Coated battery insulation structure and method

Abstract

A battery module and an associated method are disclosed. In one example, a battery module includes a thermal conditioning member having a structural support plate and an aerogel layer. An aerogel density gradient is shown to be located at an interface between the structural support plate and the aerogel layer.

Description

[0001] Priority Claim

[0002] This patent application claims the benefit of priority of U.S. Provisional Patent Application Serial No. 63 / 426,311, filed on November 17, 2022, entitled "COATED BATTERY THERMALISOLATION STRUCTURE AND METHOD", which is hereby incorporated by reference in its entirety. Technical Field

[0003] The present disclosure generally relates to materials, systems, and methods for preventing or mitigating thermal events (such as thermal runaway issues) in energy storage systems. In particular, the present disclosure provides thermal barrier materials. The present disclosure further relates to a battery module or battery pack having one or more battery cells including the thermal barrier materials, and systems including such battery modules or battery packs. The described examples may generally include aerogel materials. Background Art

[0004] Compared to traditional batteries, lithium-ion batteries (LIBs) are widely used to power portable electronic devices, such as mobile phones, tablets, laptop computers, power tools, and other high-current devices, such as electric vehicles, due to their high operating voltage, low memory effect, and high energy density. However, safety is an issue because LIBs are prone to catastrophic failures under "abuse conditions", such as when a rechargeable battery is overcharged (charged to a voltage higher than the design voltage), over-discharged, operated at high temperature and high pressure, or exposed to high temperature and high pressure.

[0005] To prevent cascading thermal runaway events, effective thermal insulation and heat dissipation strategies are needed to address these and other technical challenges of LIBs. Brief Description of the Drawings

[0006] Figure 1 A battery system is shown in accordance with some aspects.

[0007] Figure 2 A battery module is shown in accordance with some aspects.

[0008] Figure 3 Another battery module is shown in accordance with some aspects.

[0009] Figure 4 Another battery module is shown in accordance with some aspects.

[0010] Figure 5A A thermal regulation member is shown in accordance with some aspects.

[0011] Figure 5B Another thermal regulation member is shown in accordance with some aspects.

[0012] Figure 5C Another thermal regulation member according to some aspects is shown.

[0013] Figure 5D Another thermal regulation member according to some aspects is shown.

[0014] Figure 5E Another thermal regulation member according to some aspects is shown.

[0015] Figure 5F Another thermal regulation member according to some aspects is shown.

[0016] Figure 6 A flowchart of a method according to some aspects is shown.

[0017] Figure 7 An electronic device according to some aspects is shown.

[0018] Figure 8 An electric vehicle according to some aspects is shown. Detailed Description

[0019] The following description and drawings fully disclose specific aspects such that those skilled in the art can practice these aspects. Other aspects may incorporate structural, logical, electrical, process, and other variations. Portions and features of some aspects may be included, or substituted for portions and features of other aspects. The aspects set forth in the claims cover all available equivalents of those claims.

[0020] The present disclosure relates to a thermal regulation member between stacks of battery cells (e.g., lithium-ion cells) in a battery module or battery pack. The thermal regulation member is also referred to hereinafter as a thermal barrier or thermal regulation barrier. The thermal regulation member includes a thermal insulation material layer and a structural support layer.

[0021] The thermal insulation material layer reduces or prevents heat transfer between the battery cells. In some aspects, the thermal insulation material layer includes aerogel. The thermal insulation material layer is therefore also referred to hereinafter as the aerogel layer.

[0022] The structural support layer mechanically supports the thermal insulation material layer. In some aspects, the structural support layer may include a thermally conductive layer. The thermally conductive layer helps dissipate unwanted heat from the battery cells.

[0023] I. Thermal Insulation Material

[0024] As described in the examples below, the thermal insulation material can be used as a single heat-resistant layer or in combination with other layers that provide additional functions to a multi-layer configuration, such as mechanical strength, compressibility, heat dissipation / thermal conductivity, etc. The thermal insulation layer described herein is responsible for reliably containing and controlling the heat flow from the heat-generating part within a small space, and provides safety and fire spread prevention for such products in the fields of electronics, industry, and automotive technology. The thermal insulation material is also referred to as a thermal insulation layer, a heat insulation layer, or an aerogel layer.

[0025] In many aspects of the present disclosure, the thermal insulation layer is used alone or in combination with other materials that enhance the performance of containing and controlling the heat flow as a flame / fire deflection layer. For example, the thermal insulation layer may be flame and / or hot gas resistant itself and also include entrained particulate materials that modify or enhance the heat containment and control.

[0026] An example of an efficient thermal insulation layer includes aerogel. Based on its structure, aerogel describes a class of materials, namely, low density, open pore structure, large surface area (usually 900 m 2 / g or higher) and sub-nanometer pore size. The pores can be filled with a gas, such as air. Aerogel can be distinguished from other porous materials by its physical and structural properties. Although aerogel materials are exemplary thermal insulation materials, the present invention is not limited thereto. Other thermal insulation layers can also be used in the examples of the present disclosure.

[0027] Selected examples of aerogel formation and properties are described. In several examples, the precursor material is gelled to form a pore network filled with a solvent. Then the solvent is extracted, leaving behind a porous matrix. A variety of different aerogel compositions are known, and they can be inorganic, organic, and inorganic / organic hybrids. Inorganic aerogels are typically based on metal alkoxides and include materials such as silica, zirconia, alumina, and other oxides. Organic aerogels include, but are not limited to, urethane aerogel, resorcinol formaldehyde aerogel, and polyimide aerogel.

[0028] Inorganic aerogels can be formed from metal oxide or metal alkoxide materials. The metal oxide or metal alkoxide materials can be oxides or alkoxides of any metal that can form an oxide. Such metals include, but are not limited to, silicon, aluminum, titanium, zirconium, hafnium, yttrium, vanadium, cerium, etc. Traditionally, inorganic silica aerogels are made via hydrolysis and condensation of silica-based alkoxides (such as tetraethoxysilane), or via gelation of silicic acid or water glass. Other related inorganic precursor materials for silica-based aerogel synthesis include, but are not limited to, metal silicates, such as sodium silicate or potassium silicate, alkoxysilanes, partially hydrolyzed alkoxysilanes, tetraethoxysilane (TEOS), partially hydrolyzed TEOS, condensates of TEOS, tetramethoxysilane (TMOS), partially hydrolyzed TMOS, condensates of TMOS, tetra-n-propoxysilane, partially hydrolyzed tetra-n-propoxysilane, and / or condensates of tetra-n-propoxysilane, ethyl polysilicate, partially hydrolyzed ethyl polysilicate, monomeric alkyl alkoxysilanes, bis-trialkoxyalkyl or aryl silanes, polyhedral silsesquioxane, or combinations thereof.

[0029] In certain aspects of the present disclosure, pre-hydrolyzed TEOS (such as Silbond H-5 (SBH5, Silbond Corporation)) hydrolyzed at a water / silica ratio of about 1.9 - 2 can be obtained commercially and used, or can be further hydrolyzed before being incorporated into the gelling process. Partially hydrolyzed TEOS or TMOS (such as ethyl polysilicate (Silbond 40) or methyl polysilicate) can also be obtained commercially and used, or can be further hydrolyzed before being incorporated into the gelling process.

[0030] Inorganic aerogels may also include gel precursors containing at least one hydrophobic group, such as alkyl metal alkoxides, cycloalkyl metal alkoxides, and aryl metal alkoxides, which can impart or improve certain properties in the gel, such as stability and hydrophobicity. Inorganic silica aerogels may specifically include hydrophobic precursors, such as alkyl silanes or aryl silanes. The hydrophobic gel precursor can be used as the main precursor material to form the framework of the gel material. However, the hydrophobic gel precursor is more commonly combined with simple metal alkoxides and used as a co-precursor in the formation of amalgam aerogels. Hydrophobic inorganic precursor materials for silica-based aerogel synthesis include, but are not limited to, trimethylmethoxysilane (TMS), dimethyldimethoxysilane (DMS), methyltrimethoxysilane (MTMS), trimethylethoxysilane, dimethyldiethoxysilane (DMDS), methyltriethoxysilane (MTES), ethyltriethoxysilane (ETES), diethyldiethoxysilane, dimethyldiethoxysilane (DMDES), ethyltriethoxysilane, propyltrimethoxysilane, propyltriethoxysilane, phenyltrimethoxysilane, phenyltriethoxysilane (PhTES), hexamethyldisilazane, and hexaethyldisilazane, etc. Any derivatives of any of the above precursors can be used, and certain polymers of other chemical groups can be specifically added or these polymers can be crosslinked with one or more of the above precursors.

[0031] Organic aerogels are generally formed from carbon-based polymer precursors. Such polymer materials include, but are not limited to, resorcinol formaldehyde (RF), polyimide, polyacrylate, polymethyl methacrylate, acrylate oligomer, polyalkylene oxide, polyurethane, polyphenol, polybutadiene, trialkoxysilyl-terminated polydimethylsiloxane, polystyrene, polyacrylonitrile, polyfurfural, melamine-formaldehyde, cresol formaldehyde, phenol-furfural, polyether, polyol, polyisocyanate, polyhydroxybenze, polyvinyl aldehyde, polycyanurate, polyacrylamide, various epoxy resins, agar, agarose, chitosan, and combinations thereof. As an example, organic RF aerogels are generally made by sol-gel polymerization of resorcinol or melamine with formaldehyde under alkaline conditions.

[0032] Organic / inorganic hybrid aerogels mainly consist of organically modified silica (“ormosil”) aerogels. These ormosil materials include organic components covalently bonded to the silica network. Ormosil is typically formed by the hydrolysis and condensation of an organic-modified silane R--Si(OX)3 with a conventional alkoxide precursor Y(OX)4. In these formulas, X can represent, for example, CH3, C2H5, C3H7, C4H9; Y can represent, for example, Si, Ti, Zr, or Al; and R can be any organic moiety, such as methyl, ethyl, propyl, butyl, isopropyl, methacrylate, acrylate, vinyl, epoxide, etc. The organic components in the ormosil aerogel can also be dispersed throughout the silica network or chemically bonded to the silica network.

[0033] Aerogels can be formed from flexible gel precursors. Various flexible layers, including flexible fiber-reinforced aerogels, can be easily combined and shaped to give a preform that gives a strong compression body along any one of the axes when mechanically compressed along one or more axes.

[0034] One method of aerogel formation includes batch casting. Batch casting includes catalyzing an entire volume of sol to initiate gelation of the entire volume simultaneously. Gel formation techniques include adjusting the pH and / or temperature of a diluted metal oxide sol to the point where gelation occurs. Suitable materials for forming inorganic aerogels include oxides of most metals that can form oxides, such as oxides of silicon, aluminum, titanium, zirconium, hafnium, yttrium, vanadium, etc. Particularly preferred are gels formed mainly from alcoholic solutions of hydrolyzed silicate esters (alcogels), due to their easy availability and low cost. Organic aerogels can also be made from melamine formaldehyde, resorcinol formaldehyde, etc.

[0035] In one example, the aerogel material can be monolithic or continuous throughout a structure or layer. In other examples, the aerogel material can include a composite aerogel material having aerogel particles mixed with an adhesive. Other additives can be included in the composite aerogel material, including but not limited to surfactants that aid in the dispersion of the aerogel particles within the adhesive. The composite aerogel slurry can be applied to a support plate, such as a mesh, felt, netting, foam, felt, mesh fabric, batting, etc., and then dried to form a composite aerogel structure.

[0036] As described above, the aerogel can be organic, inorganic, or a mixture thereof. In some examples, the aerogel comprises a silica-based aerogel. One or more layers in the thermal barrier can include a reinforcement material. The reinforcement material can be any material that provides resilience, conformability, or structural stability to the aerogel material. Examples of reinforcement materials include, but are not limited to, open-cell macroporous framework reinforcement materials, closed-cell macroporous framework reinforcement materials, open-cell membranes, honeycomb reinforcement materials, polymeric reinforcement materials, and fibrous reinforcement materials such as discrete fibers, woven materials, non-woven materials, needle-punched non-woven materials, flocks, waddings, meshes, mats, felts, or combinations thereof.

[0037] The reinforcement material can be selected from organic polymer-based fibers, inorganic fibers, carbon-based fibers, or combinations thereof. The inorganic fibers are selected from glass fibers, rock fibers, metal fibers, boron fibers, ceramic fibers, basalt fibers, or combinations thereof. In some examples, the reinforcement material can include a reinforcement that comprises multiple material layers.

[0038] Fiber reinforcing materials can include a range of materials, including but not limited to: polyester, polyolefin terephthalate, polyethylene naphthalate, polycarbonate (e.g., rayon, nylon), cotton (e.g., Lycra manufactured by DuPont), carbon (e.g., graphite), polyacrylonitrile (PAN), oxidized PAN, pre-oxidized PAN, PAN without carbonization heat treatment (such as those manufactured by SGL Carbon), glass or glass fiber-based materials (such as S-glass, 901 glass, 902 glass, 475 glass, E-glass), silica-based fibers such as quartz (e.g., Quartzel manufactured by Saint-Gobain), Q-felt (manufactured by Johns Manville), Saffil (manufactured by Saffil), Durablanket (manufactured by Unifrax) and other silica fibers, Duraback (manufactured by Carborundum), polyaramid fibers such as Kevlar, Nomex, Sontera (all manufactured by DuPont), Conex (manufactured by Taijin), polyolefins such as Tyvek (manufactured by DuPont), Dyneema (manufactured by DSM), Spectra (manufactured by Honeywell), other polypropylene fibers such as Typar, Xavan (both manufactured by DuPont), fluoropolymers such as PTFE with the trade name Teflon (manufactured by DuPont), Goretex (manufactured by W.L.GORE), silicon carbide fibers such as Nicalon (manufactured by COI Ceramics), ceramic fibers such as Nextel (manufactured by 3M), acrylic polymers, wool fibers, silk, hemp, leather, suede, PBO - Zylon fibers (manufactured by Tyobo), liquid crystal materials such as Vectan (manufactured by Hoechst), Cambrelle fibers (manufactured by DuPont), polyurethanes, polyamides (polyamaide), wood fibers, boron, aluminum, iron, stainless steel fibers and other thermoplastics such as PEEK, PES, PEI, PEK, PPS.

[0039] Glass or glass fiber-based fiber reinforcing materials can be manufactured using one or more techniques. In certain embodiments, it is desirable to use carding and cross-laying or air-laying processes to manufacture them. In an exemplary embodiment, carded and cross-laid glass or glass fiber-based fiber reinforcing materials offer certain advantages over air-laid materials. For example, carded and cross-laid glass or glass fiber-based fiber reinforcing materials can provide a consistent material thickness for a given basis weight of the reinforcing material. In certain additional embodiments, it is desirable to further needle-punch the fiber reinforcing materials, with the requirement of interweaving the fibers in the z-direction to obtain enhanced mechanical properties and other properties in the final aerogel composition.

[0040] II. Structural Support Layer

[0041] The thermal regulation element further includes a structural support layer. The structural support layer can be in the following forms: plate, slab, mesh, felt, netting, foam, mat, paper, meshed fabric, batting, other forms, or a combination thereof. In selected aspects, the structural support layer can include pores, fibers, or other surface structures that create a diffusion layer at the application interface. The structural support layer includes materials selected from polymers, mica, ceramics, resins, rubbers, composite materials, other suitable materials, or a combination thereof. In some aspects, the structural support layer includes an aerogel with a reinforcement, such as a fiber-reinforced aerogel mat.

[0042] In some aspects, the structural support layer can be a conductive layer. The thermally conductive layer combined with the thermal insulation layer can effectively direct unwanted heat to a desired external location, such as an external heat sink, heat dissipation housing, or other external structures, to dissipate the unwanted heat into the external ambient air. The thermally conductive layer is also referred to as a heat conducting plate hereinafter. In one aspect, one or more thermally conductive layers help dissipate heat from local heat loads within the battery module or battery pack. Examples of high thermal conductivity materials include carbon fiber, graphite, silicon carbide, metals (including but not limited to copper, stainless steel, aluminum, etc.), and combinations thereof. In one aspect, the thermally conductive layer can include coolant channels therein with a coolant flow.

[0043] In at least one aspect, to help distribute and remove heat, the thermally conductive layer is coupled to a heat sink. It should be understood that there are various types and configurations of heat sinks, as well as different techniques for coupling the heat sink to the thermally conductive layer, and the present disclosure is not limited to using any one type of heat sink / coupling technique. For example, at least one thermally conductive layer of the multi-layer material disclosed herein can be in thermal communication with an element of the cooling system of the battery module or battery pack, such as a cooling plate or a coolant channel of the cooling system. For another example, at least one thermally conductive layer of the multi-layer material disclosed herein can be in thermal communication with other elements of the battery pack, battery module, or battery system that can act as a heat sink, such as the walls of the battery pack, module, or system, or with other multi-layer materials of the multi-layer material disposed between battery cells. The thermal communication between the thermally conductive layer of the multi-layer material within the battery system and the heat sink element can allow excess heat to be removed from one or more cells adjacent to the multi-layer material to the heat sink, thereby reducing the impact, severity, or spread of thermal events that may generate excess heat.

[0044] III. Aspects of the Battery System Including the Thermal Regulation Component

[0045] Figure 1 An example of a battery system 100 is shown. The system 100 includes one or more battery modules 102. In Figure 1In the example, each module includes a carrier frame and two batteries. The radiator 104 is shown to be located on one side of the system 100 and is in thermal communication with the battery module 102. Figure 2 A cross-section of a battery module 200 similar to the battery module 102 in Figure 1 is shown. A first battery 210 and a second battery 212 are shown. The carrier frame 202 includes a first cavity 204 and an opposing second cavity 206. The first battery 210 and the second battery 212 are shown to be at least partially located within the first cavity 204 and the second cavity 206. In one example, the batteries 210, 212 are lithium-ion batteries, sodium-ion batteries, other alkaline ion batteries, or combinations thereof. The form of the batteries 210, 212 can be prismatic, pouch, or cylindrical cells, but the present invention is not limited thereto. Lithium-ion pouch and prismatic cells are often used in electric vehicle battery modules. A central separator 208 is shown to be located between the pair of opposing cavities 204, 206.

[0046] Figure 3 A battery module 300 similar to the battery module 102 in Figure 1 is shown. The module 300 includes a stack of lithium-ion pouch cells 302. Although pouch cells are used as an example, the present invention is not limited thereto. Other battery configurations and chemical compositions are also within the scope of the present invention. A multi-layer thermal regulation member 310 is shown to separate one or more of the cells 302. The multi-layer thermal regulation member 310 includes a thermal insulation layer 312 and a heat conducting plate 314. The thermal insulation layer and the heat conducting layer are also referred to as an aerogel layer and a heat conducting plate, respectively. In one example, in addition to conducting heat, the heat conducting plate 314 also serves as a structural support plate. In one example, the aerogel layer 312 is a continuous aerogel. In one example, the aerogel layer 312 includes aerogel particles within an adhesive. In one aspect, the aerogel layer 312 includes an aerogel with reinforcing materials. In Figure 3 the example, a second heat conducting plate 316 is included and the aerogel 312 is located between the two heat conducting plates. The radiator 304 is shown in Figure 3 to be in thermal communication with the edges of the heat conducting plates 314, 316.

[0047] In one example, a material such as metal forms the heat conducting plate 314. In operation, the metal or other heat conducting material transfers heat out of the cell 302 and into one or more radiators 304 located adjacent to the stack of lithium-ion pouch cells 302 and the heat conducting plate 314. The incorporation of the aerogel layer 312 provides thermal insulation in the event of thermal runaway in one or more of the cells 302. One or more aerogel layers 312 help to thermally isolate the system (such as Figure 1isolates any overheated battery in the stack within the system 100). Meanwhile, the heat conduction from the heat conduction plate 314 helps cool the unit 302. In this way, the heat regulation member 310 not only provides cooling to improve battery performance but also provides heat insulation from the aerogel layer 312.

[0048] In one example, the aerogel layer 312 forms a direct interface with the heat conduction plate 314 without any intermediate adhesion layer. In operation, the adhesion layer generally has a lower thermal decomposition temperature compared to the aerogel layer 312. By eliminating the adhesion layer, the battery module 300 will exhibit stable operation at a higher temperature window because there is no intermediate layer that decomposes prematurely.

[0049] In one example, the aerogel layer 312 is applied or directly sprayed onto the heat conduction plate 314. This manufacturing process helps to omit the adhesion layer or other adhesive layers. In one example, the slurry is applied in the form of a solution onto the heat conduction plate 314 and then gelled on the heat conduction plate 314. In one example, the gelled sol can be applied onto the heat conduction plate 314.

[0050] In one example, the aerogel layer 312 includes a density gradient at the interface 315 between the heat conduction plate 314 and the aerogel layer 312. In one example, due to the direct application or spraying of the aerogel layer 312, the region adjacent to the interface 315 will have a higher density than the positions within the aerogel layer 312 that are further away from the interface 315.

[0051] In one example, the heat conduction plate 314 includes a porous or open surface structure that provides a diffusion layer at the interface 315. Examples of such heat conduction plates include, but are not limited to, metal mesh, metal foam, mesh fabric, metal wool, metal floss, or other open structures. In these examples, the density gradient at the interface 315 will be caused at least in part by a portion of the applied or sprayed aerogel precursor diffusing into the pores, fibers, structures, etc. of the heat conduction plate 314.

[0052] Figure 4 shows a battery module 400 similar to the Figure 1 battery module 102 in. The module 400 includes a stack of lithium-ion pouch cells 402. Other battery configurations and chemical compositions are also within the scope of the present invention. A multi-layer heat regulation member 410 is shown separating one or more of the cells 402. The multi-layer heat regulation member 410 includes an aerogel layer 412 and a heat conduction plate 416. In one example, in addition to heat conduction, the heat conduction plate 416 also serves as a structural support plate. In the Figure 4 example, a second heat conduction plate 417 is included, and the aerogel 412 is located between the two heat conduction plates. A heat sink 404 is shown in the Figure 4 in thermal communication with the edges of the heat conduction plates 416, 417.

[0053] Figure 4 The first elastic material layer 414 and the second elastic material layer 415 are shown. Although two elastic material layers 414, 415 are shown, the present invention is not limited thereto. A single elastic layer or more than two elastic layers are also possible. In operation, the incorporation of the elastic material layers 414, 415 provides the ability to increase or decrease the amount of space in response to thermal expansion and contraction, or in response to the expansion and contraction of the battery electrodes within the unit 402. Additionally, in the event of a fire or a thermal runaway event, the elastic material layers 414, 415 may burn out and leave a gap that provides a physical separation between the layers in the multi-layer thermal regulation member 410. The physical separation may further assist in reducing the heat diffusion to the adjacent unit 402 on the other side of the thermal regulation member 410.

[0054] In the selected examples described above, the heat conducting plate as described may be replaced with a non-heat conducting material that provides structural support without serving to conduct heat to any heat sink. The structural support plate may be used to form the thermal regulation member as it provides a base for applying the aerogel precursor to coat or spray onto it. Examples of the structural support plate that is not a heat conductor include, but are not limited to, mica plates, mica papers, other forms of mica, felts, foam polymers, solid polymers, composite materials, etc. In the selected examples, the non-heat conducting structural support plate may include holes, fibers, or other surface structures that form a diffusion layer at the application interface. As discussed above, in these examples, the density gradient at the interface wall is at least partially caused by a portion of the applied aerogel precursor diffusing into the holes, fibers, structures, etc. of the structural support plate.

[0055] Figures 5A to 5F Selected examples of the structural support plate are shown. In the example where the structural support plate is formed of a heat conducting material, the structural support plate is also a heat conducting plate. Figures 5A to 5F The exemplary structural support plate and / or heat conducting plate shown can be used in any combination with the examples of the battery module as described above, for example, in Figures 1 to 3 as described.

[0056] Figure 5A A thermal regulation member 500 according to one example is shown. The thermal regulation member 500 includes a structural support plate 502 and an aerogel layer 504 coupled to the structural support plate. As discussed in the above examples, due to the manufacturing method, there is an aerogel density gradient at the interface 506 between the structural support plate 502 and the aerogel layer 504. In the example shown, the aerogel layer 504 surrounds all sides of the structural support plate 502. Alternatively, the aerogel layer 504 may only surround the lateral sides of the structural support plate 502. In the example where the structural support plate 502 is formed of a conductive material such as metal, the exposed top or bottom end of the structural support plate 502 may be coupled to a heat sink for heat conduction.

[0057] In an alternative aspect, the structural support plate 502 may include mica sheets, mica paper, or other mica structures, or combinations thereof.

[0058] In an alternative aspect, the structural support plate 502 may be a first aerogel with a reinforcement, where the aerogel layer 504 may be a second aerogel layer. The second aerogel layer may include the same aerogel as the first aerogel layer, such as mica aerogel. The second aerogel layer may include a different aerogel from the first aerogel layer. For example, the first aerogel layer may include an inorganic aerogel, while the second aerogel layer may include an organic aerogel. In one aspect, the first aerogel layer is a fiber-reinforced aerogel felt, and the second aerogel layer is an aerogel coating, where the second aerogel layer encapsulates the first aerogel layer, thereby preventing dust generation from the first aerogel layer.

[0059] Figure 5B A thermal regulation member 510 according to one example is shown. The thermal regulation member 510 includes a structural support plate 512 and an aerogel layer 514 coupled to one side of the structural support plate 512. As discussed in the above example, due to the manufacturing method, there is an aerogel density gradient at the interface 516 between the structural support plate 512 and the aerogel layer 514.

[0060] Figure 5C A thermal regulation member 520 according to one example is shown. The thermal regulation member 520 includes a structural support plate 522 and an aerogel layer 524 coupled to the structural support plate 522. Due to the manufacturing method, there is an aerogel density gradient in the form of a diffusion layer 526 at the interface between the structural support plate 522 and the aerogel layer 524. In the example shown, the aerogel layer 524 surrounds all the lateral sides of the structural support plate 522. In an example where the structural support plate 522 is formed of a conductive material such as metal, the exposed top or bottom end of the structural support plate 502 may be coupled to a heat sink for heat conduction. The structural support plate 522 may be a mesh, foam, fiber, felt, etc., such that the aerogel in the adhesive diffuses into the mesh, foam, fiber, or felt after application. The diffusion forms a gradient at the interface.

[0061] Figure 5D A thermal regulation member 530 according to one example is shown. The thermal regulation member 530 includes a structural support plate 532 and an aerogel layer 534 coupled to one side of the structural support plate. Due to the manufacturing method, there is an aerogel density gradient in the form of a diffusion layer 536 at the interface between the structural support plate 532 and the aerogel layer 534.

[0062] Figure 5EShows a thermal regulation member 540 according to an example. The thermal regulation member 540 includes a structural support plate 542 and an aerogel layer 544 coupled to the structural support plate. Due to the manufacturing method, there is an aerogel density gradient in the form of a diffusion layer 546 at the interface between the structural support plate 542 and the aerogel layer 544. In Figure 5E the example of, the aerogel layer 544 is reinforced, for example, with a fiber reinforcement, a fabric reinforcement, etc. In one example, the aerogel layer 544 is reinforced by adding fibers, or other reinforcing phases, to an aerogel slurry including aerogel particles and a binder as described above. In one example, the aerogel layer 544 is reinforced by adding fibers, or other reinforcing phases, to a sol, which forms a monolithic aerogel including entrapped reinforcing fibers.

[0063] Figure 5F Shows a thermal regulation member 550 according to an example. The thermal regulation member 550 includes a structural support plate 552 and a first aerogel layer 554 coupled to the first side of the structural support plate 552. Due to the manufacturing method, there is an aerogel density gradient in the form of a diffusion layer 556 at the interface between the structural support plate 552 and the first aerogel layer 554. A second aerogel layer 558 is also shown coupled to the second side of the structural support plate 552. Examples of the support plate 552 include, but are not limited to, a mesh, a foam, a fiber, a felt, etc. Due to the manufacturing method, there is a second aerogel density gradient in the form of a second diffusion layer 560 at the interface between the structural support plate 552 and the second aerogel layer 558. In one example, the first aerogel layer 554 and the second aerogel layer 558 are the same material. In one example, the first aerogel layer 554 and the second aerogel layer 558 are different materials. In one aspect, the first aerogel layer 554 can be an inorganic aerogel layer, while the second aerogel layer 558 is an organic aerogel layer. In another aspect, the first aerogel layer 554 can be a mica aerogel layer, while the second aerogel layer 558 is an aluminum aerogel layer.

[0064] Figure 6 Shows a flowchart of an example manufacturing method. In operation 602, a plurality of battery cells are stacked together. In operation 604, a multi-layer thermal barrier is formed, which includes applying an aerogel precursor to the surface of a structural support. In operation 606, a multi-layer thermal barrier is formed, which includes curing the aerogel precursor on the structural support to form an aerogel adhered to the structural support. In operation 608, the multi-layer thermal barrier is stacked between at least some of the units in a stack of lithium-ion pouch cells.

[0065] The battery module as described above is used in a plurality of electronic devices. Figure 7An example electronic device 700 including a battery module 710 is shown. The battery module 710 is coupled to functional electronics 720 via a circuit 712. In the example shown, the battery module 710 and the circuit 712 are housed in a housing 702. A charging port 714 is shown coupled to the battery module 710 to facilitate recharging of the battery module 710 when needed.

[0066] In one example, the functional electronics 720 includes devices such as semiconductor devices having transistors and storage circuits. Examples include but are not limited to telephones, computers, display screens, navigation systems, etc.

[0067] Figure 8 Another electronic system utilizing a battery module including a multi-layer thermal barrier as described above is shown. Figure 8 An electric vehicle 800 is shown. The electric vehicle 800 includes a chassis 802 and wheels 822. In the example shown, each wheel 822 is coupled to a drive motor 820. A battery module 810 is shown coupled to the drive motor 820 via a circuit 806. A charging port 804 is shown coupled to the battery module 810 to facilitate recharging of the battery module 810 when needed.

[0068] Examples of the electric vehicle 800 include but are not limited to consumer vehicles such as sedans, trucks, etc. Commercial vehicles such as tow trucks and semi-trailer trucks are also within the scope of the present invention. Although four-wheel vehicles are shown, the present invention is not limited thereto. For example, two-wheel vehicles such as motorcycles and scooters are also within the scope of the present invention.

[0069] To better illustrate the methods and devices disclosed herein, the following non-limiting list of aspects is provided:

[0070] Aspect 1. A thermal regulation member for a battery module, comprising: a structural support plate; an aerogel layer coupled to the structural support plate; and an aerogel density gradient at an interface between the structural support plate and the aerogel layer.

[0071] Aspect 2. The thermal regulation member according to aspect 1, wherein the aerogel density gradient includes a diffusion layer.

[0072] Aspect 3. The thermal regulation member according to aspect 1, further comprising an elastic layer.

[0073] Aspect 4. The thermal regulation member according to aspect 1, wherein the aerogel layer includes aerogel particles within an adhesive.

[0074] Aspect 5. The thermal regulation member according to aspect 1, wherein the aerogel layer surrounds all lateral sides of the structural support plate.

[0075] Aspect 6. The thermal regulation member as described in Aspect 1, wherein the aerogel layer is located between two structural support plates.

[0076] Aspect 7. The thermal regulation member as described in Aspect 1, wherein the structural support plate comprises a metallic material.

[0077] Aspect 8. The thermal regulation member as described in Aspect 1, wherein the structural support plate comprises an elastic material.

[0078] Aspect 9. The thermal regulation member as described in Aspect 1, wherein the structural support plate comprises a metallic mesh.

[0079] Aspect 10. The thermal regulation member as described in Aspect 1, wherein the structural support plate comprises a foam material.

[0080] Aspect 11. The thermal regulation member as described in Aspect 1, wherein the structural support plate comprises a felt material.

[0081] Aspect 12. The thermal regulation member as described in Aspect 1, wherein the structural support plate comprises a polyurethane material.

[0082] Aspect 13. The thermal regulation member as described in Aspect 1, wherein the structural support plate comprises mica.

[0083] Aspect 14. The thermal regulation member as described in Aspect 1, wherein the structural support plate comprises an aerogel with a reinforcement.

[0084] Aspect 15. A battery module, comprising: a stack of lithium-ion pouch cells; a multi-layer thermal regulation member located between cells in the stack of lithium-ion pouch cells, the multi-layer thermal regulation member comprising: a heat conducting plate; and an aerogel layer adhered to the heat conducting plate and forming a direct interface with the heat conducting plate.

[0085] Aspect 16. The battery module as described in Aspect 15, wherein the aerogel layer surrounds all lateral sides of the heat conducting plate.

[0086] Aspect 17. The battery module as described in Aspect 15, further comprising a heat sink located on one side of the stack of lithium-ion pouch cells and thermally coupled to the heat conducting plate on an end surface.

[0087] Aspect 18. The battery module as described in Aspect 15, further comprising an aerogel density gradient at the direct interface.

[0088] Aspect 19. The battery module as described in Aspect 15, wherein the aerogel layer comprises aerogel particles within an adhesive.

[0089] Aspect 20. A method of forming a battery module, comprising: stacking a plurality of lithium-ion pouch cells; forming a multi-layer thermal barrier, including: applying an aerogel precursor to a surface of a structural support; curing the aerogel precursor on the structural support to form an aerogel adhered to the structural support; and stacking the multi-layer thermal barrier between at least some of the plurality of lithium-ion pouch cells.

[0090] Aspect 21. The method according to aspect 20, wherein applying includes smearing the aerogel precursor.

[0091] Aspect 22. The method according to aspect 20, wherein applying includes spraying the aerogel precursor.

[0092] Aspect 23. The method according to aspect 20, wherein curing includes removing a solvent from a gelled aerogel sol precursor.

[0093] Aspect 24. The method according to aspect 20, wherein curing includes drying the aerogel slurry.

[0094] The foregoing description is intended to be illustrative and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other aspects may be used by those of ordinary skill in the art after reviewing the above description. The abstract is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It should be understood that the submitted abstract will not be used to interpret or limit the scope or meaning of the claims. Additionally, in the above aspect descriptions, various features may be combined together to streamline the disclosure. This should not be construed as intending that an unclaimed disclosed feature is essential for any claim. Rather, the subject matter of the invention may lie in less than all of the features of a particular disclosed aspect. Accordingly, the appended claims are hereby incorporated into the aspect descriptions, where each claim stands on its own as a separate aspect, and it is contemplated that such aspects may be combined with each other in various combinations or permutations. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

[0095] Although the subject matter of the invention has been described with reference to particular aspects, various modifications and changes can be made to these aspects without departing from the broad scope of the disclosure. Such aspects of the subject matter of the invention may be referred to herein individually or collectively by the term "invention" merely for convenience and not intended to voluntarily limit the scope of the application to any single disclosed or inventive concept, if more than one is in fact disclosed.

[0096] The aspects shown herein are described in sufficient detail to enable those skilled in the art to practice the disclosed teachings. Other aspects can be used and derived from the described aspects, such that structural and logical substitutions and changes can be made without departing from the scope of the present disclosure. The detailed description should not, therefore, be taken in a limiting sense, and the scope of the various aspects is defined only by the appended claims, along with the full scope of equivalents to such claims.

[0097] As used herein, the term "or" can be interpreted in an inclusive or exclusive sense. In addition, multiple instances can be provided for resources, operations, or structures described herein as a single instance. Further, the boundaries between various resources, operations, modules, engines, and data repositories are somewhat arbitrary, and particular operations are illustrated in the context of a particular illustrative configuration. Other allocations of functionality are envisioned and can fall within the scope of the various aspects of the present disclosure. In general, structures and functions presented as separate resources in an example configuration can be implemented as a combined structure or resource. Similarly, structures and functions presented as a single resource can be implemented as separate resources. These and other variations, modifications, additions, and improvements fall within the scope of the various aspects of the present disclosure as expressed by the appended claims. The specification and drawings are to be regarded in an illustrative rather than a restrictive sense.

[0098] For purposes of explanation, the foregoing description has been made with reference to specific aspects. However, the above illustrative discussion is not intended to be exhaustive or to limit the possible aspects to the exact forms disclosed. Numerous modifications and variations are possible in light of the above teachings. The aspects are chosen and described in order to best explain the principles involved and their practical application, so that others skilled in the art can best utilize the various aspects with various modifications as are suited to the particular use contemplated.

[0099] It should also be understood that although terms such as "first", "second", etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, without departing from the scope of the aspects of the present invention, a first contact can be referred to as a second contact, and similarly, a second contact can be referred to as a first contact. The first contact and the second contact are both contacts, but they are not the same contact.

[0100] The terms used in the description of various aspects herein are for the purpose of describing specific aspects only and are not intended to be limiting. Unless the context clearly dictates otherwise, as used in the description of the various aspects and the appended examples, the singular forms "a", "an", and "the" are also intended to include the plural forms. It should also be understood that the term "and / or" as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It should be further understood that the terms "comprises" and / or "comprising", when used in this specification, specify the presence of the stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or combinations thereof.

[0101] As used herein, the term "if" may be interpreted to mean "when" or "after" or "in response to determining" or "in response to detecting", depending on the context. Similarly, the phrase "if determined" or "if detected [the stated condition or event]" may be interpreted to mean "after determining" or "in response to determining" or "after detecting [the stated condition or event]" or "in response to detecting [the stated condition or event]", depending on the context.

Claims

1. A thermal regulation member for a battery module, comprising: A structural support plate; And An aerogel layer coupled to the structural support plate; And An aerogel density gradient at the interface between the structural support plate and the aerogel layer.

2. The thermal regulation member according to claim 1, wherein the aerogel density gradient includes a diffusion layer.

3. The thermal regulation member according to claim 1, further comprising an elastic layer.

4. The thermal regulation member according to claim 1, wherein the aerogel layer includes aerogel particles within an adhesive.

5. The thermal regulation member according to claim 1, wherein the aerogel layer surrounds all lateral sides of the structural support plate.

6. The thermal regulation member according to claim 1, wherein the aerogel layer is located between two structural support plates.

7. The thermal regulation member according to claim 1, wherein the structural support plate comprises a metallic material.

8. The thermal regulation member according to claim 1, wherein the structural support plate comprises an elastic material.

9. The thermal regulation member according to claim 1, wherein the structural support plate comprises a metallic mesh.

10. The thermal regulation member according to claim 1, wherein the structural support plate comprises a foam material.

11. The thermal regulation member according to claim 1, wherein the structural support plate comprises a felt material.

12. The thermal regulation member according to claim 1, wherein the structural support plate comprises a polyurethane material.

13. The thermal regulation member according to claim 1, wherein the structural support plate comprises mica.

14. The thermal regulation member according to claim 1, wherein the structural support plate comprises an aerogel with a reinforcement.

15. A battery module, comprising: A stack of lithium-ion pouch cells; A multi-layer thermal regulation member located between cells in the stack of lithium-ion pouch cells, the multi-layer thermal regulation member comprising: A heat conducting plate; And An aerogel layer adhered to the heat conducting plate and forming a direct interface with the heat conducting plate.

16. The battery module according to claim 15, wherein the aerogel layer surrounds all lateral sides of the heat conducting plate.

17. The battery module according to claim 15, further comprising a radiator located on one side of the stack of lithium-ion pouch cells and thermally coupled to the heat conducting plate on an end surface.

18. The battery module according to claim 15, further comprising an aerogel density gradient at the direct interface.

19. The battery module according to claim 15, wherein the aerogel layer includes aerogel particles within an adhesive.

20. A method of forming a battery module, comprising: Stacking a plurality of lithium-ion pouch cells; Forming a multi-layer thermal barrier, comprising: Applying an aerogel precursor to a surface of a structural support; Curing the aerogel precursor on the structural support to form an aerogel adhered to the structural support; and Stacking the multi-layer thermal barrier between at least some of the plurality of lithium-ion pouch cells.

21. The method according to claim 20, wherein applying comprises smearing the aerogel precursor.

22. The method according to claim 20, wherein applying comprises spraying the aerogel precursor.

23. The method according to claim 20, wherein curing comprises removing the solvent from the gelled aerogel sol precursor.

24. The method according to claim 20, wherein curing comprises drying the aerogel slurry.

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