Cooling techniques for battery packages

Abstract

A method includes forming a cooling plate including an electrically conductive material and having a plurality of openings, and applying a dielectric coating on the cooling plate. The method further includes placing the cooling plate in proximity to a metal sheet including one or more metals and exposing the cooling plate to moisture and / or water. In one example, a minimum lateral distance between the cooling plate and the metal plate is at most 0.5 inches. The method further includes applying a voltage across the cooling plate and the metal plate when the cooling plate is exposed to moisture and / or water, and measuring a leakage current through the cooling plate resulting therefrom. A thickness of the dielectric coating on an edge of an opening of the plurality of openings is at least 0.003 inches.

Description

Technical Field

[0001] This disclosure relates generally to batteries, and more specifically to the cooling of battery modules. Background Technology

[0002] A battery is a common power source, for example, providing direct current (DC) to a load. A battery has a positive terminal (cathode) and a negative terminal (anode). Multiple batteries can be connected in series and / or in parallel to form a high-voltage and / or high-power DC power source.

[0003] Rechargeable batteries can be charged and discharged, and this charge-discharge cycle can occur multiple times throughout the battery's lifespan. For example, once a battery is discharged during use, it can be charged using an applied current, during which the original components of the battery electrodes can be fully or at least partially restored by a reverse current. Examples of such rechargeable batteries include lead-acid and lithium-ion batteries. Batteries can be used in a variety of applications, such as consumer electronics, wearable devices, computers, electric and non-electric vehicles, and / or many other devices or systems that use DC power. Several important issues remain regarding the design and operation of battery packs. Attached Figure Description

[0004] Figure 1A , Figure 1B , Figure 1C and Figure 1D Various views of an example battery assembly according to an embodiment of this disclosure are shown.

[0005] Figure 2 It shows Figures 1A to 1D The battery assembly is shown in the diagram, and condensate deposited on the cooling plate of the battery assembly is further illustrated schematically according to an embodiment of the present disclosure.

[0006] Figure 3 It shows Figures 1A to 1D and Figure 2 The dielectric material coating on the cooling plate of the battery assembly is shown, and an example location of the wires and the cooling plate of the battery assembly according to an embodiment of the present disclosure is further schematically illustrated and susceptible to short circuit.

[0007] Figure 4 Embodiments according to this disclosure are shown. Figures 1A to 1D and Figure 2 Another dielectric material coating on the cooling plate of the battery assembly, wherein the coating has a threshold thickness T1 at the edge of the opening of the cooling plate.

[0008] Figure 5 The following is illustrated: a test cooling plate (e.g.) according to an embodiment of the present disclosure. Figures 1A to 1D , Figure 2 and Figure 4 A flowchart of a method for manufacturing a battery assembly including any one of the cooling plates in the battery assembly, thereby eliminating or at least reducing the possibility of an electrical short circuit between the wires of the battery assembly and the cooling plate.

[0009] Figure 6A and Figure 6B An embodiment of the present disclosure is shown for use in accordance with... Figure 5 The method is used to test the test setup of the cooling plate.

[0010] Figure 7A Example types of battery cells according to embodiments of the present disclosure are shown, and Figure 7B It shows multiple Figure 7A Another example of a battery assembly is a battery cell.

[0011] Figure 7C Embodiments according to this disclosure are shown. Figure 7B Example location of water droplets within the battery assembly.

[0012] The accompanying drawings are for illustrative purposes only and are not necessarily drawn to scale. Various variations, configurations, and other embodiments will become clear through the following detailed discussion. Summary of the Invention

[0013] This description includes a battery assembly comprising a cooling arrangement. In one example, the cooling arrangement includes one or more cooling plates comprising a conductive material coated with one or more layers of dielectric material, wherein each cooling plate has multiple openings to drain vents from the corresponding one or more battery cells, for example, during faulty operation of the battery cells. Furthermore, each of the one or more cooling plates may have a sufficiently thick dielectric coating on the sidewalls and edges of the openings to prevent or reduce the likelihood of electrical short circuits between the edges of the respective openings of the cooling plate and wires connected to the battery terminals. For example, such a coating can help reduce electrical short circuits due to the accumulation of condensate in the cooling plate (condensate tends to accumulate on the sidewalls of the openings of the cooling plate).

[0014] In one embodiment, the battery assembly includes a first cooling plate comprising a conductive material and coated with a dielectric coating, wherein the first cooling plate includes a first array of openings. A first battery has a first positive terminal adjacent to and substantially aligned with a first opening of the first opening array. A wire is connected to the first positive terminal of the first battery. In one example, the distance between the wire and the edge of the first opening is at most 0.4 inches. A second cooling plate is substantially parallel to the first cooling plate, wherein the second cooling plate comprises a conductive material and coated with a dielectric coating. The second cooling plate includes a second array of openings. A second battery has a second positive terminal adjacent to and substantially aligned with a second opening of the second opening array.

[0015] In one example, the first battery is configured to discharge vent gas from or near the positive terminal of the first battery during a faulty operation of the first battery, such that the vent gas is discharged outside the battery assembly through a first opening in the opening array of the first cooling plate. Similarly, the second battery is configured to discharge vent gas from or near the positive terminal of the second battery during a faulty operation of the second battery, such that the vent gas is discharged outside the battery assembly through a second opening in the opening array of the second cooling plate.

[0016] In another example, a method for forming and testing a cooling plate for a battery assembly is also disclosed. For example, a cooling plate is formed, comprising a conductive material and having multiple openings. The cooling plate is coated with a dielectric coating. The cooling plate is placed near a metal plate comprising one or more metals, exposing the cooling plate and the metal plate to moisture and / or water. For example, the cooling plate and the metal plate are exposed to moisture and / or water by immersing them in water. In another example, the cooling plate and the metal plate are exposed to moisture and / or water by spraying water onto the cooling plate and / or operating a water humidifier near the cooling plate. In one example, the minimum lateral distance between the cooling plate and the metal plate is at most 0.5 inches. A voltage is applied to the cooling plate and the metal plate, and the resulting leakage current through the cooling plate is measured. In response to a leakage current exceeding a threshold, the cooling plate is recoated with the dielectric coating, and the leakage current is tested again, repeating this process until the leakage current is below the threshold. In one example, the thickness of the dielectric coating at the edges of the openings in the plurality of openings of the cooling plate is at least 0.003 inches. Given this disclosure, many variations and implementations will be apparent. Detailed Implementation

[0017] General Overview

[0018] As mentioned above, several issues remain to be addressed in the design and operation of battery packs. For example, battery packs may generate heat during operation, necessitating the deployment of cooling arrangements to keep battery temperatures within acceptable ranges. Due to the relatively low temperature of these cooling arrangements (e.g., compared to ambient temperature), water may condense on one or more sections of the cooling arrangements, potentially increasing the likelihood of electrical short circuits in the battery components. Furthermore, during malfunctioning operation of a battery cell (e.g., in a thermal runaway state or due to other reasons), the battery cell may release gases, referred to herein as "venting" of the battery cell. For instance, during such venting events (e.g., due to increased internal pressure caused by malfunctioning operation of the battery cell), a pressure relief valve or diaphragm of the battery cell may rupture, releasing such gases.

[0019] Therefore, this paper describes a technique for forming a battery assembly including a cooling arrangement comprising one or more cooling plates, each having multiple openings for venting fumes during faulty operation of the battery cell. Furthermore, to avoid the possibility of electrical short circuits caused by condensation buildup (which tends to accumulate on the sidewalls of the openings in the cooling plates), each cooling plate may have a sufficient dielectric coating on the sidewalls and edges of the openings to prevent or reduce the likelihood of electrical short circuits between the edges of the individual openings of the cooling plate and the wires connected to the battery terminals.

[0020] In one embodiment, the battery assembly described herein has one or more cooling plates, such as two substantially parallel cooling plates, for example, a first cooling plate and a second cooling plate. Battery cells are arranged laterally between the first and second cooling plates. The battery cells are arranged alternately. In one example, some battery cells have a positive terminal facing the first cooling plate and a negative terminal facing the second cooling plate; while other battery cells have a positive terminal facing the second cooling plate and a negative terminal facing the first cooling plate. Each cooling plate comprises a conductive material (e.g., a metal and / or a metal alloy) coated with one or more dielectric material coatings.

[0021] The positive terminal of each battery cell is adjacent to and substantially aligned with the corresponding opening of the corresponding cooling plate. For example, the first battery cell has a first positive terminal facing the first cooling plate, such that the first positive terminal of the first battery cell is adjacent to and substantially aligned with the corresponding first opening of the first cooling plate. Similarly, the second battery cell has a second positive terminal facing the second cooling plate, such that the second positive terminal of the second battery cell is adjacent to and substantially aligned with the corresponding second opening of the second cooling plate.

[0022] In one example, the openings in the first and second cooling plates are used to drain vents that the battery cell may release, such as during malfunctions of the battery cell. For example, a pressure relief valve or diaphragm may be located on or near the cathode or positive terminal of the battery cell, for instance, on or near the surface of the battery cell (including the positive terminal). During such venting events (e.g., due to pressure buildup inside the battery cell caused by malfunctions), the pressure relief valve or diaphragm may rupture, thereby releasing such vents.

[0023] Because these vents exit from or near the positive terminal of the battery cell, and each battery cell's positive terminal is adjacent to and substantially aligned with a corresponding opening, the vents exiting from the battery cell can be discharged outside the battery assembly through the corresponding openings in the cooling plate. Therefore, the openings in the cooling plate provide a safe venting path for the vents. Discharging vents through the corresponding openings within the cooling plate prevents or at least reduces the propagation of vents to the battery cell itself or adjacent battery cells, thereby preventing or at least reducing the fire hazard within the battery assembly.

[0024] Please note that because venting may not originate from or near the corresponding negative terminal of the battery cell, the negative terminal of the battery cell may not have a corresponding adjacent opening on the cooling plate. For example, venting from the negative side might be possible, but given the manufacturing method of individual battery cells, this is unlikely to occur. In some examples, the negative terminal of the battery cell may be adjacent to an opening, for example, in place of or supplementing the case where the positive terminal of the battery cell is adjacent to an opening.

[0025] In one embodiment, the battery cells are secured in place by a honeycomb structure. This structure prevents or reduces movement of individual battery cells and includes a rigid material (e.g., aluminum, epoxy resin, and / or other suitable materials) with holes or slots machined inside to mount the battery cells into corresponding slots.

[0026] In one embodiment, the battery assembly includes multiple conductive busbars or connecting wires, for example, for connecting the positive or negative terminals of battery cells to adjacent battery cells (or to other components of the battery assembly). In one embodiment, these connecting wires are made of a conductive material, such as one or more metals and / or alloys thereof.

[0027] In one embodiment, the battery assembly includes a flame-retardant dielectric material, such as dielectric foam near the connector between the battery terminals and the wires. This foam serves as a flame-retardant and thermal insulation layer, for example, to prevent or reduce the possibility of fire spread and / or heat transfer from one battery cell to an adjacent battery cell. A thermally conductive pad (also referred to herein as a gap pad) is located between the cooling plate and the wires. The thermally conductive pad serves as the thermal interface material between the cooling plate and the battery cells. For example, during battery assembly operation, the thermally conductive pad transfers heat from the battery cells to the cooling plate, thereby preventing or reducing the possibility of the battery cells overheating. The thermally conductive pad includes a dielectric material with relatively high thermal conductivity. In one example, the thermally conductive pad is also used to fill air gaps caused by the uneven (or smooth) surfaces of the wires. Figure 1D As shown, each thermal pad (e.g., one adjacent to the first cooling plate and the other adjacent to the second cooling plate) has a corresponding array of openings that is substantially aligned with the array of openings of the adjacent cooling plates, thereby allowing exhaust gas to be discharged from the positive terminal of the aligned battery cell.

[0028] like Figure 1D As shown, some wires are separated from the cooling plates by gaps or air, and the minimum distance between one wire and the opening of the first cooling plate is L1, and the minimum distance between the other wire and the opening of the second cooling plate is L2 (see...). Figure 1D In one example, lengths L1 and L2 are at most 1 inch, or at most 0.8 inches, or at most 0.4 inches, or at most 0.2 inches, or at most 0.1 inches, or at most 0.08 inches, or at most 0.06 inches, or at most 0.05 inches, or at most 0.04 inches.

[0029] In one example, the first and second cooling plates are relatively cold, for example, colder than the ambient air in which the battery assembly operates. Therefore, moisture may condense on the walls of the cooling plates (e.g., see...). Figure 2 For example, water droplets may accumulate on the cooling plate. These droplets may be located on the sides of the cooling plate, for example, adhering to the sides due to surface tension. Furthermore, water tends to drip and accumulate or pool on the bottom sidewalls of openings in the cooling plate (see, for example, [reference needed]). Figure 2 For example, water droplets from the sides of the cooling plate fall and flow downwards (e.g., due to gravity) and tend to accumulate on the bottom sidewalls of the various openings.

[0030] As described above, the first and second cooling plates have one or more layers of dielectric material coating. In one example, the dielectric coating is thicker on the non-edge surfaces of the cooling plates and thinner at the edges of the openings in the cooling plates. For example, the coating thickness on the non-edge surfaces can be 0.005 to 0.01 inches, for example, at least 0.003 inches, or at least 0.005 inches, or at least 0.008 inches, or at least 0.01 inches, or at least 0.015 inches, or at least 0.02 inches. Conversely, the dielectric coating thickness at the edges of the openings can be less than 0.003 inches, or less than 0.002 inches, or less than 0.001 inches. Examples of the difference in dielectric coating thickness are as follows: Figure 3 and Figure 4 As shown. The thinner dielectric coating at the edges may be due to the deposition technique used when depositing the coating on the cooling plate. For example, after the coating is deposited on the cooling plate, the coating retention rate at the edges is relatively low compared to the coating retention rate on the non-edge surfaces of the cooling plate. For example, the coating may not bond sufficiently to the edges compared to the bonding of the coating on the non-edge surfaces of the cooling plate.

[0031] Furthermore, in one example, the battery assembly could be installed inside the aircraft, for example, in either a pressurized or unpressurized section. In one example, as the aircraft's altitude increases, the air pressure inside the aircraft and near the battery assembly decreases, which could increase the electrical conductivity of the air (e.g., air has higher electrical conductivity at lower pressures). Additionally, or rather, the electrical conductivity at high altitudes is higher than at sea level due to the presence of high-energy particles from space (whose energy decreases as they approach the Earth's surface).

[0032] Therefore, in one example, (i) water droplets accumulate on or near the edge of the opening in the cooling plate; (ii) the coating thickness at or near the edge of the opening in the cooling plate may be relatively thin (e.g., less than the coating thickness on the non-edge surface of the cooling plate); (iii) the distance between the line and the edge of the opening in the cooling plate (e.g., Figure 2 The length L1 in the circuit may be relatively small, as described above; (iv) the operating voltage of the battery assembly at the positive terminal of the battery may be relatively high; and / or (v) during operation of the battery assembly (e.g., when the aircraft carrying the battery assembly is flying at high altitudes), the electrical conductivity of the air at high altitudes may be higher than at sea level. In one example, one or more of the above factors may cause an arc or short circuit between the wire and the edge of the cooling plate, such as Figure 3 As shown.

[0033] In one example, to prevent or at least reduce the possibility of such short circuits, the dielectric coating at the edges of the various openings in the cooling plate may have a minimum threshold thickness T1 (see [reference needed]). Figure 4In one example, the thickness T1 is, for example, at least 0.002 inches, or at least 0.003 inches, or at least 0.004 inches, or at least 0.005 inches, or at least 0.006 inches, or at least 0.007 inches, or at least 0.008 inches, or at least 0.01 inches, or at least 0.012 inches, or at least 0.015 inches. Furthermore, the average thickness T2 of the coating on the non-edge surfaces of the cooling plate (see...) Figure 4 For example, it may be at least 0.005 inches, or at least 0.007 inches, or at least 0.009 inches, or at least 0.01 inches, or at least 0.02 inches, or at least 0.025 inches, or at least 0.03 inches. In one example, the possibility of an electrical short circuit between the cooling plate and the wire can be eliminated or at least reduced due to the increased coating thickness T1 at or near the edge of the opening, and / or due to the appropriate selection of the dielectric material used for the coating.

[0034] In one example, to ensure that the dielectric coating on the cooling plate is sufficient to eliminate or reduce the possibility of the aforementioned electrical short circuit, the cooling plate can be rigorously tested. For example, one or more layers of dielectric material coating are first applied to the cooling plate. Subsequently, a metal plate is placed near the cooling plate (see...). Figure 6A and Figure 6B The lateral distance D between the metal plate and the cooling plate can be, for example, at most 1 inch, at most 0.8 inches, at most 0.7 inches, at most 0.5 inches, at most 0.3 inches, at most 0.1 inches, at most 0.05 inches, or at most 0.03 inches. In one example, the distance D is essentially zero (D≈0), in which case at least a portion of the cooling plate is in contact with at least a portion of the metal plate.

[0035] The cooling plate and metal plate are then exposed to moisture and / or water. In one example, the cooling plate is sprayed with water and / or placed in a humid environment (see [link]). Figure 6A In another example, the cooling plate and metal plate are immersed in water (see...). Figure 6B In both examples, the water droplets ( Figure 6A ) or water ( Figure 6B The water droplets are located on the sidewalls and edges of the opening in the cooling plate. This simulates the situation described above caused by condensation during normal operation of the cooling plate (e.g., water droplets are located on the sidewalls and edges of the opening in the cooling plate).

[0036] Subsequently, a voltage V1 is applied to the cooling plate and the metal plate, and the leakage current I is measured. If the dielectric coating is well applied (e.g., the coating thickness at the edge of the opening is at least T1), the coating can prevent a large current I between the metal plate and the cooling plate. However, if the dielectric coating is insufficiently applied (e.g., the coating thickness at the edge of the opening is insufficient), the coating may not be able to prevent leakage current between the metal plate and the cooling plate. Therefore, in one example, a high current I value (e.g., current I is above the threshold current value) indicates an electrical short circuit between the metal plate and the cooling plate, which in turn indicates a weak coating on the cooling plate (e.g., insufficient coating thickness at the edge of the opening).

[0037] Please note that the test voltage V1 may be higher than the battery module's operating voltage Va, for example, to account for the battery module's rated operating altitude. For instance, the battery module may be installed inside an aircraft, either in a pressurized or unpressurized section. In one example, as the aircraft's altitude increases, the air pressure inside the aircraft and near the battery module may decrease, which may increase the electrical conductivity of the air (e.g., air conductivity is higher at lower pressures). Furthermore, the electrical conductivity at higher altitudes may be higher than at sea level due to the presence of high-energy particles from space (which decrease near the Earth's surface). Therefore, in one example, to compensate for the increased air conductivity at higher altitudes and to maintain a safety margin during testing, the test voltage V1 is higher than the battery module's operating voltage Va, as described below.

[0038] As described above, in one example, it is determined whether the leakage current I is greater than a threshold current value. If the leakage current I is greater than the threshold current value, one or more layers of coating are recoated onto the cooling plate, and the cooling plate is tested again. This testing and recoating process continues until the cooling plate passes the test, for example, the leakage current I is less than the threshold current value. For example, a leakage current I less than the threshold current value means that the coating at the edge of the opening of the cooling plate is sufficient to prevent or at least reduce the possibility of an electrical short circuit.

[0039] The battery assembly is then formed using a cooling plate that has been coated and tested according to the above process. In one example, the battery assembly can be installed inside an aircraft; in another example, it can be installed in other suitable applications.

[0040] According to some embodiments of this disclosure, these different methods can be used alone or together to operate the cooling arrangement of the battery assembly while allowing exhaust gas and preventing or at least reducing the possibility of electrical short circuits due to the accumulation of condensate in the cooling arrangement.

[0041] As used herein, the term “about” indicates that the listed value may vary slightly, or be within acceptable tolerances, as long as such variation does not cause the process or equipment to be nonconforming. For example, for some elements, “about” may refer to a variation of ±0.1%; for others, “about” may refer to a variation of ±1% or ±10%, or any point thereof. In this document, terms defined in the singular also encompass terms defined in the plural, and vice versa.

[0042] Any range of values ​​mentioned in this document explicitly includes every value (including fractions and integers) within that range. For illustrative purposes, the range of "at least 50" or "at least about 50" mentioned in this document includes integers 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, etc., and fractions 50.1, 50.2, 50.3, 50.4, 50.5, 50.6, 50.7, 50.8, 50.9, etc. To further clarify, the range of "less than 50" or "less than about 50" mentioned in this document includes integers 49, 48, 47, 46, 45, 44, 43, 42, 41, 40, etc., and fractions 49.9, 49.8, 49.7, 49.6, 49.5, 49.4, 49.3, 49.2, 49.1, 49.0, etc.

[0043] The terms “substantially” or “essentially” used in this article are also used with a negative connotation, referring to the complete or near-complete lack of an action, characteristic, attribute, state, structure, item, or result. For example, a “substantially” flat surface is either completely flat or nearly flat, such that its effect is the same as if it were completely flat.

[0044] Architecture

[0045] Figure 1A , Figure 1B , Figure 1C and Figure 1D Various views of an example battery assembly 100 according to an embodiment of the present disclosure are shown.

[0046] Figure 1A A perspective view of a battery assembly 100 (also referred to simply as assembly 100) is shown, and the cooling arrangement of the battery assembly 100 is shown, including cooling plates 104a and 104b and coolant pipes 112a and 112b located on the cooling plates 104a and 104b respectively, but other components of the assembly 100 are not shown. Figure 1B Another perspective view of the battery assembly 100 is shown, including cooling plates 104a, 104b and example battery cells 116a, 116b, 118a, 118b, but other components of the assembly 100 are not shown. Figure 1C A cross-section of the cooling plate 104a is shown. Figure 1DA cross-sectional view of the battery assembly 100 is shown, for example along... Figure 1B A cross-sectional view of line A-A' in the diagram.

[0047] See Figure 1A The assembly 100 includes two substantially parallel cooling plates 104a and 104b. In one example, cooling plates 104a and 104b comprise a thermally conductive material, such as one or more metals and / or alloys thereof, and are coated with one or more layers of dielectric coating material. Cooling plates 104a and 104b provide cooling for the battery assembly 100, for example, by transferring heat from the assembly 100 to the coolant flowing through coolant pipes (also simply pipes) 112a and 112b and / or to the surrounding environment. Cooling plates 104a and 104b may be made of one or more thermally conductive metals, such as copper and / or aluminum.

[0048] Each cooling plate 104 is associated with a corresponding coolant pipe 112, which contacts or is in close contact with the cooling plate. For example, the coolant pipe 112 meanders around the corresponding cooling plate 104, thereby covering a large area of ​​the cooling plate. Figure 1A An example layout of coolant pipes 112a and 112b is shown, although coolant pipes 112a and 112b can be configured in any other suitable layout. Figure 1A In the diagram, the coolant pipe 112b of the cooling plate 104b is indicated by a dashed line because the coolant pipe 112b is installed on or near the surface of the cooling plate, and this surface is... Figure 1A It is not visible in the middle, therefore the coolant pipe 112b is in Figure 1A Not visible in the middle. In one example, coolant pipes 112a and 112b may be machined or brazed within the corresponding cooling plates 104a and 104b, respectively, so that the coolant pipes are sealed by the surface of the corresponding cooling plates.

[0049] The pipes 112a and 112b of the cooling plates 104a and 104b are schematically shown in thick lines. Each of the pipes 112a and 112b receives a relatively cold coolant (e.g., Figure 1A (See the "coolant inflow" arrow in the diagram), and the cold coolant flows from one end of the pipe to the other. Cooling plates 104a and 104b transfer the heat generated from batteries 116 and 118 to the coolant in pipes 112a and 112b, respectively, thereby raising the temperature of the coolant. The relatively hot coolant leaves pipes 112a and 112b and is cooled by an external cooling arrangement; the cooled coolant then circulates again within pipes 112a and 112b.

[0050] like Figure 1A and Figure 1BAs shown, cooling plate 104a has an array of openings 108a, and cooling plate 104b has an array of openings 108b. In each cooling plate 104, the corresponding openings 108 are arranged in rows and columns. In one example, the openings 108a of cooling plate 104a are offset from (e.g., misaligned) the openings 108b of cooling plate 104b. For example, if cooling plate 104a were arranged aligned on top of cooling plate 104b (e.g., so that the boundaries of cooling plate 104a are substantially aligned with the boundaries of cooling plate 104), then openings 108a and 108b would be misaligned, for example, offset from each other. Figure 1D The openings 108a1 and 108b1 of the cooling plate 104a are also shown to be offset relative to each other.

[0051] Therefore, for example, an imaginary line passing through opening 108a1 and extending to cooling plate 104b (wherein the imaginary line is substantially orthogonal to one or both of cooling plates 104a and 104b) will not intersect or pass through the opening on cooling plate 104b. Similarly, for example, an imaginary line passing through opening 108b1 and extending to cooling plate 104a (wherein the imaginary line is substantially orthogonal to one or both of cooling plates 104a and 104b) will not intersect or pass through the opening on cooling plate 104a. Note that in Figure 1A and Figure 1B For clarity, the sidewalls of the opening are not shown (see [link to diagram of the sidewalls of the opening portion]). Figure 1D ).

[0052] In one embodiment, a plurality of battery cells 116, 118 are arranged laterally between cooling plates 104a, 104b. Figure 1B Some example battery cells 116a, 116b, 118a, and 118b are shown.

[0053] In one example, each battery cell 116, 118 is substantially orthogonal to one or both of the cooling plates 104a, 104b (note that in one example, the cooling plates 104a, 104b are parallel to each other). For example, each battery cell 116, 118 extends from the vicinity of one cooling plate to the vicinity of another cooling plate.

[0054] Each battery cell 116, 118 has a cathode or positive terminal and an anode or negative terminal. Battery cell 116 (e.g., battery cells 116a, 116b) has a corresponding positive terminal facing the cooling plate 104b, and battery cell 118 (e.g., battery cells 118a, 118b) has a corresponding positive terminal facing the cooling plate 104a, such as... Figure 1B As shown.

[0055] For example, the cathode or positive terminal of each battery cell is adjacent to a corresponding opening in cooling plate 104a or cooling plate 104b. For example, the positive terminal of battery cell 116a is adjacent to and substantially aligned with the corresponding opening 108b1 of cooling plate 104b; the positive terminal of battery cell 116b is adjacent to and substantially aligned with the corresponding opening 108b2 of cooling plate 104b, see [reference]. Figure 1B Therefore, the positive terminals of battery cells 116a and 116b face the cooling plate 104b and are substantially aligned with the corresponding openings of the cooling plate 104b.

[0056] On the other hand, for example, the positive terminal of battery cell 118a is adjacent to and substantially aligned with the corresponding opening 108a1 of cooling plate 104a; the positive terminal of battery cell 118b is adjacent to and substantially aligned with the corresponding opening 108a2 of cooling plate 104a. Therefore, the positive terminals of battery cells 118a and 118b face cooling plate 104a and are substantially aligned with the corresponding openings of cooling plate 104a.

[0057] Component 100 also contains many other battery cells, which, for clarity, Figure 1B These units are not shown. For example, each corresponding opening corresponds to one battery cell. Therefore, each opening 108b of the cooling plate 104b has a corresponding positive terminal of the corresponding battery cell 116 adjacent to the corresponding opening. Similarly, each opening 108a of the cooling plate 104a has a corresponding positive terminal of the corresponding battery cell 11b adjacent to the corresponding opening.

[0058] In one example, openings 108a and 108b are used to release vents that the battery cell may release, such as during malfunction of the battery cell. For example, during malfunction of the battery cell (e.g., during thermal runaway or other causes), the battery cell may release a gas, referred to herein as a “vent” of the battery cell. For example, a pressure relief valve or diaphragm may be provided on or near the cathode or positive terminal of the battery cell, for example, on or near the surface of the battery cell including the positive terminal. During such a venting event (e.g., due to pressure buildup inside the battery cell caused by malfunction of the battery cell), the pressure relief valve or diaphragm may rupture, thereby releasing this gas.

[0059] Since these gases are discharged from or near the positive electrode of the battery cell, and the positive electrode of each battery cell is adjacent to and substantially aligned with a corresponding opening, for example, the discharged fumes can be discharged from the assembly 100 through this opening. Therefore, this opening provides a safe discharge path for the fumes. Discharging fumes through the corresponding opening prevents or at least reduces the propagation of fumes to the battery cell itself or adjacent battery cells, thereby preventing or at least reducing the fire hazard in the assembly 100.

[0060] Now for reference Figure 1C The figure shows the cross-section of the opening 108a1 within the cross-section of the cooling plate 104a. It should be noted that... Figure 1C The opening 108a1 is not fully shown. The opening 108a1 has a sidewall 109a extending from the left surface of the cooling plate 104a to the right surface. The right edge 109a of the opening 108a1 is located between the sidewall 109a of the opening 108a1 and the right surface of the cooling plate 104a. The left edge 109b of the opening 108a1 is located between the sidewall 109a of the opening 108a1 and the left surface of the cooling plate 104a.

[0061] Similarly, other openings in component 100 also include one or more sidewalls, a left edge, and a right edge. Figures 1A to 1C In the example, the cross-sectional shape of the opening 108 is circular or elliptical, but the opening 108 can also have other suitable cross-sectional shapes, such as square, rectangular or rhomboid.

[0062] Now for reference Figure 1D It shows along Figure 1B A cross-sectional view of component 100 along line A-A'. Please note, Figure 1D Only a portion of component 100 is shown, which includes two example battery cells 116a and 118a.

[0063] Such as combination Figure 1A and Figure 1B As stated, and Figure 1D As shown, cooling plates 104a and 104b are arranged parallel to each other, and battery cells 116 and 118 are arranged laterally between cooling plates 104a and 104b. For example, each battery 116 and 118 extends laterally from the vicinity of one cooling plate to the vicinity of another cooling plate. In one example, each battery cell 116 and 118 is arranged substantially orthogonal to one or both of cooling plates 104a and 104b.

[0064] As described above, each cooling plate 104a and 104b includes corresponding openings 108a and 108b, respectively. For example, Figure 1D The opening 108a1 in the cooling plate 104a and the opening 108b1 in the cooling plate 104b are shown.

[0065] As described above, each battery cell 116, 118 has a cathode or positive terminal and an anode or negative terminal. For example, as Figure 1D As shown, battery cell 116a has a corresponding positive terminal (in Figure 1D The positive terminal (marked with "+") faces the cooling plate 104b, and the corresponding negative terminal (in...) Figure 1DThe negative terminal (marked with "-") faces the cooling plate 104a. Similarly, the battery cell 118a has a corresponding positive terminal (marked with "-"). Figure 1D The positive terminal (marked with "+") faces the cooling plate 104a, and the corresponding negative terminal (in...) Figure 1D (marked as "-"), the negative terminal faces the cooling plate 104b.

[0066] like Figure 1D As shown, the positive terminal of battery cell 116a is close to (e.g., adjacent to) opening 108b1. For example, the positive terminal of battery cell 116a is substantially aligned with opening 108b1, such that venting events of battery cell 116a will release vents through a valve or diaphragm located at or near the positive terminal of battery cell 116a, and these vents will exit assembly 100 through opening 108b1. In one example, the distance between the positive terminal of battery cell 116a and opening 108b1 is at most 2 inches, or at most 1.5 inches, or at most 1 inch, or at most 0.8 inches, or at most 0.4 inches, or at most 0.2 inches, or at most 0.1 inches, or at most 0.08 inches, or at most 0.06 inches, or at most 0.05 inches, or at most 0.04 inches.

[0067] Similarly, such as Figure 1D As shown, the positive terminal of battery cell 118a is close to (e.g., adjacent to) opening 10ab1. For example, the positive terminal of battery cell 118a is substantially aligned with opening 108a1, such that venting events of battery cell 118a will release vents through a valve or diaphragm located at or near the positive terminal of battery cell 118a, and these vents will exit assembly 100 through opening 108a1. In one example, the distance between the positive terminal of battery cell 118a and opening 108a1 is at most 2 inches, or at most 1.5 inches, or at most 1 inch, or at most 0.8 inches, or at most 0.4 inches, or at most 0.2 inches, or at most 0.1 inches, or at most 0.08 inches, or at most 0.06 inches, or at most 0.05 inches, or at most 0.04 inches.

[0068] Please note that because exhaust may not exit from or near the corresponding negative terminal of the battery cell, the negative terminal of the battery cell may not have an opening adjacent to the cooling plate. Figure 1D As shown. For example, discharge from the negative electrode side may be possible, but given the way individual battery cells are manufactured, this possibility is likely unlikely. In some examples, the negative terminal of the battery cell may be adjacent to the opening, for example, replacing or supplementing the positive terminal of a battery cell adjacent to the opening.

[0069] In one embodiment, battery cells 116a and 118a are secured in place by a honeycomb structure 122. Structure 122 is located on the sidewalls of the battery cells, wherein the sidewalls of the battery cells extend from their positive terminals to their negative terminals, as shown below. Figure 1D As shown. Structure 122 can prevent or reduce the individual battery cells 116 and 118 in the z-axis direction (e.g., Figure 1D The vertical direction) and the y-axis direction (e.g., Figure 1D Movement in the direction of paper entry and exit. In one example, structure 122 includes a rigid material, such as a dielectric material, like a relatively rigid plastic. In another example, structure 122 includes a rigid material, such as aluminum or other suitable material, and has holes or slots machined inside it to mount the battery cells in corresponding slots. It is worth noting that, although Figure 1D Structure 122 is shown, but for clarity, Figure 1A and Figure 1B Structure 122 is not shown.

[0070] In one embodiment, component 100 includes a trapping or holding plate 124 adjacent to cooling plate 104a, and another trapping or holding plate 124 adjacent to cooling plate 104b. The plates 124 secure corresponding battery cells 116, 118 in place. For example, each plate 124 has finger-like protrusions that at least partially restrict the battery cells 116, 118 in place. Figure 1D The component 100 shown is moved along the x-axis in an example direction. In one example, plate 124 includes a dielectric material. In one example, plate 124 includes epoxy resin or other suitable dielectric material. Each plate 124 has openings or holes aligned with the corresponding positive terminal of the battery cell and with openings of the corresponding adjacent cooling plate, such as... Figure 1D As shown.

[0071] In one embodiment, component 100 includes a plurality of conductive busbars or connecting wires 132, for example Figure 1D The busbars or wires 132a, 132b, and 132c in the battery cell. For example, wire 132a connects the positive terminal of battery cell 118a to the negative terminal of battery cell 116a. Wire 132b connects the negative terminal of battery cell 118a to... Figure 1D Another component, not shown (e.g., connecting the negative terminal of battery cell 118a to the positive terminal of another battery cell). Similarly, line 132c connects the positive terminal of battery cell 116a to... Figure 1D Another component not shown (e.g., connecting the positive terminal of battery cell 116a to the negative terminal of another battery cell).

[0072] Therefore, in Figure 1A In this example, battery cells 118a and 116a are connected in series via lines 132a, 132b, and 132c. However, in other examples, battery cells 116a and 118a may also be connected in other suitable ways (e.g., in parallel).

[0073] In one embodiment, wires 132a, 132b, 132c comprise a conductive material, such as one or more metals and / or alloys thereof. Example metals for wires 132a, 132b, 132c include copper, aluminum, nickel, and / or one or more other metals and / or metal alloys used as busbars or wires in battery assemblies.

[0074] In one embodiment, the component includes a flame-retardant dielectric material 130, such as dielectric foam 130 near the connection between the battery terminal and the wire 132. The foam 130 serves as a flame retardant, for example, to prevent or reduce the possibility of fire spreading from the battery cell to the outside of the battery cell.

[0075] A thermally conductive pad (also referred to herein as a gap pad) 126 is located between (i) the cooling plate and (ii) plates 124, lines 132a, 132b, 132c, and foam 130. The thermally conductive pad 126 serves as the thermal interface material between the cooling plate and the battery cells 116, 118. For example, during operation of the battery assembly 100, the thermally conductive pad 126 transfers heat from the battery cells 116, 118 to the cooling plates 104a, 104b, thereby preventing or reducing the possibility of overheating of the battery cells 116, 118. The thermally conductive pad 126 comprises a dielectric material with relatively high thermal conductivity. In one example, the thermally conductive pad 126 is also used to fill air gaps caused by imperfectly flat (or smooth) surfaces of lines 132 and plates 124. In one example, the thermally conductive pad is relatively rigid at room temperature but softens at relatively high temperatures and may fill the gap between (i) the cooling plate 104 and (ii) the lines 132 and plates 124.

[0076] like Figure 1D As shown, each thermal pad 126 has an array of openings that are substantially aligned with the array of openings on the adjacent cooling plate. For example, the space between a portion of wire 132a (e.g., connected to the positive terminal of battery cell 118a) and cooling plate 104a cannot be filled by the thermal pad 126, thus leaving space for venting exhaust generated by the positive terminal of battery cell 118a. Similarly, the space between a portion of wire 132c (e.g., connected to the positive terminal of battery cell 116a) and cooling plate 104b cannot be filled by the thermal pad 126, thus leaving space for venting exhaust generated by the positive terminal of battery cell 116a.

[0077] like Figure 1DAs shown, line 132a and cooling plate 104a are separated by a gap or air, and the minimum distance between line 132a and cooling plate 104a is L1. Similarly, line 132c and cooling plate 104b are separated by a gap or air, and the minimum distance between line 132c and cooling plate 104b is L2.

[0078] In one example, lengths L1 and L2 are at most 1 inch, or at most 0.8 inches, or at most 0.4 inches, or at most 0.2 inches, or at most 0.1 inches, or at most 0.08 inches, or at most 0.06 inches, or at most 0.05 inches, or at most 0.04 inches. Please note that... Figure 1D The portion of line 132b shown is not adjacent to the cooling plate 104b and is completely separated from the cooling plate 104b by the thermal pad 126 (including dielectric material).

[0079] Figure 2 It shows Figure 1D The image shows a battery assembly 100, and further schematically illustrates condensation deposited on cooling plates 104a, 104b of the battery assembly 100 according to an embodiment of the present disclosure. For example, the cooling plates 104a, 104b are relatively cold, for example, colder than the ambient air in which the assembly 100 operates. Therefore, moisture condenses on the walls of the cooling plates 104a, 104b. For example, Figure 2 Water droplets are shown on cooling plates 104a and 104b. The droplets may be located on the sides of the cooling plates 104a and 104b, for example, adhering to the sides due to surface tension. Furthermore, water tends to drip and accumulate or collect on the bottom sidewalls of openings 108a1 and 108b1, such as... Figure 2 As shown. For example, water droplets from the sides of cooling plates 104a and 104b fall and flow downwards (e.g., due to gravity) and tend to accumulate on the bottom sidewalls of openings 108a1 and 108b1.

[0080] Figure 3 It shows Figure 1D and Figure 2 The dielectric material coating 308 on the cooling plates 104a and 104b of the battery assembly 100 is shown, and the weak points of electrical short circuits between the wires 132a and 132c of the battery assembly 100 according to the embodiments of the present disclosure and the cooling plates 104a and 104b are further schematically shown.

[0081] For example, Figure 3 An enlarged view 304 of a cross-section of cooling plate 104a is shown. As shown, cooling plate 104a has one or more layers of dielectric material coating 308. Cooling plate 104b also has a similar dielectric material coating.

[0082] As shown in the figure, coating 308 is thicker on the non-edge surfaces of cooling plate 104a and thinner at the edges of the openings in cooling plate 104a. For example, Figure 3 The edge 312 of the opening 108a1 is marked in the middle, while Figure 1C Edge 312 is also shown as edges 109a and 109b. In one example, coating 308 is relatively thin at the edge of the opening (e.g., compared to the thickness of coating 308 on the non-edge surface of plate 104a). For example, the thickness of coating 308 on the non-edge surface can be 0.005 to 0.01 inches, for example, at least 0.003 inches, or at least 0.005 inches, or at least 0.008 inches, or at least 0.01 inches, or at least 0.015 inches, or at least 0.02 inches. Conversely, the thickness of coating 308 on the edge 312 of opening 108a1 can be less than 0.003 inches, or less than 0.002 inches, or less than 0.001 inches. Figure 3 The cross section 304 of the cooling plate in the image shows this thickness difference.

[0083] The dielectric material coating on edge 312 is thinner, likely due to the deposition technique used when depositing coating 308 on cooling plate 104a. For example, when coating cooling plate 104a (e.g., using any suitable coating deposition technique), the thickness of coating 308 on non-edge surfaces is inherently greater than the thickness of coating 308 on edge 312, for example, due to unforeseen limitations of the coating deposition process. For example, after coating is deposited on cooling plate 104a, the retention of coating 308 on edge 312 is relatively lower than the retention on non-edge surfaces of cooling plate 104a. For example, the coating may not bond sufficiently to edge 312 compared to the adhesion of coating 308 on non-edge surfaces of cooling plate 104a.

[0084] Furthermore, in one example, the battery assembly 100 is installed inside the aircraft, for example, within a pressurized or unpressurized section of the aircraft. In one example, as the aircraft's altitude increases, the air pressure inside the aircraft and near the battery assembly may decrease, which could increase the electrical conductivity of the air (e.g., air has higher electrical conductivity at lower pressures). Additionally, or rather, due to the presence of high-energy particles from space at higher altitudes (the presence of such high-energy particles decreases near the Earth's surface), the electrical conductivity at higher altitudes may be higher than at sea level.

[0085] Therefore, in one example, (i) water droplets accumulate on or near the edge 312 of the opening 108a1 of the cooling plate 104a, (ii) the thickness of the coating 308 at or near the edge is relatively small, and (iii) the distance between line 132a and the edge 312 of the cooling plate 104a (e.g., Figure 2The length L1 is relatively small, as described above, (iv) the battery assembly 100 may have a relatively high voltage at the positive terminal of the battery 118a (e.g., approximately 800V in the example implementation), and / or (v) the battery assembly 100 may be rated to operate at higher altitudes (e.g., when the aircraft with the battery assembly installed is flying at high altitudes), where the conductivity of the air is higher than at sea level.

[0086] In one example, one or more of the factors mentioned above could cause an arc or short circuit 320 between line 132a and cooling plate 104a, such as Figure 3 As shown in line 320. In one example, a similar arcing or short circuit may also occur between line 132c and cooling plate 104b, although Figure 3 Not shown in the image.

[0087] Figure 4 Embodiments according to this disclosure are shown. Figure 1D and Figure 2 Another dielectric material coating 408 is shown on the cooling plates 104a and 104b of the battery assembly 100, wherein the coating 408 has at least a threshold thickness T1 on the edge 312 of the opening 108a1 of the cooling plate 104a. In one example, the thickness T1 of the coating 408 on the edge 312 of the cooling plate 104a is, for example, at least 0.002 inches, at least 0.003 inches, at least 0.004 inches, at least 0.005 inches, at least 0.006 inches, at least 0.007 inches, at least 0.008 inches, at least 0.01 inches, at least 0.012 inches, or at least 0.015 inches.

[0088] In addition, the average thickness T2 of the coating 408 on the non-edge surface of the cooling plate 104a is, for example, at least 0.005 inches, or at least 0.007 inches, or at least 0.009 inches, or at least 0.01 inches, or at least 0.02 inches, or at least 0.025 inches, or at least 0.03 inches.

[0089] In one example, Figure 4 In this case, due to the increased thickness of the coating 408 at or near the edge 312 of the cooling plate 104a (e.g., with...), Figure 3 Compared to the thickness shown) and / or due to the sensible selection of the dielectric material used in coating 408, the thickness is eliminated or at least reduced. Figure 4 The possibility of an electrical short circuit occurring between the intermediate cooling plate 104a and the line 132a. Therefore, even if (i) water droplets accumulate on or near the edge 312 of the opening 108a1 of the cooling plate 104a, (ii) the distance between the line 132a and the edge 312 of the cooling plate 104a (e.g., Figure 2(iii) the length L1 is relatively small, the voltage on the positive terminal of battery 118a is relatively high (e.g., about 800V in the example embodiment), and / or (iv) battery assembly 100 can be rated for operation at higher altitudes where the conductivity of air is higher than at sea level, and the selection of thicknesses T1 and T2 and / or dielectric material coating 408 eliminates or at least reduces the likelihood of an electrical short circuit between cooling plate 104a and line 132a. Similarly, the thickness and / or selection of dielectric material coating 408 eliminates or at least reduces the likelihood of an electrical short circuit between cooling plate 104b and line 132c (and between any cooling plate 104a, 104b and any line of assembly 100). Therefore, with Figure 3 compared to, Figure 4 The battery components in the battery pack will not experience electrical short circuits.

[0090] Coating 408 may include a suitable dielectric material that can adhere well to the edge of the opening in the cooling plate and has sufficient dielectric properties. Examples of coating 408 include ethylene trifluorochloroethylene (ECTFE), semi-crystalline melt-processable semi-fluorinated polymers, thermoplastic powder coatings, and / or other suitable dielectric material coatings.

[0091] Figure 5 The following is illustrated: a test cooling plate (e.g.) according to an embodiment of the present disclosure. Figure 1A , Figure 1B , Figure 1C , Figure 1D , Figure 2 and Figure 4 The flowchart of any cooling plate 104a, 104b in the battery assembly 100 and the method 500 for manufacturing the battery assembly 100 including the cooling plate is provided to eliminate or at least reduce the possibility of an electrical short circuit between the wire 132 of the battery assembly 100 and the cooling plate. Figure 6A and Figure 6B The embodiments according to this disclosure are shown. Figure 5 Method 500 describes the test setup for testing cooling plates. Figure 5 , Figure 6A and Figure 6B They will be discussed at the same time.

[0092] refer to Figure 5 At 504 of method 500, one or more layers of dielectric material coating (e.g., ...) are coated on the cooling plate (e.g., cooling plate 104a). Figure 4 (Coating 408 in the middle). This coating can be applied using appropriate techniques for coating on a cooling plate.

[0093] As described herein, the coating may not adhere to or bond to the edges of the openings in the cooling plate compared to the non-edge surfaces. For example, the coating on the edges of the openings in the cooling plate may be smaller than T1 (see [link to article]). Figure 4 ), just as Figure 3 As mentioned above, this may increase the cooling plate and line 132 (see...) Figure 3 The possibility of an electrical short circuit between them. Therefore, after the coating is applied, the cooling plate can be tested to check whether its performance is satisfactory, as described below.

[0094] Method 500 proceeds from 504 to 508. At 508, the cooling plate is sprayed with water and / or placed in a humid environment, such as... Figure 6A As shown. Alternatively, immerse the cooling plate in water, for example, as shown. Figure 6B As shown. Furthermore, the metal plate 604 is placed near the cooling plate, as... Figure 6A and Figure 6B As shown. Therefore, the cooling plate and metal plate 604 are exposed to moisture and / or water.

[0095] For example, in Figure 6A In this embodiment, a water sprayer 612 sprays water onto the cooling plate 104. In one example, the water sprayer 612 can be a water bottle, a sprayer connected to a water pipe, or a faucet, and can be operated manually or automatically to spray water onto the cooling plate 104. In one example, in addition to or instead of water spraying, a water humidifier 608 operates near the cooling plate 104a. The water humidifier 608 can humidify the environment, for example, by releasing water vapor or steam and increasing the humidity in the air near the cooling plate 104a. Therefore, due to the operation of the water sprayer and / or the water humidifier 608, water droplets will form on the surface of the cooling plate 104a and on the sidewalls of the openings, such as... Figure 6A As shown.

[0096] like Figure 6A As shown, a metal plate 604 is placed near a cooling plate 104a. In one example, the metal plate 604 has no dielectric coating. The metal plate 604 is laterally separated from the cooling plate 104a by a distance D. In one example, the distance D is at most 1 inch, or at most 0.8 inches, or at most 0.7 inches, or at most 0.5 inches, or at most 0.3 inches, or at most 0.1 inches, or at most 0.05 inches, or at most 0.03 inches. In one example, the distance D is essentially zero (D≈0), in which case at least a portion of the cooling plate 104a is in contact with at least a portion of the metal plate 604.

[0097] exist Figure 6B In the container 616, the cooling plate 104 and the metal plate 604 are spaced apart by the aforementioned distance D, and the combination of the cooling plate 104 and the metal plate 604 is submerged in the water.

[0098] Therefore, in Figure 6A and Figure 6B In the middle, water droplets ( Figure 6A ) or water ( Figure 6B This is located on the sidewall and edge of the opening in cooling plate 104a. This simulates the above description regarding... Figure 3 and Figure 4 The conditions described (e.g., water droplets are located on the sidewalls and edges of the opening in the cooling plate 104a).

[0099] Then, method 500 proceeds from 508 to 512. At 512, a voltage V1 is applied to the cooling plate 108a1 and the metal plate 604, and the leakage current I is measured, as shown below. Figure 6A and Figure 6B As shown. If the dielectric material coating in process 504 is applied well (e.g., the coating thickness at the edge of the opening is at least T1), see [reference needed]. Figure 4 If the coating 408 is applied, it will prevent a large current I from occurring between the metal plate 604 and the cooling plate 104a, for example, as mentioned above. Figure 4 However, if the dielectric material coating in process 504 is not applied effectively (e.g., insufficient coating thickness at the edges of the openings), see [reference needed]. Figure 3 If the coating fails to prevent leakage current between the metal plate 604 and the cooling plate 104a, then the coating may not be able to prevent leakage current between the metal plate 604 and the cooling plate 104a.

[0100] Therefore, in one example, in process 512 (also...) Figure 6A and Figure 6B A high value of current I at (shown in the figure) (e.g., current I is higher than the threshold current value) indicates that there is an electrical short circuit between metal plate 604 and cooling plate 104a, which in turn indicates that the coating on cooling plate 104a is weak (e.g., the coating thickness at the edge of the opening is insufficient).

[0101] Assume that when battery module 100 is operating, battery module 100 outputs a voltage Va. In one example, the test voltage V1 applied in process 512 is greater than Va. In one example, the test voltage V1 is greater than the operating voltage Va of battery module 100 to maintain a safety margin and take into account the higher rated operating altitude of battery module 100, where the conductivity of air is higher (e.g., due to the presence of higher-energy particles from space and / or due to lower air pressure, which leads to higher air conductivity).

[0102] For example, Figure 6A and Figure 6BThe tests can be conducted in a test facility with ground-level air pressure (e.g., this ground-level air pressure may differ slightly from sea-level air pressure, depending on the altitude of the physical facility where the test is being conducted). However, in one example, the battery assembly 100 can be mounted on an aircraft that may reach high altitudes during flight, where the electrical conductivity of the air may be lower than at ground level for the reasons described above.

[0103] Therefore, the "rated altitude" of the battery module may be much higher than the "test altitude" (e.g., when conducting...). Figure 6A and Figure 6B (Test altitude). For example, the rated altitude of the battery assembly may be at least 1,000 feet, or at least 2,000 feet, or at least 5,000 feet, or at least 10,000 feet, or at least 15,000 feet, or at least 20,000 feet higher than the test altitude, depending on the rated flight altitude of the aircraft. Furthermore, as mentioned above, an increase in altitude leads to a corresponding increase in the electrical conductivity of the air, thereby correspondingly increasing the likelihood of the aforementioned electrical short circuit.

[0104] Therefore, in order to compensate for the battery module's rated altitude being higher than the test altitude and to maintain a safety margin during the testing process, Figure 6A and Figure 6B The test voltage V1 is higher than the operating voltage Va of the battery assembly 100. For example, the test voltage V1 is at least 1.2 times, 1.5 times, 2 times, 2.5 times, 2.8 times, 3 times, 3.5 times, 4 times, 4.5 times, or 5 times the operating voltage Va (for example, at least 1.2 times means that V1 is at least 1.2 times Va). By way of example only, the operating voltage Va of the battery assembly 100 may be approximately 800V, while the test voltage V1 of the battery assembly 100 may be approximately 3,000V, 3,500V, or 3,550V, but the actual voltage may vary depending on the specific implementation.

[0105] In one example, the voltage can be applied for at least a threshold time. For instance, the test can last for at least 60 seconds, although this threshold time may vary depending on the specific implementation.

[0106] Method 500 proceeds from 512 to 516. At 516, the leakage current I is determined (see...). Figure 6A and Figure 6B Whether it exceeds the threshold current value. In one example, the threshold current value could be 0.2 mA, 0.5 mA, 0.7 mA, 1 mA, 1.2 mA, 1.5 mA, 2 mA, 5 mA, or 10 mA. In one example, the threshold current value may depend on the sensitivity of the battery assembly 100 to leakage current between the cooling plate and the wire 132, and / or may depend on the criticality of the operation to which the battery assembly 100 is to be deployed.

[0107] If the result at 516 is "yes" (e.g., leakage current I is greater than the threshold current value), it means that the coating applied at process 504 is insufficient to prevent the aforementioned electrical short circuit. For example, the coating at edge 312 may be insufficient, as mentioned above. Figure 3 Therefore, if the result at 516 is "yes", method 500 continues from 516 to 520. At 520, one or more additional coatings are recoated onto the cooling plate. Subsequently, method 500 returns to 508, where water is re-sprayed onto the cooling plate and / or the cooling plate is placed in a humid environment, or the cooling plate is immersed in water, and the cooling plate test at 512 is performed again between the cooling plate and the metal plate.

[0108] On the other hand, if the result at 516 is "No" (e.g., leakage current I is less than the threshold current value), it indicates that the coating at process 504 is sufficient to prevent the aforementioned electrical short circuit. For example, as mentioned above... Figure 4 The coating at edge 312 is sufficient. Therefore, if the result at 516 is "No", method 500 continues from 516 to 524. At 524, the battery assembly 100 is formed using cooling plates coated and tested according to processes 504-520. For example, each cooling plate 104a, 104b for the battery assembly 100 can be coated and tested according to processes 504 to 520. Figures 1A to 1D The description is provided. Appropriate techniques can be used to form the battery assembly 100.

[0109] Method 500 proceeds from 524 to 528. At 528, in one example, the aforementioned battery assembly 100 may be installed inside an aircraft. In other examples, the battery assembly 100 may also be installed for other suitable applications.

[0110] Please note that, for ease of description, the various processes in method 500 are shown in a specific order. However, according to some embodiments, one or more processes may be performed in a different order, or not at all (and are therefore optional). Given this disclosure, numerous variations of method 500 and the techniques described herein will become apparent.

[0111] Figure 7A An example type of battery cell 718 is shown, while Figure 7B The embodiments of the present disclosure are shown, including multiple Figure 7A Another example of battery assembly 700 is battery cell 718.

[0112] See Figure 7AThe positive terminal 703 of the battery cell 718 is located on one side of the battery cell 718 (labeled "+"), and the negative terminal 707 is located on the other side of the battery cell 718 (labeled "-"). The battery cell 718 also includes a conductive housing 705, which at least partially encloses the battery cell 718 and is connected to the negative terminal 707 of the battery cell 718. The conductive housing 705 is also referred to herein as the conductive outer surface 705 of the battery cell 718.

[0113] The conductive outer surface 705 comprises a conductive material, such as one or more metals and / or alloys thereof. The conductive outer surface 705 forms an extension of the negative terminal 707. For example, a wire connected to any portion of the conductive outer surface 705 is electrically connected to the negative terminal 707. It should be noted that the conductive outer surface 705 at least partially encloses the sidewall between the positive and negative terminals of the battery cell 718 and conducts current.

[0114] As shown in the figure, the positive terminal 703 and a portion of the conductive outer surface 705 are located on the same side of the battery cell 718 (e.g., Figure 7A (Left side of the direction). Therefore, the positive and negative terminals of the battery cell 718 can be accessed from the same side of the battery cell 718.

[0115] Now for reference Figure 7B The battery assembly 700 includes a single cooling plate 704a. In one example, the cooling plate 704a includes a thermally conductive material, such as one or more metals and / or alloys thereof, and is coated with one or more layers of dielectric coating material 708 (see [link to product description]). Figure 7C Cooling plate 704 provides cooling for battery assembly 700, for example, by transferring heat from assembly 700 to coolant flowing through coolant pipes and / or to the surrounding environment. The coolant pipes are located in... Figure 7B Not shown in the diagram, and likely similar to the coolant pipes 112a and 112b described above with respect to battery assembly 100.

[0116] In one embodiment, a plurality of battery cells 718 are arranged to extend laterally from the cooling plate 704. Figure 7B Some example battery cells 718a, 718b, 718c, and 718d are shown.

[0117] In one example, each battery cell 718 is substantially orthogonal to the cooling plate 704. Each battery cell 718 has a cathode or positive terminal 703 and an anode or negative terminal 707. As shown, the battery cell 718 has a corresponding negative terminal 707 facing the cooling plate 704. Therefore, unlike battery assembly 100, in battery assembly 700, the negative terminal 707 of each battery 718 faces the cooling plate 704. Since the negative terminal 707 of the battery cell 718 faces the cooling plate 704, the cooling plate 704 does not need to have an opening for venting exhaust gas.

[0118] A thermally conductive pad (also referred to herein as a gap pad) 726 is located between the cooling plate 704 and the battery cell 718. It should be noted that the cooling plate 704 is located on one side of the battery cell 718; therefore, the thermally conductive pad 726 is also located on the same side of the battery cell 718. The thermally conductive pad 726 serves as the thermal interface material between the cooling plate and the battery cells 116, 118. For example, during operation of the battery assembly 700, the thermally conductive pad 726 transfers heat from the battery cell 718 to the cooling plate 704, thereby preventing or reducing the possibility of overheating of the battery cell 718. The thermally conductive pad 726 is composed of a dielectric material with relatively high thermal conductivity.

[0119] In one embodiment, the battery cell 718 is secured in place by a honeycomb structure 722. For example... Figure 7B As shown, structure 722 is located on the sidewall of battery cell 718, wherein the sidewall of battery cell extends from its positive terminal to its negative terminal. Structure 722 can prevent or reduce the individual battery cell 718 from being in the z-axis direction (e.g., Figure 7B The vertical direction) and the y-axis direction (e.g., Figure 7B (In the direction of entering and exiting the paper). In one example, structure 722 also includes finger-like protrusions near the positive terminal 703 of the battery cell, which prevent or at least reduce the movement of the individual battery cell 718 in the x-axis direction ( Figure 7B (In the direction shown) it moves to the left. Therefore, unlike the battery assembly 100 in Figure 1 (e.g., which has a trapping plate or holding plate 124), Figure 7B Battery assembly 700 does not have a trapping plate or retaining plate. In one example, structure 722 also serves as a trapping plate. However, in another example, battery assembly 700 may have a separate trapping plate, similar to battery assembly 100.

[0120] In one example, structure 722 includes a rigid material, such as a dielectric material, like a relatively rigid plastic. In another example, structure 722 includes a rigid material, such as aluminum or another suitable material.

[0121] In one embodiment, component 700 includes a plurality of conductive busbars or connecting wires 732, for example Figure 7B The busbars or lines 732a, 732b, 732c, and 732d in the diagram. Please note, as mentioned above... Figure 7A The negative terminal 707 of the battery cell 718 extends electrically to the same side as the positive terminal 703 via a conductive casing or outer surface 705. Therefore, both the positive and negative terminals are led out from the same side of the battery cell 178, for example... Figure 7B To the left in the direction shown.

[0122] Therefore, wire 732b connects the negative terminal of battery cell 718a to the positive terminal of battery cell 718b; wire 732c connects the negative terminal of battery cell 718b to the positive terminal of battery cell 718c; wire 732d connects the negative terminal of battery cell 718c to the positive terminal of battery cell 718d, and so on. Thus, battery cells 718a, 718b, 718c, and 718d are connected in series via wires 732a, 732b, 732c, and 732d. However, in other examples, battery cells 718 can also be connected in other suitable ways (e.g., in parallel).

[0123] In one embodiment, wire 732 comprises a conductive material, such as one or more metals and / or alloys thereof. Example metals of wire 732 include copper, aluminum, nickel, and / or one or more other metals and / or metal alloys used for busbars or wires in battery assemblies.

[0124] In one embodiment, component 700 includes a flame-retardant dielectric material 730, such as dielectric foam 730 near the connection between the battery terminal and the wire 732. The foam 730 acts as a flame retardant and thermal barrier, for example, to prevent or reduce the possibility of fire spreading from the battery cell to the outside of the battery cell.

[0125] Figure 7B The foam 730 shown is a continuous foam with wires 732 extending therein. However, the foam 730 can also be discontinuous and / or have openings, such as the foam 130 of the battery assembly 100 previously described.

[0126] Please note that since the negative terminal 707 of the battery cell 718 faces the cooling plate 704, the cooling plate 704 does not need to have an opening for venting exhaust. The foam 730 is not rigid, and exhaust from the positive terminal 703 of the battery assembly 718 can be vented through the template 730. For example, during this venting process, the foam 730 may burst, thus creating a path for venting. In another example, although... Figure 7B Not shown, but foam 730 may have an opening for venting exhaust gas (e.g., an opening similar to that in foam 130 of the battery assembly 100 described above).

[0127] In one embodiment, component 700 includes a plurality of mounting hardware 711, such as bolts or screws. As shown, the mounting hardware 711 mounts the thermal pad 726 and the cooling plate 704 to structure 722. For example, the mounting hardware 711 secures the thermal pad 726 and the cooling plate 704 in place relative to structure 722. For example, a first end of the mounting hardware 711 is located on the outer surface of the cooling plate 704, and a second end is secured within structure 722 by screws or bolts, for example, to secure the cooling plate 704 in place.

[0128] In one embodiment, the cooling plate 722 has openings 708 (e.g., example openings 708a, 708b) through which mounting hardware 711 is inserted into the cooling plate 704. Note that, unlike the battery assembly 100, in the battery assembly 700, the openings 708 are not aligned with the battery cells 718. Instead, the openings are aligned with the structure 722. The number of openings 708 within the cooling plate 704 depends on the required number of mounting hardware 711 used to secure the cooling plate 704 to the structure 722.

[0129] In one example, water can enter opening 708, for example, through capillary action or wicking, due to surface tension and / or gravity. Figure 7C Embodiments according to this disclosure are shown. Figure 7B An example location of a water droplet within the battery assembly 700. It should be noted that, unlike battery assembly 100, in battery assembly 700, the opening 708 of the cooling plate 704 is not near any wire 732. Instead, the opening 708 of the cooling plate 704 is now close to the conductive casing or outer surface 705 of the battery cell 718. For example, a water droplet could increase the likelihood of an electrical short circuit occurring between the edge of the opening 708 and the conductive casing or outer surface 705 of the adjacent battery cell 718.

[0130] Figure 7C A dielectric material coating 708 on a cooling plate 704 of the battery assembly 700 is also shown, wherein the coating 708 has at least a threshold thickness T1 on the edge 712 of the opening 708 of the cooling plate 704. In one example, the thickness T1 of the coating 708 has been shown above regarding... Figure 4The following description is provided. For example, the thickness T1 on the edge 712 of the cooling plate 704 is, for example, at least 0.002 inches, at least 0.003 inches, at least 0.004 inches, at least 0.005 inches, at least 0.006 inches, at least 0.007 inches, at least 0.008 inches, at least 0.01 inches, at least 0.012 inches, or at least 0.015 inches. Furthermore, the average thickness T2 of the coating 708 on the non-edge surface of the cooling plate 704 is, for example, at least 0.005 inches, or at least 0.007 inches, or at least 0.009 inches, or at least 0.01 inches, or at least 0.02 inches, or at least 0.025 inches, or at least 0.03 inches.

[0131] exist Figure 7C In the example, due to the increased thickness of the coating 708 at or near the edge 712 of the cooling plate 704 (e.g., with... Figure 3 Compared to the thickness shown) and / or due to the appropriate selection of the dielectric material used for coating 708, the possibility of an electrical short circuit between cooling plate 704 and conductive outer surface 705 is eliminated, or at least reduced, for example, similar to the description above regarding battery assembly 100.

[0132] In one example, cooling plate 704 was tested, and at least in part according to the above. Figure 5 Method 500 is used to manufacture battery components 700.

[0133] Further exemplary implementations

[0134] The following examples illustrate further implementations, from which various arrangements and configurations can be clearly seen.

[0135] Example 1. A battery assembly comprising: a cooling plate including a conductive material and coated with a dielectric coating, the cooling plate including an array of openings therein; a battery adjacent to the cooling plate; and a wire connected to the positive terminal of the battery; wherein (i) the distance between the edge of an opening in the array of openings and (ii) one or both of the wire and the battery is at most 0.4 inches.

[0136] Example 2. A battery assembly according to Example 1, wherein the cooling plate is a first cooling plate, the battery is a first battery, the positive terminal is a first positive terminal, the opening array is a first opening array, wherein the first positive terminal of the first battery is adjacent to and substantially aligned with a first opening of the first opening array; and wherein the battery assembly further includes: a second cooling plate substantially parallel to the first cooling plate, the second cooling plate comprising a conductive material and coated with a dielectric coating, the second cooling plate including a second opening array; and a second battery having a second positive terminal, the second positive terminal being adjacent to and substantially aligned with a second opening of the second opening array.

[0137] Example 3. According to the battery assembly of Example 2, wherein: the first negative terminal of the first battery faces the second cooling plate and is not aligned with any opening of the second opening array; and the second negative terminal of the second battery faces the first cooling plate and is not aligned with any opening of the first opening array.

[0138] Example 4. A battery assembly according to any one of Examples 2 to 3, further comprising: a structure including aluminum, wherein the structure includes at least a first slot and a second slot, and wherein the first battery is located in the first slot and the second battery is located in the second slot.

[0139] Example 5. A battery assembly according to any one of Examples 1 to 4, wherein: the battery is configured to discharge exhaust gas from or near the positive terminal of the battery during fault operation of the battery, such that the exhaust gas is discharged from the battery assembly through the opening of the opening array of the cooling plate.

[0140] Example 6. A battery assembly according to any one of Examples 1 to 5, wherein the cooling plate includes a first surface facing the battery and a second surface opposite to the first surface, and wherein the battery assembly further includes a coolant pipe disposed on the second surface of the cooling plate.

[0141] Example 7. A battery assembly according to any one of Examples 1 to 6, wherein the opening array is a first opening array, and wherein the battery assembly further includes: a thermal pad between the wire and the cooling plate, wherein the thermal pad has a second opening array substantially aligned with the first opening array of the cooling plate.

[0142] Example 8. A battery assembly according to any one of Examples 1 to 7, further comprising: a structure including a slot, wherein the battery is located within the slot; and mounting hardware extending through an opening in the array of openings of the cooling plate and extending within the structure.

[0143] Example 9. A battery assembly according to any one of Examples 1 to 8, wherein the thickness of the dielectric coating on the edge of the opening is at least 0.003 inches.

[0144] Example 10. A method comprising: forming a cooling plate comprising a conductive material and having a plurality of openings; coating the cooling plate with a dielectric coating; placing the cooling plate near a metal plate comprising one or more metals and exposing the cooling plate to moisture and / or water, wherein the minimum lateral distance between the cooling plate and the metal plate is at most 0.5 inches; applying a voltage to the cooling plate and the metal plate while the cooling plate is exposed to moisture and / or water, and measuring a resulting leakage current through the cooling plate; and recoating the cooling plate with the dielectric coating in response to the leakage current being higher than a threshold.

[0145] Example 11. The method of Example 10, wherein exposing the cooling plate to moisture and / or water comprises: immersing the cooling plate and the metal plate in water.

[0146] Example 12. The method of Example 10, wherein exposing the cooling plate to moisture and / or water includes: spraying water onto the cooling plate and / or operating a water humidifier near the cooling plate.

[0147] Example 13. The method according to any one of Examples 10 to 11 further includes, after recoating the cooling plate with the dielectric coating: placing the recoated cooling plate near the metal plate and exposing the recoated cooling plate to moisture and / or water; and while the recoated cooling plate is exposed to moisture and / or water, reapplying a voltage to the recoated cooling plate and the metal plate, and measuring the final leakage current through the recoated cooling plate.

[0148] Example 14. The method according to any one of Examples 10 to 13 further includes: determining that the cooling plate forming process has been completed in response to the leakage current being below the threshold.

[0149] Example 15. According to the method of Example 14, wherein, after the formation process is completed, the thickness of the dielectric coating on the edge of one of the plurality of openings is at least 0.003 inches.

[0150] Example 16. A method according to any one of Examples 10 to 15, wherein the battery assembly to be used with the cooling plate is rated to operate at a first voltage, and applying voltage to the cooling plate and the metal plate comprises: applying a voltage at least three times the first rated voltage of the battery assembly to the cooling plate and the metal plate, thereby taking into account that the battery assembly is rated to operate at an altitude of at least 10,000 feet.

[0151] Example 17. The method according to any one of Examples 10 to 16, wherein applying voltage includes: applying a voltage for at least a threshold time period to the cooling plate and the metal plate.

[0152] Example 18. A system comprising: an aircraft; and a battery assembly mounted within the aircraft, wherein the battery assembly includes: a cooling plate comprising a conductive material and coated with a dielectric coating, the cooling plate including a first array of openings therein such that the thickness of the dielectric coating on the edges of the openings of a plurality of openings is at least 0.003 inches; a battery having battery terminals adjacent to and substantially aligned with the openings of the first array of openings; wires connected to the battery terminals; and a thermally conductive pad located between the wires and the cooling plate, wherein the thermally conductive pad has a second array of openings substantially aligned with the first array of openings of the cooling plate.

[0153] Example 19. The system according to Example 18, wherein the battery assembly is installed within a portion of the aircraft, wherein the air pressure within that portion of the aircraft is not regulated when the aircraft is flying at a certain altitude.

[0154] Example 20. The system according to any one of Examples 18 to 19, wherein the distance between the wire and the edge of the opening is at most 0.4 inches.

[0155] The foregoing description of exemplary embodiments is for illustrative and descriptive purposes only. It is not intended to be exhaustive or to limit this disclosure to the precise form disclosed. Various modifications and variations are possible in light of this disclosure. The scope of this disclosure is not limited by this detailed description but by the appended claims. Future applications claiming priority to this application may assert the disclosed subject matter in different ways and may generally include any set of one or more limiting conditions disclosed or otherwise argued herein.

Claims

1. A battery assembly, comprising: A cooling plate comprising a conductive material and coated with a dielectric coating, the cooling plate comprising an array of openings therein; The battery is adjacent to the cooling plate; as well as A wire that connects to the positive terminal of the battery; Wherein, (i) the distance between the edge of the opening in the array of openings and (ii) the distance between one or both of the wire and the battery is at most 0.4 inches.

2. The battery assembly according to claim 1, wherein, The cooling plate is a first cooling plate, the battery is a first battery, the positive terminal is a first positive terminal, and the opening array is a first opening array, wherein the first positive terminal of the first battery is adjacent to and substantially aligned with the first opening of the first opening array; and wherein the battery assembly further includes: A second cooling plate substantially parallel to the first cooling plate, the second cooling plate comprising a conductive material and coated with a dielectric coating, and the second cooling plate including a second array of openings; and The second battery has a second positive terminal that is adjacent to and substantially aligned with the second opening of the second opening array.

3. The battery assembly according to claim 2, wherein: The first negative terminal of the first battery faces the second cooling plate and is not aligned with any opening of the second opening array; and The second negative terminal of the second battery faces the first cooling plate and is not aligned with any opening of the first opening array.

4. The battery assembly according to claim 2, further comprising: The structure includes aluminum, wherein the structure includes at least a first slot and a second slot, and wherein the first battery is located in the first slot and the second battery is located in the second slot.

5. The battery assembly according to claim 1, wherein: The battery is configured to vent exhaust gas from the positive terminal or vicinity of the battery during fault operation, such that the exhaust gas is discharged from the battery assembly through the opening of the opening array of the cooling plate.

6. The battery assembly according to claim 1, wherein, The cooling plate includes a first surface facing the battery and a second surface opposite the first surface, and wherein the battery assembly further includes: Coolant pipes arranged on the second surface of the cooling plate.

7. The battery assembly according to claim 1, wherein, The aperture array is the first aperture array, and the battery assembly further includes: The thermal pad between the conductor and the cooling plate has a second array of openings that is substantially aligned with the first array of openings on the cooling plate.

8. The battery assembly according to claim 1, further comprising: The structure includes a slot, wherein the battery is located within the slot; and The mounting hardware extends through the openings of the array of openings in the cooling plate and extends within the structure.

9. The battery assembly according to claim 1, wherein, The thickness of the dielectric coating on the edge of the opening is at least 0.003 inches.

10. A method comprising: A cooling plate comprising conductive material and having multiple openings is formed; The cooling plate is coated with a dielectric coating. The cooling plate is placed near a metal plate comprising one or more metals and exposed to moisture and / or water, wherein the minimum lateral distance between the cooling plate and the metal plate is at most 0.5 inches; When the cooling plate is exposed to moisture and / or water, a voltage is applied to the cooling plate and the metal plate, and the resulting leakage current through the cooling plate is measured; and In response to the leakage current exceeding the threshold, the cooling plate is recoated with the dielectric coating.

11. The method according to claim 10, wherein, Exposure of the cooling plate to moisture and / or water includes: Immerse the cooling plate and the metal plate in water.

12. The method according to claim 10, wherein, Exposure of the cooling plate to moisture and / or water includes: Spray water onto the cooling plate and / or operate a water humidifier near the cooling plate.

13. The method of claim 10, further comprising, after recoating the cooling plate with the dielectric coating: placing the recoated cooling plate near the metal plate and exposing the recoated cooling plate to moisture and / or water; and When the recoated cooling plate is exposed to moisture and / or water, a voltage is reapplied to the recoated cooling plate and the metal plate, and the final leakage current through the recoated cooling plate is measured.

14. The method of claim 10, further comprising: In response to the leakage current being below the threshold, it is determined that the cooling plate formation process has been completed.

15. The method according to claim 14, wherein, After the formation process is completed, the thickness of the dielectric coating on the edge of the opening of the plurality of openings is at least 0.003 inches.

16. The method of claim 10, wherein, For the battery assembly to operate at a rated first voltage using this cooling plate, applying voltage to the cooling plate and the metal plate includes: A voltage of at least three times the first rated voltage of the battery assembly is applied to the cooling plate and the metal plate, taking into account that the battery assembly is rated to operate at an altitude of at least 10,000 feet.

17. The method according to claim 10, wherein, The applied voltage includes: A voltage for at least a threshold time period is applied to the cooling plate and the metal plate.

18. A system comprising: Aircraft; as well as A battery assembly installed within the aircraft, wherein the battery assembly includes: A cooling plate comprising a conductive material and coated with a dielectric coating, the cooling plate including a first array of openings therein, such that the thickness of the dielectric coating on the edges of the openings of the plurality of openings is at least 0.003 inches; A battery having battery terminals that are adjacent to and substantially aligned with the openings of the first opening array; The wires connected to the battery terminals; and A thermal pad is located between the conductor and the cooling plate, wherein the thermal pad has a second array of openings substantially aligned with the first array of openings on the cooling plate.

19. The system according to claim 18, wherein, The battery assembly is installed within a section of the aircraft, wherein the air pressure within that section of the aircraft is not regulated when the aircraft is flying at a certain altitude.

20. The system according to claim 18, wherein, The distance between the wire and the edge of the opening is at most 0.4 inches.

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