Controlling internal battery pressure build-up of rechargeable batteries using crushable insert layers

Abstract

Over-expansion of a rechargeable battery pack during recharging is an important problem because internal expansion within a limited space causes uncontrolled accumulation of high pressure inside the battery pack, which may lead to failure of the separator and / or thermal runaway of the battery pack cells. A crushable foam or honeycomb insert layer is placed inside the rigid battery pack fixture to automatically limit gradual build-up of internal battery pack pressure due to expansion caused by charging of the battery pack cells during recharging. A crushable insert layer is included as part of a rigid battery pack fixture. The aluminum honeycomb core and the porous aluminum metal foam material have significant crushability in a wide compressive strain range. Alternatively, the porous metal foam or metal honeycomb material may be infused with a liquid polymer (e.g., silicone, rubber, EDPM, or polyurethane) to enhance the mechanical properties of the polymer infused metal foam or honeycomb metal / polymer composite.

Description

Technical Field

[0001] The present disclosure relates to rechargeable batteries (eg, lithium ion or lithium metal batteries) for electric vehicles or other electric devices. A crushable interposer is used to limit the buildup of internal pressure within the battery during recharging. Background Art

[0002] Figure 1 A schematic diagram of an example of internal battery pressure (MPa) vs. number of battery charge cycles for a lithium-ion battery confined in a rigid battery fixture is shown. When a lithium-ion battery is charged or recharged, an initial minimum internal (compressed) battery pressure is beneficial. This initial compressed internal battery pressure can be 14-120psi (0.1-0.8MPa). However, each time the battery cells are recharged, the cells expand (i.e., swell) a small amount, which results in a net increase in the average internal battery pressure when the battery cells are confined in a rigid battery fixture (i.e., a housing, can, cover, or between a pair of bolted rigid plates). The net increase in average internal battery pressure occurs due to irreversible electrochemical processes within the battery cells. Therefore, as the number of recharge cycles increases, the average internal battery pressure continues to increase indefinitely. After multiple recharge cycles, the compressed internal battery pressure can be as high as 1.6MPa (240psi), such as Figure 1 When the internal cell pressure of a battery pack exceeds a critical threshold, the battery pack may be damaged. Such damage can include destruction of internal components, electrodes, and electrical connections; and growth of internal dendrites across the separator, which can lead to electrical shorts and subsequent thermal runaway (TR).

[0003] Therefore, there is a need for a mechanical design that automatically limits and controls the buildup of internal battery pressure to acceptable levels by utilizing a crushable insert layer disposed within an external fixture of a battery cell. Summary of the invention

[0004] Excessive expansion of rechargeable battery packs during recharging is a significant issue because expansion in a confined space (e.g., a rigid battery pack fixture) results in an uncontrolled buildup of high pressures inside the battery pack, potentially leading to failure of the isolation membrane and / or initiation of thermal runaway in the battery pack cells. In some embodiments, a crushable foam or honeycomb insert layer is placed inside the battery pack fixture to automatically limit the gradual buildup of internal battery pack pressure due to expansion caused by charging of the battery pack cells when the battery is restrained in the rigid battery pack fixture. The crushable insert layer is included as part of the battery pack fixture. Metallic materials having a honeycomb or porous metal foam structure have significant crushability over a wide range of compressive strains.

[0005] In some embodiments, a battery module includes: a rigid battery fixture; a battery cell restrained in the rigid battery fixture; and a crushable insert having a crush strength and located inside the rigid battery fixture adjacent to the battery cell. The crushable insert and the rigid battery fixture are cooperatively configured to limit internal battery pressure buildup inside the battery cell during a recharge cycle to less than or equal to the crush strength of the crushable insert.

[0006] In some embodiments, the crushable insert layer is a metal honeycomb material.

[0007] In some embodiments, the metal honeycomb material is an aluminum metal honeycomb material.

[0008] In some embodiments, the crushable insert layer is a porous metal foam material.

[0009] In some embodiments, the porous metal foam material is an aluminum porous metal foam material.

[0010] In some embodiments, the crushable insert has a crush strength of 1 to 1.5 MPa.

[0011] In some embodiments, the crushable insert is infused with a polymer material to create a polymer-infused crushable insert.

[0012] In some embodiments, the polymer-infused crushable insert has a surface, and the battery module further includes an additional layer comprising a polymer material disposed on the surface of the polymer-infused crushable insert.

[0013] In some embodiments, the polymer used for the polymer-infused crushable insert is selected from silicone, silicone foam, polyurethane, polyurethane foam, EDPM, EDPM foam, rubber or rubber foam, or combinations thereof.

[0014] In some embodiments, the battery module is a lithium ion or lithium metal battery module.

[0015] In some embodiments, the battery module further includes a polymer interlayer disposed adjacent to the crushable insert and within the rigid battery fixture.

[0016] In some embodiments, an electric vehicle includes: a body having a passenger compartment; a plurality of wheels connected to the body; one or more traction motors connected to the body, operable to drive one or more of the plurality of wheels to propel the electric vehicle; and a traction battery pack connected to the body and electrically connected to the one or more traction motors. The traction battery pack includes a plurality of prismatic battery modules arranged in mutually parallel rows; and each prismatic battery module includes: a rigid battery fixture; a battery cell restrained in the rigid battery fixture; and a crushable insert having a crushable strength located inside the rigid battery fixture adjacent to the battery cell. The crushable insert and the rigid battery fixture are cooperatively configured to limit internal battery pressure buildup inside the battery cell during a recharge cycle to less than or equal to the crushing strength of the crushable insert.

[0017] In some embodiments, a method of manufacturing a battery module includes: providing a battery cell; providing a rigid battery fixture; restraining the battery cell in the rigid battery fixture; and placing a crushable insert layer having a crush strength inside the rigid battery fixture adjacent to the battery cell. The crushable insert layer and the rigid battery fixture are cooperatively configured to limit the internal battery pressure buildup inside the battery cell during a recharge cycle to less than or equal to the crush strength of the crushable insert layer.

[0018] In some embodiments, the battery cell is a lithium ion or lithium metal battery cell; and the crushable insert layer is an aluminum honeycomb material or an aluminum porous metal foam material.

[0019] The present invention discloses the following technical solutions.

[0020] Solution 1. A battery module, comprising:

[0021] Rigid battery pack fixture;

[0022] Battery cells restrained in a rigid battery fixture; and

[0023] a crushable insert having a crush strength disposed within a rigid battery fixture adjacent to the battery cells;

[0024] Therein, the crushable insert and the rigid battery fixture are cooperatively configured to limit internal battery pressure buildup within the battery cells during a recharge cycle to less than or equal to a crush strength of the crushable insert.

[0025] Option 2. A battery pack module according to Option 1, wherein the crushable insert layer comprises a metal honeycomb material.

[0026] Option 3. A battery pack module according to Option 2, wherein the metal honeycomb material comprises an aluminum metal honeycomb material.

[0027] Option 4. A battery pack module according to Option 1, wherein the crushable insert layer comprises a porous metal foam material.

[0028] Option 5. The battery module according to Option 4, wherein the porous metal foam material comprises a porous aluminum foam material.

[0029] Aspect 6. The battery module according to aspect 1, wherein the crushable insert layer has a crush strength of 1 to 1.5 MPa.

[0030] Option 7. The battery module of Option 1, wherein the crushable insert is infused with a polymer material to produce a polymer-infused crushable insert.

[0031] Solution 8. The battery pack module according to Solution 7,

[0032] wherein the polymer-infused crushable insert has a surface; and

[0033] Wherein the battery module further includes an additional layer comprising a polymer material disposed on a surface of the polymer-infused crushable insert layer.

[0034] Option 9. The battery module according to Option 7, wherein the polymer material is selected from silicone, silicone foam, polyurethane, polyurethane foam, EDPM, EDPM foam, rubber, rubber foam or a combination thereof.

[0035] Option 10. The battery module according to Option 1, wherein the battery module comprises a lithium-ion or lithium metal battery module.

[0036] Option 11. The battery pack module according to Option 1, further comprising a polymer interlayer, wherein the polymer interlayer is disposed adjacent to the crushable insert layer and inside the rigid battery pack fixture.

[0037] Solution 12. An electric vehicle, comprising:

[0038] a vehicle body having a passenger compartment;

[0039] a plurality of wheels connected to the vehicle body;

[0040] one or more traction motors connected to the vehicle body and operable to drive one or more of the plurality of wheels to propel the electric vehicle; and

[0041] a traction battery pack connected to the vehicle body and electrically connected to one or more traction motors;

[0042] wherein the traction battery pack comprises a plurality of square battery modules arranged in mutually parallel rows; and

[0043] Each square battery pack module includes:

[0044] Rigid battery pack fixture;

[0045] Battery cells restrained in a rigid battery fixture; and

[0046] a crushable insert having a crush strength disposed within a rigid battery fixture adjacent to the battery cells;

[0047] Therein, the crushable insert and the rigid battery fixture are cooperatively configured to limit internal battery pressure buildup within the battery cells during a recharge cycle to less than or equal to a crush strength of the crushable insert.

[0048] Option 13. An electric vehicle according to Option 12, wherein the crushable insert layer comprises an aluminum metal honeycomb material.

[0049] Option 14. An electric vehicle according to Option 12, wherein the crushable insert layer comprises a porous aluminum metal foam material.

[0050] Embodiment 15. The electric vehicle according to Embodiment 12, wherein the crushable insert layer has a crush strength of 1 to 1.5 MPa.

[0051] Embodiment 16. The electric vehicle of Embodiment 12, wherein the crushable insert layer is infused with a polymer material.

[0052] Option 17. An electric vehicle according to Option 16, wherein the polymer material is selected from silicone, silicone foam, polyurethane, polyurethane foam, EDPM, EDPM foam, rubber or rubber foam or a combination thereof.

[0053] Option 18. An electric vehicle according to Option 12, wherein the battery cell comprises a lithium ion or lithium metal battery cell.

[0054] Embodiment 19. A method for manufacturing a battery module, the method comprising:

[0055] Provide battery pack cells;

[0056] Provide a rigid battery pack fixture;

[0057] restraining the battery cells in a rigid battery fixture; and

[0058] disposing a crushable insert having a crush strength inside a rigid battery fixture adjacent to a battery cell;

[0059] Wherein the crushable insert and the rigid battery fixture are cooperatively configured to limit internal battery pressure buildup within the battery cells during a recharge cycle to less than or equal to a crush strength of the crushable insert.

[0060] Scheme 20. The method according to Scheme 19,

[0061] wherein the battery cell comprises a lithium ion or lithium metal battery cell; and

[0062] The crushable insert layer comprises an aluminum honeycomb material or a porous aluminum metal foam material. BRIEF DESCRIPTION OF THE DRAWINGS

[0063] Figure 1 Graph illustrating an example of internal battery pressure versus number of battery recharge cycles for a lithium-ion battery cell contained in a rigid battery fixture without a crushable insert according to the present disclosure.

[0064] Figure 2 Graph illustrating an example of internal battery pressure versus number of battery recharge cycles for a lithium-ion battery cell contained in a rigid battery fixture having a crushable insert according to the present disclosure.

[0065] Figure 3A A schematic cross-sectional view of an example of a rechargeable battery cell having a pressure-limiting crushable interposer sandwiched between a pair of rigid plates according to the present disclosure prior to recharging is shown.

[0066] Figure 3B A schematic cross-sectional view of an example of a rechargeable battery cell having a pressure-limiting crushable interposer sandwiched between a pair of rigid retaining plates according to the present disclosure after undergoing multiple recharging cycles is shown.

[0067] Figure 4 Perspective views of examples of different crushable aluminum honeycomb and aluminum metal foam materials according to the present disclosure are shown.

[0068] Figure 5 Schematic compressive stress vs. strain graph of an example of a generic crushable metal honeycomb core material undergoing permanent compression (ie, crushing) and subsequent densification in accordance with the present disclosure is shown.

[0069] Figure 6 Schematic compressive stress vs. strain graph of an example of a general crushable porous metal foam material undergoing permanent compression (ie, crushing) and subsequent densification in accordance with the present disclosure is shown.

[0070] Fig. 7AA schematic cross-sectional view of an example of a crushable metal foam infused with a polymer material (MFIP) according to the present disclosure is shown.

[0071] Figure 7B A schematic cross-sectional view of an example of a crushable metal honeycomb material (MHIP) infused with a polymer material according to the present disclosure is shown.

[0072] Figure 8 A schematic perspective view of an example of an electric vehicle having a rechargeable battery pack and a traction motor according to the present disclosure is shown. DETAILED DESCRIPTION

[0073] Representative embodiments of the present disclosure are shown in the drawings and will be described in detail herein, it should be understood that these embodiments are provided as examples of the disclosed principles, rather than limitations on the broad aspects of the present disclosure. In this regard, elements and limitations such as those described in the abstract, technical field, summary of the invention, and specific embodiments but not explicitly set forth in the claims should not be incorporated into the claims individually or collectively by implication, inference, or otherwise.

[0074] For specific embodiments, unless expressly denied: the singular includes the plural and vice versa; the words "and" and "or" are both conjunctions and transitions; the words "any" and "all" refer to "any and all"; the words "include", "contain", "includes", "have", etc. each mean "including but not limited to". In addition, approximate words such as "about", "almost", "substantially", "generally", "approximately", etc. may each be used in this document with a meaning such as "at, approximately or nearly", or "within 0-5% of..." or "within acceptable manufacturing tolerances" or any logical combination thereof. Finally, directional adjectives and adverbs such as front, rear, inboard, outboard, starboard, port, vertical, horizontal, upward, downward, front, rear, left, right, etc. may be with respect to a motor vehicle, such as the forward travel direction of a motor vehicle when the vehicle is operably oriented on a horizontal running surface.

[0075] The terms "crushable" and "crushability" refer to the permanent deformation of a porous or cellular crushable material during a compressive load that results in a net permanent deformation (i.e., "permanent set") after the compressive load is removed. The terms "expansion" and "swelling" are used interchangeably and occur during battery recharging. The terms "layer" and "insert" are used interchangeably as they refer to a crushable insert layer. The terms "accumulation" and "rise" are used interchangeably as they refer to the increase in internal battery pressure when the battery is recharged. The terms "honeycomb core" and "honeycomb matrix" are used interchangeably.

[0076] In some embodiments, a battery housing or battery can that houses one or more rechargeable battery cells may have a cylindrical or prismatic (eg, rectangular) shape.

[0077] Figure 1 A schematic diagram of an example of internal battery pressure (MPa) on the vertical axis 3 vs. the number of battery recharge cycles on the horizontal axis 2 for a rechargeable battery cell contained in a rigid battery fixture (not shown) is shown. A small amount of internal (compressed) battery pressure 4 is beneficial when the rechargeable battery is charged or recharged. This initial compressed internal battery pressure 4 can be, for example, 14-120 psi (0.1-0.8 MPa). However, each time the rechargeable battery cell is recharged, the battery cell expands (i.e., swells) a small amount, which causes the internal battery pressure to gradually increase during the recharging process when the battery cell is confined in a rigid battery fixture (e.g., a pair of rigid plates securely secured by bolts). A net increase in average internal battery pressure 6 occurs due to irreversible electrochemical processes within the battery cell. Therefore, as the number of recharge cycles increases, the average internal battery pressure 6 continues to increase indefinitely. After multiple recharge cycles, the internal battery pressure can be as high as, for example, 1.6 MPa (240 psi). When the internal battery pack pressure 4 exceeds a critical threshold, the battery pack may be damaged. Such damage may include destruction of internal components, electrodes, and electrical connections; and growth of internal metal dendrites across the isolation membrane, which may lead to short circuits across the isolation membrane and thermal runaway (TR).

[0078] Figure 2 A schematic diagram of an example of internal battery pressure on a vertical axis 3 with a crushable insert vs. number of battery recharge cycles on a horizontal axis 2 for a rechargeable battery cell contained in a rigid battery fixture according to the present disclosure having a crushable insert disposed inside the battery fixture. In this example, the crush strength limit 11 is equal to, for example, 1.2 MPa, which automatically limits the accumulation of internal battery pressure 4 during battery recharging to a crush strength limit of less than or equal to 1.2 MPa. The average internal battery pressure 6 is also limited by the use of the crushable insert. Expansion of the battery cells due to swelling caused by charging is accommodated (i.e., buffered) by simultaneously crushing the crushable insert. NOTE: Crushing is a gradual process because the deformation is permanent and therefore irreversible.

[0079] Figure 3AA schematic cross-sectional view of an example of a rechargeable battery cell 10 having a pressure-limiting crushable insert layer 14 prior to recharging according to the present disclosure is shown, the insert layer 14 being sandwiched between a rigid battery fixture including two rigid plates 16 and 18. In this embodiment, the rechargeable battery cell 10 has a prismatic shape (e.g., rectangular) and is confined in a rigid battery fixture 17 by a pair of parallel rigid plates 16 and 18, which are rigidly secured by a pair of bolts 20 and nuts 22. Optionally, the rigid battery fixture 17 can be replaced with a welded and / or extruded rigid battery housing or battery can (not shown). Optionally, a polymer interlayer 12 can be disposed inside the rigid battery fixture 17, adjacent to the battery cell 10 or adjacent to the crushable insert layer 14. The polymer interlayer 12 may be made of silicone, silicone foam, polyurethane, polyurethane foam, EDPM, EDPM foam, rubber or rubber foam material or a combination thereof, which helps provide uniform compressive pressure on the surface of the battery cell 10. Permanent deformation of the polymer interlayer 12 may occur at relatively low compressive stresses, for example, 40 psi (0.3 MPa) for silicone foam. Both the crushable insert 14 and the optional polymer interlayer 12 may be placed on the upper side of the battery cell 10; on the lower side of the battery cell 10, and / or on both sides of the battery cell 10. The crushable insert 14, the optional polymer interlayer 12, and the rigid battery fixture 17 are cooperatively configured to limit the internal battery pressure buildup inside the battery cell during a recharge cycle to less than or equal to the crush strength of the crushable insert 14. The crushable insert 14 may be 0.5 mm to 30 mm thick; and it may be as thick as several centimeters (e.g., for large battery packs). The crushable insert 14 may also function as a thermal conductor to conduct heat away from the battery cells 10 .

[0080] Figure 3B A schematic cross-sectional view of an example of a rechargeable battery cell 10 having a pressure-confining crushable insert 14 sandwiched between two rigid plates 16 and 18 after undergoing multiple recharging cycles in accordance with the present disclosure is shown. In this embodiment, the rechargeable battery cell 10 has a prismatic shape (e.g., rectangular) and is constrained in a rigid battery fixture 17 by a pair of parallel rigid plates 16 and 18, which are rigidly secured by a pair of bolts 20 and nuts 22. The battery cell 10 swells and expands upward due to recharge swelling (see upward arrows 8 and 8'). This electrochemical expansion of the battery cell 10 is automatically accommodated by the simultaneous compression of the crushable insert 14. NOTE: In Figure 3B In the embodiment, the insert 14 has been compressed (with Figure 3A ). The optional polymer interlayer 12 is Figure 3BThe inner portion is also partially compressed due to the expansion of the battery cell 10 during the recharging cycle.

[0081] Figure 4 Various examples of different crushable aluminum honeycomb and aluminum foam materials according to the present disclosure are shown. The pressure-limited crushable insert layer 14 may include metal foam materials 32 and 34, or a metal honeycomb material 30. In some embodiments, the material for the crushable insert layer 14 may be selected from, for example, aluminum, aluminum alloys, steel, nickel, copper, copper alloys, or polymers, or combinations thereof. Figure 4 Examples of various porous aluminum structures are shown, including: (a) aluminum honeycomb core material 30; (b) "CrushLite TM Aluminum foil-based honeycomb material 32; porous aluminum foam material 34 (which includes a plurality of aluminum mesh strips 36 and hollow pores 38). CrushLite TM The aluminum foil honeycomb material 32 has a crush strength of 8 to 750 psi (0.05 to 5 MPa), depending on the specific design (eg, alloy composition, yield strength, pore size, cell geometry, and / or wall thickness, etc.).

[0082] Figure 5 A schematic stress vs strain curve of an example of a general crushable metal honeycomb core material undergoing permanent compression (i.e., crushing) and subsequent densification according to the present disclosure is shown. The stress-strain curve 28 shows the compressive strain on the X-axis 24 and the compressive stress on the Y-axis 26. The figure shows a plurality of different regions of the overall stress-strain curve 28, including (a) an elastic region 40 at low strain (e.g., less than about 0.05 strain); (b) a crush region 42, in which the honeycomb material is crushed (i.e., buckled), which limits the stress to not exceed the crush strength limit (e.g., 4 MPa). This is followed by (c) a densification region 44, in which the honeycomb is finally completely crushed and densified, which exhibits a rapid increase in stress for a small amount of additional strain in the densification region 44.

[0083] Figure 6 A schematic stress vs strain curve 28 of an example of a general crushable porous metal foam material undergoing permanent compression and subsequent densification according to the present disclosure is shown. The stress-strain curve 28 shows compressive strain on the X-axis 24 and compressive stress on the Y-axis 26. The figure shows multiple regions of the stress-strain curve 28, including (a) an elastic region 40 at low strain (e.g., less than about 0.05 strain); (b) a crushing region 42, in which the porous foam material is crushed (which limits the stress to no more than the crush strength limit (e.g., 2-3 MPa)); followed by (c) a densification region 44, in which the porous metal foam material eventually becomes fully crushed and densified, which exhibits a rapid increase in stress for a small amount of additional strain in the densification region 44.

[0084] Fig. 7A A schematic cross-sectional view of an example of a crushable porous metal foam material infused with a polymer material according to the present disclosure is shown. In this embodiment, the crushable polymer-infused foam material 66 includes a crushable porous metal foam matrix 60 (e.g., a porous scaffold) having a plurality of pores 62 distributed throughout the porous metal foam matrix 60. The porous metal matrix 60 is infused with a liquid polymer resin 64 to produce a metal foam infused with a polymer (MFIP) composite material 66, which includes a crushable metal foam matrix 60 having polymer-filled pores 64.

[0085] Still reference Fig. 7A , an optional cover layer 68 made of the same or similar polymer material can be deposited or disposed on one (or more) surfaces of the MFIP material 66. The polymer cover layer 68 can help ensure that uniform pressure is applied evenly across the surface of the battery cell 10. The polymer cover layer 68 can be the same polymer material used to inject the porous metal foam matrix 60 to make the MFIP material 66.

[0086] Figure 7B A schematic cross-sectional view of an example of a crushable metal honeycomb material 90 (MHIP 94) infused with a polymer material 92 according to the present disclosure is shown. The metal honeycomb core material 90 is infused with a liquid polymer resin 92 to make a metal honeycomb infused polymer (MHIP) composite material 94. An optional cover layer 96 made of the same or similar polymer material can be deposited or disposed on one (or more) surfaces of the MHIP material 94. The polymer cover layer 96 can help ensure that uniform pressure is evenly applied across the surface of the battery cell 10. The optional polymer cover layer 96 can be the same polymer material as the polymer material used to infuse the metal honeycomb matrix 90 to make the MHIP material 94.

[0087] refer to Fig. 7A and 7B The mechanical properties (e.g., stress-strain curve, crush strength, etc.) of the MFIP material 66 or the MHIP material 94 can be enhanced depending on the amount and type of polymer material injected into the porous foam or honeycomb matrix. Silicone, polyurethane, EDPM or rubber or a combination thereof can be used as the polymer material injected into the MFIP material 66 or the MHIP material 94.

[0088] Figure 8A schematic perspective view of an example of an electric vehicle 72 having a rechargeable battery pack 80 according to the present disclosure is shown. The electric vehicle 72 includes a body 74, a passenger compartment 71 disposed inside the body 74, a plurality of wheels 76, 76', etc. connected to the body 74, and a rechargeable battery pack 80 located inside the electric vehicle 72. The electric vehicle 72 also includes one or more electric traction motors 82 connected to the body 74, which are operable to drive one or more of the wheels 76, 76', etc., thereby propelling the electric vehicle 72. The rechargeable battery pack 80 is connected to the body 74. The battery pack 80 is electrically connected to the one or more electric traction motors 82 via a power cable 84. The battery pack 80 includes a plurality of square battery pack modules 86 arranged in rows parallel to each other.

[0089] In some embodiments, Figure 3A and 3B The crushable insert 14 shown may also be used at the battery module / pack level.

[0090] While the best modes for carrying out the disclosure have been described in detail, those familiar with the art to which this disclosure relates will recognize various alternative designs and embodiments for practicing the disclosure within the scope of the appended claims.

Claims

1. A battery module, comprising: Rigid battery pack fixture; Battery cells restrained in a rigid battery fixture; and a crushable insert having a crush strength disposed within a rigid battery fixture adjacent to the battery cells; Therein, the crushable insert and the rigid battery fixture are cooperatively configured to limit internal battery pressure buildup within the battery cells during a recharge cycle to less than or equal to a crush strength of the crushable insert. 2 . The battery module of claim 1 , wherein the crushable insert comprises a metal honeycomb material. 3 . The battery module of claim 2 , wherein the metal honeycomb material comprises an aluminum metal honeycomb material. 4 . The battery module of claim 1 , wherein the crushable insert comprises a porous metal foam material. 5 . The battery module of claim 4 , wherein the porous metal foam material comprises an aluminum porous metal foam material. The battery module according to claim 1 , wherein the crushable insert layer has a crush strength of 1 to 1.5 MPa.

7. The battery module of claim 1, wherein the crushable insert is infused with a polymer material to produce a polymer-infused crushable insert.

8. The battery module according to claim 7, wherein the polymer-infused crushable insert has a surface; and Wherein the battery module further includes an additional layer comprising a polymer material disposed on a surface of the polymer-infused crushable insert layer.

9. The battery module of claim 7, wherein the polymer material is selected from silicone, silicone foam, polyurethane, polyurethane foam, EDPM, EDPM foam, rubber, rubber foam, or a combination thereof.

10. The battery module of claim 1, wherein the battery module comprises a lithium ion or lithium metal battery module.

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