfer performance using a heat flow meter apparatus (ASTM C518, ASTM International, West Conshohocken, PA); a test method for steady-state heat flux measurement and heat transfer characteristics using a protective hot plate apparatus (ASTM C177, ASTM International, West Conshohocken, PA); test methods for steady-state heat transfer performance of pipe insulation (ASTM C335, ASTM International, West Conshohocken, PA); thermal conductivity testing of thin heaters (ASTM C1114, ASTM International, West Conshohocken, PA); standard test methods for the heat transfer performance of thermally conductive insulating materials (ASTM D5470, ASTM International, West Conshohocken, PA); determination of thermal resistance using a protective hot plate and heat flow meter method (EN 12667, British Standards Institution, UK); or determination of steady-state thermal resistance and related characteristics using a protective hot plate apparatus (ISO 8203, International Organization for Standardization, Switzerland). Because different methods can lead to different results, it should be understood that, within the scope of this disclosure, unless otherwise expressly stated, thermal conductivity measurements are performed according to ASTM C518 (Method for Testing Steady-State Heat Flux Properties with a Heat Flow Meter Apparatus) at ambient atmospheric pressure and a compressive load of approximately 2 pounds per square inch (psi) at a temperature of approximately 37.5°C. Measurements reported according to ASTM C518 generally correlate well with any measurements performed according to EN 12667 and with any relevant adjustments to the compressive load.

[0060] Thermal conductivity measurements can also be performed under atmospheric pressure at a temperature of about 10°C. Thermal conductivity measurements at 10°C are typically 0.5 to 0.7 mW / mK lower than the corresponding thermal conductivity measurements at 37.5°C. In some embodiments, the insulating layer of this disclosure has a thermal conductivity of about 40 mW / mK or less, about 30 mW / mK or less, about 25 mW / mK or less, about 20 mW / mK or less, about 18 mW / mK or less, about 16 mW / mK or less, about 14 mW / mK or less, about 12 mW / mK or less, about 10 mW / mK or less, about 5 mW / mK or less, or within any two of these values ​​at 10°C.

[0061] Use insulation barriers within battery modules or battery packs

[0062] Compared to traditional batteries, lithium-ion batteries (LIBS) offer advantages such as high operating voltage, low memory effect, and high energy density, making them one of the most important energy storage technologies. However, safety concerns are a major obstacle to the large-scale application of LIBs. Under abusive conditions, exothermic reactions can lead to heat release, triggering subsequent unsafe reactions. The situation worsens because the heat released by an abused battery can activate a series of reactions, leading to catastrophic thermal runaway.

[0063] As the energy density of lithium-ion batteries continues to increase, improving their safety is becoming increasingly urgent for the development of electronic devices, such as electric vehicles. The mechanisms underlying safety issues differ for each different battery chemistry. This technology focuses on customizing insulation barriers and the corresponding configurations of those barriers to achieve favorable thermal and mechanical properties. The insulation barriers of this technology provide an effective heat dissipation strategy under both normal and thermal runaway conditions, while ensuring the stability of the LIB in normal operating modes (e.g., withstanding applied compressive stress).

[0064] The insulating barrier disclosed herein can be used to separate, insulate, and protect battery cells or battery pack components of any construction, such as pouch cells, cylindrical cells, prismatic cells, and battery packs and modules incorporating or containing any such cells. The insulating barrier disclosed herein can be used with rechargeable batteries, such as lithium-ion batteries, solid-state batteries, and any other energy storage devices or technologies requiring isolation, insulation, and protection.

[0065] Passive devices such as cooling systems can be used in conjunction with the insulating barriers of this disclosure within battery modules or battery packs.

[0066] According to various embodiments of this disclosure, the insulating barrier in the battery pack includes a plurality of individual battery cells or battery cell modules for thermally separating the individual battery cells or battery cell modules from each other. A battery module consists of a plurality of battery cells arranged in a single housing. A battery pack consists of a plurality of battery modules. Figure 9 An embodiment of a battery module 900 having multiple battery cells 950 is depicted. An encapsulated insulating barrier 925 is positioned between the battery cells 950. When a battery cell experiences thermal runaway or any thermal runaway, the encapsulated insulating barrier can suppress or prevent damage to adjacent battery cells or other catastrophic battery failures.

[0067] Battery modules and battery packs can be used to provide power to devices or vehicles. Devices using battery modules or battery packs include, but are not limited to, laptops, PDAs, mobile phones, tag scanners, audio devices, video devices, display panels, cameras, digital cameras, desktop computers, military portable computers, military telephones, laser rangefinders, digital communication devices, intelligence gathering sensors, electronic integrated clothing, night vision devices, power tools, computers, radios, remote control devices, GPS devices, handheld and portable televisions, car starters, flashlights, acoustic devices, portable heating devices, portable vacuum cleaners, or portable medical tools. When used in vehicles, battery packs can be used in all-electric vehicles or hybrid vehicles.

[0068] In this disclosure, certain U.S. patents, U.S. patent applications, and other materials (such as articles) are incorporated herein by reference. However, the text of such U.S. patents, U.S. patent applications, and other materials is incorporated by reference only if there is no conflict between the text and the content and drawings set forth in this disclosure. In the event of such conflict, any such conflicting text of the U.S. patents, U.S. patent applications, and other materials incorporated by reference is expressly not incorporated herein by reference.

[0069] In view of this description, further modifications and alternative embodiments of various aspects of this disclosure will be apparent to those skilled in the art. Therefore, the description is to be interpreted merely as illustrative and for the purpose of teaching those skilled in the art a general way of carrying out this disclosure. It should be understood that the forms represented and described in this disclosure are to be considered as examples of embodiments. Elements and materials may be substituted for what is represented and described in this disclosure, components and processes may be reversed, and certain features of this disclosure may be used independently, all of which will be apparent to those skilled in the art upon benefiting from the description herein. Changes may be made to the elements described herein without departing from the spirit and scope of this disclosure as set forth in the appended claims.

Claims

1. An insulating barrier for an energy storage system, the insulating barrier comprising: Including at least one insulating layer of aerogel; An encapsulation layer, including one or more openings, is at least partially sealed around the insulating layer; as well as A particle trapping layer coupled to the encapsulation layer; The particle trapping layer is located between the at least one insulating layer and the encapsulation layer; In this process, particles and gases generated during the compression of the insulating barrier flow to one or more openings in the encapsulation layer, wherein the particles and gases enter the particle trapping layer, and wherein at least a portion of the particles remain within the particle trapping layer.

2. The insulating barrier according to claim 1, wherein, The particle trapping layer comprises a foam material.

3. The insulating barrier according to claim 1, wherein, The particle trapping layer comprises woven material, nonwoven material, or mesh material.

4. The insulating barrier according to any one of claims 1 to 3, further comprising one or more polymer films coupled to the particle trapping layer, wherein, The polymer film inhibits and / or traps particles during the compression of the insulating barrier.

5. The insulating barrier according to claim 4, wherein, One or more of the polymer membranes are in the form of filters that inhibit particle flow through the polymer membrane and allow gas to pass through the polymer membrane.

6. The insulating barrier according to claim 4, wherein, One portion of the polymer film covers a portion of the particle trapping layer relative to a portion of the insulating layer.

7. The insulating barrier according to claim 4, wherein, One of the polymer films covers a portion of the insulating layer and the particle trapping layer.

8. The insulating barrier according to any one of claims 1 to 3, wherein, The insulating layer has a thermal conductivity of less than 50 mW / m·K at 25°C and less than 60 mW / m·K at 600°C through its thickness dimension.

9. The insulating barrier according to any one of claims 1 to 3, wherein, The encapsulation layer comprises a polymer material.

10. The insulating barrier according to any one of claims 1 to 3, wherein, The encapsulation layer includes a polymer material and a metal layer embedded in the polymer material.

11. A battery module, the battery module comprising: Multiple battery cells, and One or more insulating barriers according to any one of claims 1 to 10, wherein at least one insulating barrier is disposed between adjacent battery cells.

12. An electric power system comprising one or more battery modules as described in claim 11.

13. An apparatus or carrier comprising the battery module of claim 11.

14. The apparatus according to claim 13, wherein, The device is a PDA, tag scanner, audio device, video device, display panel, camera, digital camera, laser rangefinder, digital communication device, intelligence gathering sensor, electronic integrated clothing, night vision equipment, power tool, calculator, remote control device, GPS device, car starter, flashlight, portable heating device, or portable medical tool.

15. The apparatus according to claim 13, wherein, The device can be an acoustic device, a laptop computer, a mobile phone, a desktop computer, a radio, a handheld and portable television, or a portable vacuum cleaner.

16. The apparatus according to claim 13, wherein, The device is a military-grade portable computer or a military-grade mobile phone.

17. The vehicle according to claim 13, wherein, The vehicle is an electric vehicle.

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