Battery module and battery case

Abstract

The utility model relates to a battery module and a battery case. The battery module includes a stack of lithium-ion battery cells, vents on each cell of the stack of lithium-ion battery cells, a multiple cover layer on one side of the stack of lithium-ion battery cells, and at least one channel embedded in the multiple cover layer. The battery housing includes one or more battery modules within the battery housing, each of the battery modules having a vent on each of the cells of a stack of lithium ion battery cells, a multiple cover layer on each of the stack of lithium ion battery cells, and a tube embedded in the multiple cover layer.

Description

[0001] This utility model is a divisional application of Chinese patent application No. 2023236386517, entitled "Battery Module and Electric Vehicle", filed on December 29, 2023. Technical Field

[0002] This disclosure generally relates to materials, systems, and methods for preventing or mitigating thermal events (e.g., thermal runaway problems) in energy storage systems. In particular, this disclosure provides thermal barrier materials. This disclosure also relates to a battery module or battery pack having one or more battery cells including thermal barrier materials, and systems including such battery modules or battery packs. The described embodiments typically include aerogel materials. Background Technology

[0003] Lithium-ion batteries (LIBs) are widely used to power portable electronic devices such as mobile phones, tablets, laptops, power tools, and other high-current devices such as electric vehicles because they offer higher operating voltage, lower memory effect, and higher energy density compared to conventional batteries. However, safety is a concern because lithium-ion batteries are prone to catastrophic failure under “abuse conditions” such as overcharging (charging beyond the design voltage), over-discharging, operating at high temperatures and pressures, or being exposed to high temperatures and pressures.

[0004] To prevent such cascaded thermal runaway events, effective isolation and heat dissipation strategies are needed to address these and other technical challenges of lithium-ion batteries. Utility Model Content

[0005] The following description and accompanying drawings fully illustrate specific embodiments to enable those skilled in the art to practice accordingly. Other embodiments may be incorporated with structural, logical, electronic, processing method, and other changes. Some portions and features of some embodiments may be included in, or may replace, portions and features of other embodiments. The embodiments set forth in the claims cover all available equivalents of those claims. In the following detailed description, reference is made to the accompanying drawings, which form part of the detailed description and illustrate specific examples in which this disclosure may be practiced. It should be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of this disclosure.

[0006] This disclosure relates to a battery cell (e.g., lithium-ion battery cell) stack (such as a battery module or battery pack) with channels designed to guide ejected material (such as venting gas or particles) out of the battery cells during a thermal runaway event. The channels are formed within multiple covering layers on the battery cell stack. The channels guide thermal runaway ejected material away from mechanically weaker portions of the battery cells (e.g., vents) and away from the battery cell stack, thereby minimizing damage to the battery cell stack caused by the ejected material.

[0007] This disclosure provides a battery module, characterized in that it comprises: a lithium-ion battery cell stack; vents on each battery cell of the lithium-ion battery cell stack, each vent defining a ventilation direction; a multiple covering layer located on one side of the lithium-ion battery cell stack; and at least one channel embedded in the multiple covering layer; wherein the at least one channel communicates with the vents from the lithium-ion battery cell stack, and wherein the channel is configured to redirect exhaust gas from the ventilation direction to the channel direction.

[0008] This disclosure also provides a battery module, characterized in that it comprises: a lithium-ion battery cell stack, each battery cell including electrical terminals; a vent on each battery cell of the lithium-ion battery cell stack, each vent defining a venting direction; and a tube communicating with the vent of the lithium-ion battery cell stack, wherein the tube is configured to redirect the exhaust gas and flame away from the venting direction.

[0009] This disclosure also provides a battery casing, characterized in that it comprises: one or more battery modules located within the battery casing; each battery module having: vents on each battery cell of a lithium-ion battery cell stack, each vent defining a ventilation direction; multiple covering layers located on each of the lithium-ion battery cell stacks; and a tube embedded in the multiple covering layers to provide a ventilation solution for the multiple modules.

[0010] In one embodiment, the multiple covering layers of the battery pack include a first layer containing holes (e.g., vents) aligned with the less mechanically robust portions of the battery cells to accommodate thermal runaway ejections. In one embodiment, the first layer is positioned to contact the top surface of the lithium-ion battery cell stack. The first layer may also include holes for receiving battery cell terminals, such that the first layer is coplanar with the battery cell terminals. In this compact form, the first layer occupies the same plane as the battery cell terminals, rather than occupying additional space on the battery cell terminals. This configuration effectively utilizes the limited space on the battery cell stack within the battery pack or module. The first layer may be an insulating layer, an elastic layer, a rigid layer, or a combination thereof to guide the thermal runaway ejections through the holes away from the lithium-ion battery cell stack to the channel. In one embodiment, the first layer may be an aerogel layer to prevent heat transfer from the thermally runaway battery cell to other battery cells in the battery pack that have not experienced thermal runaway.

[0011] In one embodiment, the multiple covering layers further include a second layer containing channel spaces for guiding thermal runaway ejecta. The channel spaces in the second layer are aligned with holes in the first layer. This alignment guides the thermal runaway ejecta through the channel spaces and away from the cell stack. The second layer may also contain holes aligned with the cell terminals in a similar manner to the first layer. In one embodiment, the second layer is disposed between the first and third layers. The second layer may be an insulating layer, an elastic layer, or a rigid layer to accommodate the channels. In one embodiment, the second layer may be a foam layer to provide elasticity (e.g., reversible compressibility) to the battery casing encapsulating the cell stack.

[0012] In one embodiment, the channel space of the second layer includes tubes sized and disposed therein. The tubes within the channel space are disposed within and protected by the second layer. When the second layer is an elastic layer, it also protects the tubes from mechanical damage. The tubes also enhance the protection of the battery cell from thermal runaway ejecta, particularly from damage caused by bombardment from thermal runaway ejecta. The channels can be selected from, but are not limited to, mica tubes, stainless steel tubes, or aluminum tubes.

[0013] In one embodiment, the multiple covering layers further include a third layer that is neither porous nor has channel space. In one embodiment, the second layer is disposed between the first layer and the third layer. The third layer can act as a barrier to prevent thermal runaway ejecta from damaging components near the battery cell stack, such as the passenger compartment in an electric vehicle. In one embodiment, the third layer can be a rigid layer selected from aerogel sheets, mica sheets, stainless steel sheets, titanium alloy sheets, titanium sheets, or any other rigid layer that resists damage from thermal runaway ejecta (and reduces the spread of thermal runaway ejecta), thus protecting the components above the battery module.

[0014] In one embodiment, the multiple covering layers further include a fourth layer. This fourth layer adds an additional protective layer between the electronic equipment and the battery cell stack. The electronic equipment may include, but is not limited to, busbars, electrical connectors, wires, sensors, and battery management circuitry. The fourth layer may be disposed between the first and second layers, or between the second and third layers, thereby isolating the electronic equipment and the ventilation channel. In other words, the fourth layer is disposed between the electronic equipment and the ventilation channel. The fourth layer may be an insulating layer, an elastic layer, or a rigid layer to provide heat resistance, fire resistance, and electrical resistance. In one embodiment, the fourth layer may be the same aerogel layer as the first layer.

[0015] In one embodiment, the battery cell stack is encapsulated within a housing and a housing cover. Multiple covering layers of the battery cell stack may be provided between the battery cell stack and the housing cover or between the walls (e.g., sidewalls) of the battery cell stack and the housing. Channel spaces within the multiple covering layers guide thermal runaway ejecta to the outside of the housing. In some embodiments, the channels may guide thermal runaway ejecta to the sides or bottom of the housing, or along any direction that reduces or minimizes the exposure of sensitive components (such as electronic devices, battery management circuits, integrated circuits) to the thermal runaway ejecta and its associated destructive effects.

[0016] In one embodiment, more than one battery cell stack may be housed within a housing. The more than one battery cell stack may share one or more of a first, second, third, and fourth layer. In one embodiment, the more than one battery cell stack may each have a first and second layer, while sharing a third and fourth layer. Thermal runaway ejecta may be fed through channels in the more than one battery cell stack into a main body within the housing, leading to its exit from the housing.

[0017] The following describes materials used in multiple covering layers, such as insulating materials in insulating layers, rigid materials in rigid layers, and elastic materials in elastic layers, which, as described in the various embodiments below, can be used in battery modules to divide a battery device into individual battery cells or groups of battery cells. In this disclosure, multiple battery cells coupled together are referred to as a battery module. However, the described devices and methods can be used in any type of multi-cell arrangement, which may be referred to as a battery pack, battery system, etc.

[0018] The insulating materials described below can be used as a single heat-resistant layer or in combination with other layers to provide additional functions for multilayer constructions, such as mechanical strength, compressibility, heat dissipation / conduction, etc. Attached Figure Description

[0019] Figure 1A This displays an isometric view of a battery module according to some implementation schemes.

[0020] Figure 1B Showing another isometric view of the battery module according to some implementation schemes.

[0021] Figure 2A Showing another isometric view of the battery module according to some implementation schemes.

[0022] Figure 2B This shows a cross-sectional view of a battery module according to some implementation schemes.

[0023] Figure 2C Showing another isometric view of the battery module according to some implementation schemes.

[0024] Figure 3A Showing another isometric view of the battery module according to some implementation schemes.

[0025] Figure 3B Showing another isometric view of the battery module according to some implementation schemes.

[0026] Figure 4A Showing another isometric view of the battery module according to some implementation schemes.

[0027] Figure 4B Showing another isometric view of the battery module according to some implementation schemes.

[0028] Figure 5A Showing another isometric view of the battery module according to some implementation schemes.

[0029] Figure 5B Showing another isometric view of the battery module according to some implementation schemes.

[0030] Figure 6 Showing another isometric view of the battery module according to some implementation schemes.

[0031] Figure 7 Showing another isometric view of the battery module according to some implementation schemes.

[0032] Figure 8A Showing another isometric view of the battery module according to some implementation schemes.

[0033] Figure 8B Showing another isometric view of the battery module according to some implementation schemes.

[0034] Figure 9 Showing another isometric view of the battery module according to some implementation schemes.

[0035] Figure 10A Showing side and top views of a battery module according to some implementation schemes.

[0036] Figure 10B This shows another top view of the battery module according to some implementation schemes.

[0037] Figure 11 This illustrates a method for constructing a battery module according to some implementation schemes.

[0038] Figure 12 Displaying electronic devices according to some implementation schemes.

[0039] Figure 13 This shows electric vehicles according to some implementation schemes. Detailed Implementation

[0040] Insulating layer material

[0041] The insulating layer described herein is responsible for reliably containing and controlling heat flow from heat-generating components within confined spaces, providing safety and preventing flame propagation for such products in the electronics, industrial, and automotive technology fields. In many embodiments of this disclosure, the insulating layer described herein may be used alone or in combination with other materials that enhance heat containment and control performance as a flame / fire deflection layer. In one embodiment, the insulating layer itself may be resistant to flames and / or hot gases and may also include entrained particulate materials or other types of additives or layers that may alter or enhance thermal containment and control.

[0042] One embodiment of a high-efficiency insulating layer includes aerogels. Based on its structure, aerogels describe a class of materials characterized by low density, open-cell structure, and large surface area (typically 900 m²). 2 (g or higher) and sub-nanometer pore size. The pores can be filled with a gas such as air. Aerogels can be distinguished from other porous materials by their physical and structural properties. Although aerogel materials are exemplary insulating materials, the present invention is not limited thereto. Other insulating material layers may also be used in various embodiments of the present disclosure.

[0043] Selected embodiments of the aerogel composition and properties are described below. In some embodiments, the precursor material is gelled to form a porous network filled with solvent. The solvent is then extracted, leaving a porous matrix. A variety of different aerogel compositions are known, which can be inorganic, organic, and inorganic / organic hybrids. Inorganic aerogels are typically based on metal alkoxides and include materials such as silica, zirconium oxide, alumina, and other oxides. Organic aerogels include, but are not limited to, urethane aerogels, resorcinol-formaldehyde aerogels, and polyimide aerogels.

[0044] Inorganic aerogels can be composed of metal oxides or metal alkoxides. These metal oxides or metal alkoxides can be oxides or alkoxides based on any metal that can constitute an oxide. Such metals include, but are not limited to, silicon, aluminum, titanium, zirconium, hafnium, yttrium, vanadium, and cerium. Traditionally, inorganic silica aerogels are prepared by the hydrolysis and condensation of silica-based alkoxides (e.g., tetraethoxysilanes), or by the gelation of silicic acid or water glass. Other related inorganic precursor materials for the synthesis of silica-based aerogels include, but are not limited to, metal silicates (such as sodium silicate or potassium silicate), alkoxysilanes, partially hydrolyzed alkoxysilanes, tetraethoxysilanes (TEOS), partially hydrolyzed TEOS, condensation polymers of TEOS, tetramethoxysilanes (TMOS), partially hydrolyzed TMOS, condensation polymers of TMOS, tetra-n-propoxysilanes, partially hydrolyzed tetra-n-propoxysilanes and / or tetra-n-propoxysilane condensation polymers, polyethyl silicate, partially hydrolyzed polyethyl silicate, monomeric alkylalkoxysilanes, bis(trialkoxyalkyl) or arylsilanes, polyhedral silsesquioxanes, or combinations thereof.

[0045] In certain instances of this disclosure, pre-hydrolyzed TEOS (e.g., Silbond H-5 (SBH5, Silbond) hydrolyzed at a water / silica ratio of about 1.9 to 2) may be used commercially available or may be further hydrolyzed prior to introduction into the gelation process. Partially hydrolyzed TEOS or TMOS, such as polyethylene silicate (Silbond 40) or polymethyl silicate, may also be used commercially available or may be further hydrolyzed prior to introduction into the gelation process.

[0046] Inorganic aerogels may also include gel precursors comprising at least one hydrophobic group, such as alkyl metal alkoxides, cycloalkyl metal alkoxides, and aryl metal alkoxides, which can impart or improve certain properties of the gel, such as stability and hydrophobicity. Inorganic silica aerogels may specifically include hydrophobic precursors, such as alkylsilanes or arylsilanes. Hydrophobic gel precursors can be used as master precursor materials to form the framework of the gel material. However, hydrophobic gel precursors are more often used as co-precursors in the formation of hybrid aerogels in combination with simple metal alkoxides. Hydrophobic inorganic precursor materials for the synthesis of silica-based aerogels include, but are not limited to, trimethylmethoxysilane (TMS), dimethyldimethoxysilane (DMS), methyltrimethoxysilane (MTMS), trimethylethoxysilane, dimethyldiethoxysilane (DMDS), methyltriethoxysilane (MTES), ethyltriethoxysilane (ETES), diethyldiethoxysilane, dimethyldiethoxysilane (DMDES), ethyltriethoxysilane, propyltrimethoxysilane, propyltriethoxysilane, phenyltrimethoxysilane, phenyltriethoxysilane (PhTES), hexamethyldisilazane, and hexaethyldisilazane. Any derivative of any of the above precursors may be used, and certain polymers may be specifically added with other chemical groups or crosslinked with one or more of the above precursors.

[0047] Organic aerogels are typically composed of carbon-based polymer precursors. Such polymeric materials include, but are not limited to, resorcinol-formaldehyde (RF), polyimide, polyacrylate, polymethyl methacrylate, acrylate oligomers, polyoxyethylene, polyurethane, polyphenols, polybutadiene, trialkoxysilyl-terminated polydimethylsiloxane, polystyrene, polyacrylonitrile, polyfurfural, melamine-formaldehyde, cresol-formaldehyde, phenol-furfural, polyethers, polyols, polyisocyanates, polyhydroxybenzenes, polyvinyl alcohol dialdehyde, polycyanurate, polyacrylamide, various epoxy resins, agar, agarose, chitosan, and combinations thereof. In one embodiment, the organic RF aerogel is typically prepared by sol-gel polymerization of resorcinol or melamine with formaldehyde under alkaline conditions.

[0048] Organic / inorganic hybrid aerogels are primarily composed of organically modified silica (“ormosil”) aerogels. These ormosil materials include organic components covalently bonded to a silica network. Ormosil is typically formed through the hydrolysis and condensation of an organically modified silane R—Si(OX)3 with a conventional alkoxide precursor Y(OX)4. In such formulas, X can represent substances such as CH3, C2H5, C3H7, C4H9; Y can represent substances such as Si, Ti, Zr, or Al; and R can be any organic segment, such as methyl, ethyl, propyl, butyl, isopropyl, methacrylate, acrylate, vinyl, epoxide, etc. The organic components in the ormosil aerogel can also be dispersed throughout the silica network or chemically bonded to it.

[0049] Aerogels can be composed of flexible gel precursors. Various flexible layers, including flexible fiber-reinforced aerogels, can be easily combined and molded to obtain preforms that, when mechanically compressed along one or more axes, can produce a robust, compressive-resistant body along any axis.

[0050] One method of constructing aerogels includes batch casting. Batch casting involves catalyzing a complete volume of sol to induce simultaneous gelation of the entire volume. Gel formation techniques involve adjusting the pH and / or temperature of a diluted metal oxide sol to the point where gelation occurs. Suitable materials for constructing inorganic aerogels include oxides of most oxide-forming metals, such as oxides of silicon, aluminum, titanium, zirconium, hafnium, yttrium, vanadium, etc. Gels primarily composed of alcohol solutions of hydrolyzed silicates (alcohol gels) are particularly preferred due to their availability and low cost. Organic aerogels can also be made from melamine-formaldehyde, resorcinol-formaldehyde, etc.

[0051] In one embodiment, the aerogel material may be monolithic or continuous within a single structure or layer. In other embodiments, the aerogel material may include a composite aerogel material having aerogel particles mixed with an adhesive. Other additives may be included in the composite aerogel material, including but not limited to surfactants that help disperse the aerogel particles within the adhesive. The composite aerogel slurry may be applied to a support plate, such as a mesh fabric, felt, net, etc., and then dried to form the composite aerogel structure.

[0052] As described above, aerogels can be organic, inorganic, or mixtures thereof. In some embodiments, the aerogel includes silica-based aerogels. One or more thermal barriers may include reinforcing materials. The reinforcing materials can be any material that provides elasticity, compliance, or structural stability to the aerogel material. Embodiments of reinforcing materials include, but are not limited to, open-cell macroporous framework reinforcing materials, closed-cell macroporous framework reinforcing materials, open-cell membranes, honeycomb reinforcing materials, polymer reinforcing materials, and fiber reinforcing materials, such as discrete fibers, woven materials, nonwoven materials, needle-punched nonwoven materials, cotton wool, nets, mats, and felts.

[0053] The reinforcing material can be selected from organic polymer-based fibers, inorganic fibers, carbon-based fibers, or combinations thereof. In many embodiments, the inorganic fibers are selected from glass fibers, rock fibers, metal fibers, boron fibers, ceramic fibers, basalt fibers, or combinations thereof. In some embodiments, the reinforcing material may include a reinforcing material containing multiple material layers.

[0054] Rigid layer material

[0055] In addition to the insulation layer, a rigid layer combined with the insulation layer can effectively protect components adjacent to the battery cell stack (e.g., passenger compartment in an electric vehicle) during thermal runaway events. The rigid layer effectively protects components of the battery and its associated electronic devices from bombardment by particles in thermal runaway ejecta. Rigid material embodiments for the rigid layer include, but are not limited to, carbon fiber, graphite, silicon carbide, copper, stainless steel, aluminum, titanium, other metals, titanium alloys, other metal alloys, and combinations thereof.

[0056] An additional function of the rigid layer is to direct unwanted heat to desired external locations, such as external heat sinks, heat dissipation shells, or other external structures, to dissipate unwanted heat into the ambient air or other heat dissipation locations (such as heat exchangers or radiators). This heat dissipation function is particularly prominent when the rigid layer is a rigid metal plate. In one embodiment, one or more thermally conductive layers facilitate heat dissipation from localized thermal loads within the battery module or battery pack.

[0057] In at least one instance, the thermally conductive layer is coupled to a heat sink to aid in the dissipation and removal of heat. Various heat sink types and configurations, as well as different techniques for coupling the heat sink to the thermally conductive layer, are covered in this disclosure. This disclosure is not limited to the use of any single type of heat sink / coupling technique. In one embodiment, at least one thermally conductive layer of the multilayer material disclosed herein may be in thermal communication with an element of the cooling system of a battery module or battery pack, such as a cooling plate or cooling channel of the cooling system. In another embodiment, at least one thermally conductive layer may be in thermal communication with other elements of the battery pack, battery module, or battery system that may act as a heat sink (such as walls of the battery pack, module, or system), or with other multilayer materials disposed between battery cells. Thermal communication between the thermally conductive layer and the heat sink element within the battery system allows excess heat to be removed from one or more battery cells adjacent to the multilayer material to the heat sink, thereby reducing the impact, severity, or propagation of thermal events that may generate excess heat. In addition to removing heat, the thermally conductive layer may also propagate or dissipate heat from areas of high heat concentration to areas of low heat concentration.

[0058] Elastic layer material

[0059] In addition to the insulation and rigid layers, the multiple covering layers may also include one or more elastic layers to accommodate channels for ventilation. In some embodiments, a tube may be disposed within the channel. The tube may also contain and redirect thermal runaway ejecta away from sensitive parts of the battery pack. The elastic layer also modulates the mechanical stresses applied to the battery module or battery pack under operating or improper use conditions. In one embodiment, the elastic layer may absorb mechanical stresses and strains (e.g., based on an elastic modulus of less than 1 GPa and less than 100 MPa), thus preventing mechanical stresses from damaging the tube and / or the battery pack.

[0060] The elastic layer material may include, but is not limited to, foam, fiber, fabric, sponge, spring structure, rubber, polymer, etc. In one embodiment, the elastic material layer includes an aerogel layer, such as a monolithic aerogel layer, aerogel sheet, aerogel blanket, fiber-reinforced aerogel blanket, other aerogel layers, and combinations thereof. Additional elastic layers may be disposed near or between battery cells. In one embodiment, during normal operation, the elastic layer absorbs any volumetric expansion of one or more battery cells. In one embodiment, during charging, the battery cell may expand, and during discharging, the battery cell may contract. In one embodiment, the elastic layer may also absorb any permanent volumetric expansion caused by battery cell degradation and / or thermal runaway. In one embodiment, the elastic layer may be compressed to any percentage range of its original thickness as described herein, from 5% to 95%, 10% to 90%, 30% to 90%, 40% to 85%, 60% to 80%, or as described herein.

[0061] Multiple overlays and optional channels

[0062] Figure 1A The battery module 100 includes channels defined by one or more cover layers. The channels within the cover layers guide thermal runaway ejecta away from the battery module, thereby protecting the battery module assembly from damage.

[0063] Figure 1A This illustrates one embodiment of the battery module 100. The battery module 100 also includes a battery cell stack 102 and multiple cover layers 110, which include one or more first layers 116, second layers 114, and / or third layers 112. Each cover layer is described in detail below.

[0064] In one embodiment, the battery cell stack 102 includes individual lithium-ion battery cells 102A, 102B, 102C, and 102D (collectively referred to as battery cell stack 102). The lithium-ion battery cells 102 may have several configurations. In one embodiment, the lithium-ion battery cell stack 102 includes lithium-ion pouch cells or lithium-ion prismatic cells, but the present invention is not limited thereto. Figure 1A Each of the batteries 102 includes an electrical terminal 104.

[0065] exist Figure 1A In the implementation scheme, each battery cell 102A, 102B, 102C, and 102D in the battery cell stack 102 includes a vent 106. In the event of thermal runaway in a given battery cell 102 or multiple battery cells in the battery cell stack 102, the vent 106 will guide hot gases and flames away from the battery cell 102. Ideally, it will guide (and vent to the outside) any hot gases and flames away from the direction of the battery cell stack 102 and any sensitive control components (e.g., the side of the battery module) and direct them to a safe location (e.g., away from the cabin).

[0066] exist Figure 1A In this embodiment, a lithium-ion battery cell stack includes multiple cover layers 110 on one side, the cell stack including electrical terminals 104. A first layer 116, a second layer 114, and a third layer 112 are stacked together over the battery cell 102 and the associated vent 106. A closed channel 118 is formed by a combination of individual layers such as the first layer 116, the second layer 114, and the third layer 112. The channel 118 aligns spaces / holes in one or more adjacent layers.

[0067] The first layer 116 of the multiple cover layers 110 is shown to have holes 117 to accommodate terminals 104 corresponding to battery cells 102A-102D of the battery cell stack 102. The first layer 116 also defines vent holes 107. The vent holes 107 are aligned with the corresponding vents 106 of the battery cells in the battery cell stack 102.

[0068] The second layer 114 of the multiple cover layer 110 is shown to include a hole 115 to correspond to and receive the terminal 104. A channel 118 is defined in the second layer 114. The channel 118 is aligned with the vent 106 and the vent hole 107.

[0069] The third layer 112 is shown as continuous (i.e., not limited or otherwise including holes). The third layer 112 is used to protect the components (cabin) above the battery module 100 in abnormal situations such as thermal runaway.

[0070] In one embodiment, the first layer 116, the second layer 114, and the third layer 112 of the multiple cover layer 110 may be made of the same material. In one embodiment, the multiple layers of the multiple cover layer 110 include more than one material for different layers. The layer adjacent to the channel 118 should be an insulating layer to facilitate the drainage of hot gases and flames and to prevent the layer (e.g., the second layer 114) itself from being damaged by exposure to thermal runaway ejecta. In one embodiment, one or more layers of the multiple cover layer 110 include an aerogel layer. Other layers may include structural materials such as polymers, stainless steel, etc. In one embodiment, the structural material provides sufficient rigidity to withstand operational stresses without deformation. An example of a heat-resistant layer includes a mica-containing layer. It may include a layer of elastic material to better accommodate packaging within a subsequent battery casing (not shown). In one embodiment, the first layer 116 is an aerogel blanket, the second layer 114 is a foam material, and the third layer 112 is a mica sheet. In one embodiment, the first layer 116 is an aerogel blanket, the second layer 114 is a foam material, and the third layer 112 is an aerogel board.

[0071] In one embodiment, layers 114 and 116 are aerogel layers and layer 112 is a rigid layer comprising structural material. Although three layers 116, 114, and 112 are shown as components of the multilayer cover 110, the invention is not limited thereto. Other embodiments of the multilayer cover 110 include configurations with fewer or more than three layers. The layers of the multilayer cover 110 can be joined by methods such as gluing, stitching, adhesive bonding, or hot pressing. In some embodiments, at least a portion of the multilayer cover 110 fills the vertical space created by the terminal 104, thus utilizing the previously empty space between the top of the battery cell 102 and the top of the terminal 104.

[0072] In some embodiments, the multiple cover layer 110 is configured to define a channel 118, which is configured to receive exhaust gas from the vent 106 (oriented in the venting direction). In some embodiments, the channel 118 is oriented in the channel direction (e.g., the X direction). (This is in contrast to the above and...) Figure 1AThe ventilation direction of the vent 106 shown is similar, and the channel 118 and its corresponding channel direction (e.g., the X direction) can be oriented to guide thermal runaway ejecta away from the cabin, sensitive electronics, flammable components (e.g., rubber hoses), or other components of the vehicle that would otherwise be damaged by exposure to the thermal runaway ejecta. In some embodiments, the channel direction (e.g., the X direction) is substantially perpendicular to the ventilation direction (as indicated by...). Figure 2B (as shown by the vertical arrow in the diagram), but this utility model is not limited thereto. Figure 1A The battery module described in the embodiments, including channel 118, and other embodiments described below, can be oriented to mount any number of battery modules in a device, such as an electric vehicle, and any exhaust gases can be directed away from unwanted areas, thus providing electric vehicle designers with more directional and locational options. Although an electric vehicle is used as one embodiment, the invention is not limited thereto. Redirecting exhaust gases and flames can also be applied to other battery-powered electronic devices.

[0073] Figure 1B show Figure 1A Variations of the exemplary battery module described herein. Figure 1B In, as mentioned above Figure 1A The channels 118 formed by adjacent layers are filled with sacrificial material 120. Sacrificial material 120 serves as a gap filler during normal operation of the battery module. Sacrificial material 120 is combustible in the presence of exhaust gases and flame. The sacrificial material layers may have a low heat of combustion. Sacrificial material 120 may include polymers, foams, fibers, other suitable materials that burn with a low heat of combustion, and combinations thereof.

[0074] Add 120 sacrificial materials Figure 1A The exemplary configuration shown provides advantages such as keeping channel 118 sealed until a venting event occurs. One benefit of sealing channel 118 is that dust or debris is kept out of the channel, vent 106, and therefore out of the battery pack and battery stack.

[0075] Figure 1A Another advantage of the features shown, related to the presence of the sacrificial material 120, includes helping the channel 118 maintain its shape within the multiple cover layer 110 until a thermal runaway event occurs. In one embodiment, one or more multiple cover layers 110 comprise an aerogel material. Some aerogel materials, while highly insulating, can be fragile. In one embodiment, in the event of ventilation or thermal runaway, the sacrificial material 120 burns with little or no residue and heat generation. In an alternative embodiment, the sacrificial material 120 absorbs heat when burning in the event of ventilation or thermal runaway. The inclusion of the sacrificial material 120 helps maintain the integrity of the aerogel layer until a ventilation event occurs.

[0076] Multiple layers of coverage, channels and pipes

[0077] Figure 2A This diagram shows an exploded perspective view of one embodiment of a battery module 200, which includes a tube disposed within a channel defined by multiple covering layers. In one embodiment, the tube is a component separate from the multiple covering layers. This tube provides protection for the battery module beyond that provided by the examples described above. In some embodiments, the tube's structure further confines and guides thermal runaway ejecta away from the battery assembly, beyond the limitations and directional guidance provided by the channel alone. For example, the use of the tube can prevent ejecta from penetrating the interlayer gaps of the battery cell stack and / or eroding the portions of the layer exposed to ejecta.

[0078] Figure 2A The displayed battery module 200 includes a battery cell stack 202 composed of battery cells 202A, 202B, 202C, and 202D, and a multi-layer cover 210 including a first layer 216, a second layer 214, and a third layer 212. The battery module 200 also includes a tube 220.

[0079] Figure 2A The battery cells 202A, 202B, 202C, and 202D (collectively referred to as 202A-202D) are similar to those described above. As illustrated and described earlier, each of the battery cells 202A-202D may include a set of electrical terminals 204. Furthermore, one or more battery cells 202A-202D may individually include a vent 206. The preceding description of the vent applies to the vent 206.

[0080] The multiple cover layer 210 includes one or more cover layers, each of which can be selected for one or more protection functions. In the illustrated battery module 200, the multiple cover layer 210 includes three cover layers: a first layer 216, a second layer 214, and a third layer 212, each of which is described in detail below.

[0081] In some embodiments, a multiple cover layer 210 is disposed on and / or above the lithium-ion battery cell 202A-202D including the electrical terminal 204. In some embodiments, to minimize the space occupied by the multiple cover layer 210 and / or to reduce the gap between the first layer 216 and the top surface of the battery cell 202A-202D, the first layer 216 may define an aperture 217 to receive the terminal 204. In this way, the first layer 216 may contact the top surface of the battery cell 202A-202D adjacent to and facing the first layer 216.

[0082] Figure 2A The first layer 216 shown includes vents 207. In some embodiments, the vents 207 of the first layer 216 are aligned with the vents 206 of the battery cells 202A-202D. This is similar to the above description... Figure 2B In the implementation described herein, vent 207 and vent 206 are connected to form a discharge path from one or more battery cells 202A-202D to the corresponding port of tube 220 (in Figure 2B (shown as dashed lines in the middle). Therefore, as the ejected material travels from one or more battery cells 202A-202D into the tube 220, the channel physically accommodates the ejected material, thereby providing protection for the other components of the battery module 200.

[0083] The second layer 214 may be disposed on the side of the first layer 216 opposite to the battery cells 202A-202D. In some embodiments, the second layer 214 may be disposed between the first layer 216 and the third layer 212. The second layer 214 may be made of an elastic material to provide cushioning for the battery module 200.

[0084] In some implementations, the second layer 214 defines channel 218. Channel 218 is similar to the one described above. Figure 1A and Figure 1B The passage 118 is described in the text. As previously mentioned, the passage 218 may be sized and configured to accommodate the tube 220, which will be described in detail below.

[0085] The third layer 212 may be located on the side of the second layer 214 opposite to the first layer 216. Unlike the previous layer, the third layer 212 is continuous in this embodiment and has no holes and / or channels. The third layer 212 protects components adjacent to the battery module 200 (e.g., the cabin) from damage by thermal runaway ejecta from the battery cell 202.

[0086] Although the materials of each layer are described above within the text of each individual layer, it should be understood that, generally, in some embodiments, layers 216, 214, 212 of the multiple cover layer 210 may be made of the same material. In other embodiments, different layers of the multiple cover layer 210 may each comprise more than one material and / or different layers 216, 214, 212 may be made of different materials. In some embodiments, layers adjacent to channel 218 (such as layers 214, 114) may be thermal insulation layers to facilitate adjacent heating components. In one embodiment, one or more multiple multiple cover layers 210 include an aerogel layer. Any one or more layers 216, 214, 212 may comprise a structural material, such as a polymer; or a metal, such as stainless steel. The multiple cover layer 210 may include a layer of elastic material. In some embodiments, the layers of the multiple cover layer 210 may be joined by adhesives, stitching, gluing, hot pressing, mechanical bonding (e.g., Velcro joints) or other means.

[0087] In one embodiment, the first layer 216 of the multiple cover layer 210 is an insulating layer, such as an aerogel layer. In one embodiment, the second layer 214 of the multiple cover layer 210 is an elastic layer. In one embodiment, the third layer 212 of the multiple cover layer 210 is a rigid layer.

[0088] As described above, the battery module 200 includes a tube 220 arranged in channels 218 in a second layer 214. In some embodiments, because the second layer 214 is made of an elastic material (and optionally an insulating material), the second layer 214 provides cushioning for the tube 220 (e.g., by means of an elastic modulus of less than 500 MPa). The cushioning provided by the second layer 212, which is made of an elastic material, can be used to prevent damage to the battery module 200 from possible mechanical shocks.

[0089] Figure 2A The pipe 220 shown may include multiple sub-channels 221A, 221B, 221C, 221D (collectively referred to as 221) and a main channel port 222. The main channel port may terminate at an outlet port 223, which provides an outlet for the ejected material, allowing it to exit in a direction away from the sensitive parts of the battery pack and away from the cabin.

[0090] In some implementations, sub-channels 221A, 221B, 221C, and 221D each correspond to a hole and a corresponding vent 206 in the first layer 216 of the battery cell. Sub-channels 221 feed to the main channel port 222. (See reference) Figure 2C The connection between the vent 206, sub-channel 221, main channel port 222 and outlet port 223 forms a discharge path, guiding the ejected material to a safe location.

[0091] In one embodiment, the tube 220 is integral, such as a casting, but the invention is not limited thereto. Other embodiments may include a separate sub-channel 221 that is screwed on or otherwise attached to the main channel port 222.

[0092] In one embodiment, the tube 220 is made of a refractory material. Materials used in this embodiment include, but are not limited to, ceramics, mica, resins, polymers, metals, carbon materials, and combinations thereof. Metals that can be used for the tube 220 include stainless steel or titanium, which have the advantages of high melting points and high corrosion resistance. In one embodiment, the first layer 216 is an aerogel blanket, the second layer 214 is a foam material, and the third layer 212 is a mica board. In another embodiment, the first layer 216 is an aerogel blanket, the second layer 214 is a foam material, the third layer 212 is an aerogel board, and the tube 220 is selected from mica tubes, stainless steel tubes, or aluminum tubes.

[0093] Figure 2BThis is a cross-sectional view of the battery module 200 cut along the X-direction along the centerline of pipe 220. During a catastrophic event (e.g., thermal runaway), battery cell 202 may be disturbed and eject extrusions along the Z-direction from vent 206. The extrusions are directed to corresponding sub-channels 221A, 221B, 221C, 221D (collectively referred to as 221) aligned with vent 206. The extrusions are then redirected along the X-direction to the main channel port 222 and subsequently discharged from outlet port 223. Thus, pipe 220 contains the extrusions and guides them through multiple covering layers 210 and away from sensitive parts of the battery pack and away from the cabin above the battery pack (in the Z-direction).

[0094] Figure 2C This is a perspective view of a partially assembled battery module 200. The tube 220 is located within the second layer 214. In the illustrated embodiment, the thickness of the main channel port 222 is thinner than or equal to the thickness of the second layer 214. Figure 2C The additional layer 219 is also shown. The additional layer 219 separates the conduit 220 from the cable (not shown) placed between the additional layer 219 and the third layer 212. The cable connects to terminals 204 for battery charging and discharging and collects battery test data.

[0095] Multiple layers with electrical connectors

[0096] Figure 3A An exemplary battery module 300 is shown, which includes many of the same elements as those in battery modules 100 and 200 described above, except that the multiple cover layers 310 of battery module 300 include an additional (e.g., a fourth) cover layer 332 located between the first and third layers. This fourth cover layer 332 separates the channels and electronic components. The fourth cover layer 332 provides additional protection to the battery-related electronic components by blocking thermal runaway ejecta.

[0097] In the example shown, battery module 300 includes a battery cell stack 302 composed of battery cells 302A, 302B, 302C, and 302D (collectively referred to as 302A-302D). Battery module 300 includes multiple cover layers 310. The multiple cover layers 310 include a first layer 316, a second layer 314, a third layer 312, and a fourth layer 332. Battery module 300 also includes a tube 320.

[0098] Figure 3A Each of the battery cells 302A-302D includes a corresponding electrical terminal 304 and a vent 306. The electrical terminal 304 and the vent 306 are similar to those described above, and the above also applies to this type of structure in the battery module 300.

[0099] As described above, battery cells 302A-302D can be lithium-ion battery cells, but each embodiment of this disclosure can be independently applied to battery chemistry or battery configuration.

[0100] Like battery modules 100 and 200, battery module 300 includes multiple cover layers 310. Similar to previous... Figure 1A-2B Similar to the multiple cover layers 110 and 210 described in the implementation scheme, the multiple cover layer 310 includes a first layer 316, a second layer 314, and a third layer 316. Similar to the layers 116 and 216 of the battery modules 100 and 200 described above, the first layer 316 optionally includes a hole 317, which is sized and configured to align with the electrical terminals 304. The first layer 316 optionally includes a vent 307, which is sized and configured to align with the vent 306. The configuration and function of the hole 317 and the vent 307 in the first layer 316 are similar to the function and origin of such structures described herein for battery modules 100 and 200.

[0101] Similar to layers 114 and 214 of the battery modules 100 and 200 described above, the second layer 314 optionally includes a hole 315 to receive a terminal 304. Also as described in the similar layers 114 and 214 above, the second layer 314 defines a channel 318.

[0102] The third layer 312 shown does not include any holes. Similar to... Figure 2A-2C The third layer 212 in the illustrated embodiment protects the components adjacent to the battery module 300 from damage caused by thermal runaway ejecta from the battery cell stack 302.

[0103] With the above Figure 1A-2B The multiple cover layers 110 and 210 in the embodiments are similar. In one embodiment, all multiple cover layers 310 are made of the same material. In one embodiment, the multiple cover layers 310 may include more than one material for different layers. The layer adjacent to the channel 318 may be an insulating layer to prevent heat transfer from thermal runaway ejections from the channel 318 or tube 320 to adjacent components, such as the battery cell stack 302. In one embodiment, one or more multiple cover layers 310 include an aerogel layer. Other layers may include structural materials, such as polymers; or metals, such as stainless steel. The multiple cover layers 310 may include layers of elastic material. In one embodiment, the multiple cover layers 310 may be joined by gluing, stitching, adhesive bonding, hot pressing, other suitable methods, and combinations thereof.

[0104] exist Figure 3A In one embodiment, pipe 320 is included as a separate component within the multilayer cover 310. In other words, pipe 320 is not part of the multilayer cover 310. Pipe 320 is fitted within the channel 318 of the second layer 314. In one embodiment, pipe 320 is made of a refractory material. Materials used in this embodiment include, but are not limited to, mica, metals, etc.

[0105] Figure 3AThe implementation also includes an electrical connector 330. The electrical connector 330 couples multiple terminals 304 together for further connection to device circuitry, electric motors, etc.

[0106] exist Figure 3A In this embodiment, a fourth layer 332 is also included between the second layer 314 and the electrical connector 330 to protect the electrical connector 330 from heating during thermal runaway. In the event of thermal runaway, the heat from the ejected material can transfer heat to the tube 320 and raise the surface temperature of the tube 320. The raised surface temperature may damage the electrical connector 330. The fourth layer 332 between the tube 320 and the electrical connector 330 separates the hot surface of the tube 320 from the electrical connector 330.

[0107] The fourth layer 332 comprises a material that provides suitable heat, fire, and resistance. The fourth layer 332 may comprise a material similar to the first layers 116, 216, and 316 of the battery modules 100, 200, and 300 described above. In one embodiment, the fourth layer 332 comprises an aerogel layer.

[0108] Figure 3B An alternative layer arrangement of multiple cover layers 310 is provided. In one embodiment, the electrical connector 330 is optionally located between the first layer 316 and the second layer 314. A fourth layer 332 is correspondingly disposed between the first layer 316 and the second layer 314 to separate the channel 318 (and the tube 320 disposed therein) and the electrical connector 330. Advantageously, a layer is provided on at least one side of the electrical connector 330 to provide thermal, fire, and / or dielectric isolation for the electrical connector 330.

[0109] Covering and other electronic components

[0110] Figure 4A The example battery module 400 includes many of the same components as those in battery modules 100, 200, and 300 described above, except that battery module 400 includes a battery management circuit 440 integrated with a multi-layer cover 410. The multi-layer cover 410 protects the battery management circuit 440 in the event of thermal runaway.

[0111] In the example shown, battery module 400 includes a battery cell stack 402, a multi-layer cover 410 above the battery cell stack 402, a tube 420, and an electrical connector 430 embedded in the multi-layer cover 410. Battery module 400 also includes battery management circuitry 440. Similar to multi-layer covers 110, 210, and 310, multi-layer cover 410 includes a first layer 416, a second layer 414, a third layer 412, and a fourth cover 432. Battery module 400 is described in detail below.

[0112] Module 400 includes a battery cell stack 402, such as a lithium-ion battery cell. Figure 4AEach of the battery cells 402 includes an electrical terminal 404. Figure 4A In this embodiment, each battery cell 402 of the battery cell stack includes a vent 406. Multiple cover layers 410 are included on one side of the lithium-ion battery cell stack, including electrical terminals 404. A first layer 416 is shown having holes 417 to receive terminals 404. The first layer 416 also includes vent holes 407 aligned with the vent holes 406 of the battery cells 402. A second layer 414 is also shown, which also includes holes 415 to receive terminals 404. A channel 418 is defined in the second layer 414. A third layer 412 is shown that does not include any holes.

[0113] Similar to the embodiments described above, in one embodiment, the multiple cover layers 410 are all made of the same material. In one embodiment, the multiple cover layers 410 for different layers include more than one material. The layer adjacent to the channel 418 may be an insulating layer to facilitate adjacent heated components. In one embodiment, one or more multiple cover layers 410 include an aerogel layer. Other layers may include structural materials, such as polymers; or metals, such as stainless steel. The multiple cover layers 410 may include layers of elastic materials. In one embodiment, the multiple cover layers 410 may be joined by gluing, stitching, adhesive bonding, hot pressing, etc. In one embodiment, the first layer 416 and the fourth layer 432 include aerogel, such as aerogel sheets, fiber-reinforced aerogel blankets, other layers containing aerogel, or combinations thereof. In one embodiment, the second layer 414 is an elastic layer, such as foam, fiber, resin, polymer, other materials providing elasticity, or combinations thereof. In one embodiment, the third layer 412 is a rigid layer, such as stainless steel, aluminum, mica, other rigid layers, or combinations thereof.

[0114] exist Figure 4A In one embodiment, tube 420 is a separate component included within the multiple covering layer 410. In other words, tube 420 is not part of the multiple covering layer 410. Tube 420 is fitted within the channel 418 of the second layer 414. In one embodiment, tube 420 is made of a refractory or heat-resistant material. Materials used in this embodiment include, but are not limited to, mica, metals, other refractory or heat-resistant materials, and combinations thereof.

[0115] It also shows an electrical connector 430 for coupling multiple terminals 404 together for further connection to device circuitry, electric motors, etc. Figure 4A In the implementation scheme, the fourth layer 432 is included between the second layer 414 and the electrical connector 430.

[0116] exist Figure 4AIn this implementation, the battery management circuitry 440 is located between one or more layers of multiple cover layers 410. The functions of the battery management circuitry include, but are not limited to, temperature measurement and temperature-responsive electrical feedback regulation. Other electrical feedback regulation may respond to other measured parameters, such as voltage, current, pressure sensing, humidity sensing, etc. Figure 4A In the implementation scheme, the battery management circuit 440 can communicate with other circuits wirelessly or via wired means.

[0117] Battery management circuit 440 can be embedded in Figure 4A The electrical connector 430 shown is between the same layers (e.g., between the third layer 412 and the fourth layer 432). Alternatively, the battery management circuit 440 may be separated from the electrical connector 430 by one or more multiple cover layers 410, as explained in the following reference. Figure 4B .

[0118] exist Figure 4B In this configuration, the battery management circuit 440 is embedded within a multi-layer cover 410 and is separated from the electrical connector 430 by at least one multi-layer cover 410. The battery management circuit 440, having wires 442, is used for at least some communication with external circuitry. Figure 4B An optional separate circuit board 444 for holding the battery management circuit 440 is also shown. The circuit board 444 may also include sensors such as temperature, humidity, and pressure. The battery management circuit 440, with sensors, cables, and other components, may be embedded in multiple cover layers 410. The battery management circuit 440, with sensors, cables, and other components, is separated from the channel 418 and tube 320 by one or more multiple cover layers 410.

[0119] The battery module housing includes ventilation channels embedded with multiple layers of covering.

[0120] Figure 5A The display shows a semi-assembled battery module 500, whose third layer 512 is not assembled. Figures 4A-4B Unlike the 540 battery management circuit, which is wired, the 540 battery management circuit is wired. Figure 4A and 4B The implementation includes a wireless battery management circuit 440. A wired battery management circuit 540 includes a trace circuit 546. Additional electronic components and connections (not shown) may be embedded together with the battery management circuit 540 within a multi-layer cover 510.

[0121] Figure 5A The battery module 500 includes a battery cell stack 502, multiple cover layers 510 on the battery cells 502, a tube 520, and an electrical connector 530 embedded in the multiple cover layers 510. This is similar to the battery modules 100, 200, 300, and 400 described above. Furthermore, the battery module 500 also includes a trace circuit 546 for connecting the battery management circuit 540 to the battery connector 530 and the terminal 504.

[0122] and Figures 4A-4B Unlike the wireless battery management circuit 440 in this implementation, the wired battery management circuit 540 can be electrically connected to the battery cell via a wire. Therefore, the battery management circuit 540 can be powered by the battery cell 502. Since the wired battery management circuit 540 does not require a built-in battery like the wireless battery management circuit 440, it has a smaller size and longer operating time. The battery management circuit can be connected to the battery cell 502 via trace circuit 546 to monitor the electrical characteristics of the battery cell or transmit information from other sensors (not shown), such as current, voltage, temperature, pressure, and humidity.

[0123] Figure 5B This battery module 500 is similar to the other battery modules described above, but also includes a housing 560 and a housing cover 562. In one embodiment, these housing assemblies 560 and 562 are separate from other layers (e.g., multiple cover layers 510) described in and included in the battery module 500. In other words, housing assemblies 560 and 562 are not part of the multiple cover layer 510. In one embodiment, the stacked layer 510 on the battery module 500 includes a resilient fireproof pad (e.g., a second layer 514). The multiple cover layer 510 is used to occupy the space between the battery module 500 and the housing cover 562 to reduce vibration and noise, while also providing a degree of thermal insulation and thermal runaway protection. In one embodiment, the stacked layer 510 embeds the main portion of the battery cell terminals, electrical connectors, battery management circuitry, and tube 520. The tube 520 guides thermal runaway ejections to the outside of the housing 560 through a notch 564 on the side wall of the housing 560.

[0124] Ventilation channels with multiple covering layers embedded in the battery pack

[0125] Figure 6 This illustration shows one embodiment of a battery pack 600. The battery pack 600 includes multiple battery modules 601 sharing one or more multi-layer covers 610. The multi-layer covers 610 also embed branch pipes 620. Sharing one or more multi-layer covers 610 among the modules 601 of the battery pack 600 saves battery pack space, improves battery pack efficiency, and facilitates assembly. The branch pipes 620 offer the advantage of increased design flexibility to further redirect any exhaust gases or flames away from critical components or unwanted areas. The branch pipes 620 also provide a venting solution for integrating a large number of battery cells into multiple modules.

[0126] Similar to other battery modules described in this disclosure, the battery pack 600 includes multiple battery modules, each module 601 including a stack of battery cells, such as lithium-ion battery cells 602. Each battery cell 602 includes electrical terminals 604. Figure 6As shown, each battery cell in the battery cell stack includes a vent 606. A multi-layer cover 610 is included on one side of the lithium-ion battery cell stack 602, which includes electrical terminals 604. A first layer 616 is shown having holes for receiving terminals 604. A second layer 614 is further shown also including holes for receiving terminals 604. Multiple portions of the second layer 614 provide space for branch pipes 620. A third layer 612 is shown without any holes. An electrical connector 630 is included to couple the multiple terminals 604 together. The battery pack 600 also includes a housing 660 and a housing cover 662, similar to... Figures 5A-5B The outer casing 560 and outer cover 562 in the implementation scheme.

[0127] and Figure 1A-5B The implementation schemes are different. Figure 6 The implementation scheme includes multiple battery modules 601 sharing one or more multiple cover layers 610. In one implementation, the battery pack 600 includes four battery modules 601. Each battery module 601 has its own first layer 616 and second layer 614. In one implementation, all battery modules 601 share a third layer 612 and a fourth layer 632.

[0128] The separate first layer 616 and second layer 614 of each battery module 601 provide space for the branch pipe 620 and make it easier to align the terminals 604, vents 606, and pipes 620 during battery pack 600 assembly. It also allows for individual replacement of the first layer 616 and second layer 614 of each battery module 601. In another embodiment, a shared third layer 612 and fourth layer 632 can be used because fewer components (such as electrical connectors 630 and pipes 620) need to be integrated into these two layers. Where possible, the shared third layer 612 and fourth layer 632 provide easier installation options.

[0129] Figure 6 Each implementation also includes a branch pipe 620 that houses multiple modules within the battery pack 600. The branch pipe 620 differs from the above-described... Figure 2A-5B Pipes 220, 320, 420, and 520. Branch pipe 620 includes multiple sub-channels 621 leading to the main trunk 622. Sub-channels 621 are similar to... Figure 2A-5B Pipes 220, 320, 420, and 520 are included. In the illustrated embodiment, the main branch 622 is configured to redirect exhaust gas from the exhaust direction (e.g., the Z direction) to a first channel direction (e.g., the Y direction). Figure 6In this embodiment, the first channel direction is parallel to the length of the main branch 622, which is perpendicular to the vent 606. In one embodiment, the branch pipe 620 further includes a redirection end 624, which further redirects the gas discharged along the direction of the main branch 622 (e.g., the Y direction) to be discharged along the direction of the second channel (e.g., the negative Z direction). In the illustrated embodiment, the second channel direction is perpendicular to the first channel direction and is downward (e.g., the negative Z direction), but the invention is not limited thereto.

[0130] In one embodiment, branch pipe 620 includes... Figure 2A-5B The tubes 220, 320, 420, and 520 are made of the same material. In one embodiment, branch tube 620 comprises a material selected from, but not limited to, metals, mica, other flame-retardant and / or heat-resistant materials, and combinations thereof.

[0131] Alternative venting channel configuration for battery module to vent to the side wall of the housing

[0132] Figure 7 This illustrates one embodiment of the battery module 700. A multiple cover layer 710 is disposed between the battery cell 702 and the sidewall of the housing 760, rather than disposed within... Figure 1A-6 The battery cell and casing shown in each implementation scheme.

[0133] similar Figure 1A-6 In each implementation scheme, module 700 includes battery cell 702, such as a lithium-ion battery cell. Figure 7 Each of the battery cells 702 includes an electrical terminal 704 and a vent 706. A multi-layer cover 710 is included on one side of the lithium-ion battery cell stack including the electrical terminal 704 and the vent 706. The module 700 also includes a tube 720 embedded in the multi-layer cover 710. The battery cells 702, the multi-layer cover 710, and the tube 720 are contained within a module housing 760.

[0134] The multiple covering layers 710 include a first layer 716, a second layer 714, and a third layer 712. The first layer 716 is shown having a hole 717 to receive a terminal 704. The first layer 716 also includes a vent 707 aligned with the vent 706 of the battery cell 702. The second layer 714 is also shown, which also includes a hole aligned with and receiving the terminal 704. Figure 7 In one embodiment, the second layer 714 includes a plurality of individual sheets arranged at a common level within the multiple cover layers 710. The plurality of (e.g., two) individual sheets of the second layer 714 define a channel 718 therebetween. The channel 718 spans the length of the second layer 714 and divides the second layer 714 into two sheets. A third layer 712 is shown that does not include any holes.

[0135] and Figure 1A-6The multiple cover layers 110, 210, 310, 410, 510, and 610 are all similar in embodiments. In one embodiment, the multiple cover layers 710 are all made of the same material. In another embodiment, the multiple cover layers 710 may include more than one material for different layers. The layer adjacent to the channel 718 may be an insulating layer to facilitate adjacent heating components. In one embodiment, one or more multiple cover layers 710 include an aerogel layer. Other layers (e.g., a third layer 712) may include structural materials, such as polymers; or metals, such as stainless steel. The multiple cover layers 710 may include an elastic material layer (e.g., a second layer 714). The multiple cover layers 710 may be joined by gluing, stitching, adhesive bonding, hot pressing, other joining methods, or combinations thereof. In one embodiment, the first layer 716, the second layer 714, and the third layer 712 are an aerogel layer, an elastic layer, and a rigid layer, respectively.

[0136] exist Figure 7 In various embodiments, tube 720 is a separate component included within the multiple cover layer 710. In other words, tube 720 is not part of the multiple cover layer 710. Tube 720 is fitted within channel 718 of the second layer 714. Tube 720 is similar to... Figure 1A-6 In each implementation scheme, pipes 220, 320, 420, 520, and 621 are different, except that pipe 720 has angled bends 722 at both ends, rather than only at one end of the pipe.

[0137] exist Figure 7 In this embodiment, the conduit 720 includes an angled bend 722 at either or both ends of the conduit 720. The angled bend 722 directs the thermal runaway ejecta away from critical components of the equipment and / or the user in a desired direction. The desired direction includes the bottom of the electric vehicle, i.e. Figure 7 The negative Z-direction in the implementation plan. Figure 7 In this embodiment, the housing 760 includes an opening 764 through which an angled bend 722 passes through the housing 760. Figure 2A-6 Compared to a single-angled turn configuration in the implementation scheme, the two-angled turn 722 significantly increases the ability to remove hot gases and flames to the outside of the housing 760.

[0138] In one implementation scheme, pipe 720 is composed of and Figure 2A-6 In the embodiments, tubes 220, 320, 420, 520, and 621 are made of the same material. In one embodiment, tube 720 comprises a material selected from refractory and / or heat-resistant materials. In one embodiment, tube 720 comprises a material selected from aerogel materials, aerogel blankets, mica, metals, other refractory and / or heat-resistant materials, and combinations thereof.

[0139] Figure 8AThis illustrates one embodiment of the battery module 800. An angled bend 822 in the battery module 800 is located in the middle portion of the tube 820. Figure 7 The angled bend 722 shown is located at the end of the pipe 720. Compared with its travel length, the angled bend 822 is located in the middle position, which reduces the travel length of the exhaust gas in the pipe 820.

[0140] Similar to Figure 1A-7 Modules 100, 200, 300, 400, 500, 601, and 700 in the implementation scheme, and module 800 include a battery cell stack 802 and multiple covering layers 810 on one side of the battery cell stack 802. Module 800 also includes a tube 820, a housing 860, and a housing cover 862.

[0141] In one embodiment, the battery cell stack 802 may include lithium-ion battery cells. Each battery cell stack 802 may include an electrical terminal 804 and a vent 806. The vent 806 is used to release pressure on the battery cells and to release materials generated under abuse conditions such as thermal runaway.

[0142] In one embodiment, the multiple cover layers 810 include a first layer 816, a second layer 814, and a third layer 812. The first layer 816 is shown having a hole 817 to receive a terminal 804. The first layer 816 also includes a vent 807 aligned with a vent 806 of the battery cell 802. The second layer 814 is also shown, which also includes a hole 815 for receiving the terminal 804. The second layer 814 includes a plurality of channel holes 818. The third layer 812 is shown, which also includes channel holes 819 aligned with the channel holes 818. A tube 820 passes through the second layer 814 and the third layer 812 through the channel holes 818 and 819.

[0143] In one embodiment, the material of the multiple cover layer 810 includes similar Figures 1A to 7 The materials included in the multiple covering layers 110, 210, 310, 410, 510, 610, and 710 in the embodiments. In one embodiment, the multiple covering layer 810 includes more than one material for different layers. The layer adjacent to the tube 820 and the channel hole 818 may be an insulating layer to facilitate adjacent heating components. In one embodiment, one or more multiple covering layers 810 include an aerogel layer. Other layers may include structural materials, such as polymers; or metals, such as stainless steel. The multiple covering layer 810 may include a layer of elastic material. The multiple covering layers 810 may be joined by gluing, stitching, adhesive bonding, hot pressing, other joining methods, and combinations thereof. In one embodiment, the first layer 816, the second layer 814, and the third layer 812 are an aerogel layer, an elastic layer, and a rigid layer, respectively.

[0144] exist Figures 8A-8BIn this implementation, a multiple cover layer 810 is embedded in a tube 820. The tube 820 includes one or more angled bends 822. The angled bends 822 are located in the middle portion of the tube 820 to reduce the travel length of the exhaust gas within the tube 820. The angled bends 822 are directed away from critical components of the device and / or the user's desired direction. The desired direction includes the bottom of the electric vehicle, i.e. Figures 8A-8B The negative Z direction in the implementation plan.

[0145] In one embodiment, the material of tube 820 includes similar Figure 2A-7 The materials included in tubes 220, 320, 420, 520, 621, and 720 in various embodiments. In one embodiment, tube 820 is made of a fire-resistant and / or heat-resistant material. In one embodiment, tube 820 includes, but is not limited to, aerogel sheets, mica, metals, other suitable materials, and combinations thereof.

[0146] exist Figures 8A-8B In one embodiment, module 800 further includes a housing 860 and a housing cover 862 for receiving the battery cell 802. The housing 860 includes an opening 864 in its sidewall, through which an angled bend 822 passes. The opening 864 allows the angled bend 822 to pass through the sidewall of the housing 860 to shorten the possible path for thermal runaway ejecta.

[0147] Figure 8B The assembled battery module 800 is shown, having an angled bend 822 protruding downwards from the housing 860. The angled bend 822 redirects the ejected material to the outside of the housing 860 to prevent the battery module 800 from spreading or exploding within the housing 860. The angled bend 822 redirects the ejected material downwards (in the negative Z direction) to avoid causing any injury or damage to nearby vehicles or people above (e.g., in the Z direction) or beside (e.g., in the X or Y direction) the module 800.

[0148] Figure 9 This illustrates one embodiment of a battery module 900. The battery module 900 includes a tube 920 that directs exhaust gas directly to the bottom direction (e.g., the negative Z direction) via a port 922. It is related to... Figures 8A-8B The implementation schemes shown are different, in Figures 8A-8B In the middle, pipe 820 leads the exhaust gas to the side of the battery module, and then through an angled bend 822 leads it to the bottom of the battery module.

[0149] and Figure 1A-8B Similar to modules 100-800 in the implementation scheme, module 900 includes a battery cell stack 902, such as a lithium-ion battery cell. Figure 9Each of the battery cells 902 includes an electrical terminal 904 and a vent 906. The battery module 900 includes a multi-layer cover 910 located on one side of the lithium-ion battery cell stack including the electrical terminals 904. The multi-layer cover 910 is embedded in a tube 920. The battery module also includes a housing 960 and a cover 962. In one embodiment, an additional resilient layer 963 is included between the battery cells 902 and the cover 962.

[0150] similar Figure 1A -8. In the embodiment, multiple cover layers 110-810 are shown, with multiple cover layer 910 including a first layer 916, a second layer 914, and a third layer 912. The first layer 916 includes a hole 917 to receive a terminal 904. The first layer 916 also includes a vent 907 aligned with a vent 906 of the battery cell 902. The second layer 914 is also shown, which also includes a hole 915 to receive the terminal 904. The third layer 912 is shown, which does not include a channel hole.

[0151] In one embodiment, the multiple overlay layer 910 includes similar Figure 1A -8 Materials of the Multiple Covering Layers 110-810 in Embodiment 1. In one embodiment, all multiple covering layers 910 are made of the same material. In one embodiment, the multiple covering layers 910 may include more than one material for different layers. Layers adjacent to the tube 920 (such as the first layer 916 and the second layer 914) may be insulating layers to facilitate adjacent heating components (e.g., tube 920). In one embodiment, one or more multiple covering layers 910 may include an aerogel layer. Other layers may include structural materials such as aerogel sheets, polymers, or metals (e.g., stainless steel). Multiple covering layers 910 may include layers of elastic material. In one embodiment, the multiple covering layers 910 may be joined by gluing, stitching, adhesive bonding, hot pressing, other suitable joining methods, and combinations thereof. In one embodiment, the first layer 916 is an aerogel layer, the second layer 914 is an elastic layer, and the third layer 912 is a rigid layer.

[0152] exist Figure 9 In this implementation, tube 920 is a separate component included within the multiple cover layer 910. In other words, tube 920 is not part of the multiple cover layer 910. Figure 9 In this implementation, pipe 920 includes one or more ports 922. Ports 922 are oriented away from critical components of the device and / or the user's desired direction (e.g., the bottom of an electric vehicle, negative Z-direction). Ports 922 directly guide the exhaust gas in the desired direction without deflection. Figures 8A-8B Compared to a turn at a medium angle 822, thermal runaway ejecta exits the straight-through port 922 more effectively, thus providing improved safety.

[0153] In one embodiment, the material of tube 920 includes the same material as tubes 220, 320, 420, 520, 621, 720, and 820. In one embodiment, tube 920 is made of a fire-resistant and / or heat-resistant material. In one embodiment, tube 920 includes a material selected from aerogels, mica, metals, other suitable materials, and combinations thereof.

[0154] Module 900 also includes a housing 960 and a housing cover 962 to accommodate the battery cell 902, multiple covering layers 910, and tube 920. Figure 9 In one embodiment, the housing 960 includes an opening 964 through which a port 922 extends through the bottom wall of the housing 960. This significantly increases the ability to remove hot gases and flames to the outside of the housing 960. The opening 964 facilitates direct access to the port 922 and the exit of thermal runaway ejecta from the housing 960. In one embodiment, the module 900 also includes an additional elastic layer 963. The additional elastic layer 963 provides cushioning for the battery cell 902 to prevent mechanical damage under abusive conditions such as impact, explosion, and thermal runaway. In one embodiment, the additional elastic layer 963 is an aerogel layer.

[0155] Top view, side view, and layer-by-layer view of a multi-layered structure with embedded ventilation channels.

[0156] Figure 10A This illustrates one embodiment of the battery module 1000. The battery module 1000 is similar to... Figure 1A-9 Battery modules 100-900 are described in the implementation scheme, except that battery module 1000 includes battery cells arranged in multiple rows 1001 and multiple columns 1003. Battery module 1000 demonstrates the flexibility of multiple cover layers 1010 and channels 1020 in battery modules with different battery cell arrangements.

[0157] Module 1000 includes multiple battery cells 1002, such as lithium-ion battery cells. Figure 10A Each battery cell 1002 includes an electrical terminal 1004 and a vent 1006. Multiple covering layers 1010 are included on one side of the plurality of battery cells including the electrical terminals 1004. Figures 10A-10B In the implementation plan, the battery cells 1002 are arranged in multiple rows 1001 and columns 1003.

[0158] similar Figure 1A-9 The multiple cover layers 110-910 in the embodiments include a first layer 1016, a second layer 1014, and a third layer 1016. The multiple cover layers 1010 may additionally include structural materials, such as polymers or metals (e.g., stainless steel). The multiple cover layers 1010 may include layers of elastic material. The multiple cover layers 1010 may be joined by methods such as gluing, stitching, adhesive bonding, hot pressing, other suitable methods, and combinations thereof.

[0159] In one embodiment, the multiple overlay layer 1010 includes... Figure 1A-9 In one embodiment, the multiple cover layers 110-910 are made of the same material. In another embodiment, all multiple cover layers 1010 are made of the same material. In yet another embodiment, the multiple cover layers 1010 may include more than one material for different layers. In one embodiment, one or more multiple cover layers 1010 may include an aerogel layer. In one embodiment, the first layer 1016 is an insulating layer (e.g., an aerogel layer), the second layer 1014 is an elastic layer, and the third layer is a rigid layer.

[0160] Figure 10B show Figure 10A Cross-sectional views along the center line BB' of the first layer 1016, the center line CC' of the second layer 1014, and the center line DD' of the third layer 1012. The first layer 1016 includes holes 1007 located in multiple rows and columns, which are aligned with vent holes 1006 of the battery cells 1002. In the second layer 1014, multiple channels 1020 are included to align with multiple rows 1001 of the battery cells 1002. Other embodiments described in this disclosure include material and configuration embodiments suitable for the channels 1020. A third layer 1012 without any holes is also shown.

[0161] Method for constructing a battery module with multiple covering layers and embedded ventilation channels

[0162] Figure 11 A flowchart illustrating an embodiment of method 1100 for constructing a battery module is shown. In operation 1102, multiple lithium-ion battery cells are stacked, each cell including electrical terminals and a vent, the vent defining a venting direction. In operation 1104, the terminal surfaces of the multiple lithium-ion battery cells are covered by a first layer, wherein the electrical terminals pass through the first layer, and the first layer includes an opening of the vent, the opening of which is configured to allow exhaust gas to pass through the first layer. In operation 1106, a channel is formed connected to the opening of the vent, wherein the channel is configured to redirect exhaust gas from the venting direction to the channel direction.

[0163] Power battery system with multiple layers of battery module with embedded ventilation channels

[0164] The aforementioned battery modules are used in many electronic devices. Figure 12 One embodiment of the display electronic device 1200 includes a battery module 1210. The battery module 1210 is coupled to functional electronics 1220 via circuitry 1212. In the illustrated embodiment, the battery module 1210 and circuitry 1212 are contained within a housing 1202. A connection port 1214 is shown coupled to the battery module 1210 for recharging the battery module 1210 when needed.

[0165] In one embodiment, the functional electronic device 1220 includes a device, such as a semiconductor device having transistors and storage circuitry. Embodiments include, but are not limited to, telephones, computers, displays, navigation systems, etc.

[0166] Figure 13 This shows another electronic system that utilizes the aforementioned battery module, which includes multiple thermal barriers. Figure 13 An electric vehicle 1300 is shown. The electric vehicle 1300 includes a chassis 1302 and wheels 1322. In the illustrated embodiment, each wheel 1322 is coupled to a drive motor 1320. A battery module 1310 is shown coupled to the drive motor 1320 via circuitry 1306. A charging port 1304 is shown coupled to the battery module 1310 to facilitate recharging of the battery module 1310 when needed.

[0167] Embodiments of the electric vehicle 1300 include, but are not limited to, consumer vehicles such as cars and trucks. Commercial vehicles such as tractors and semi-trailer trucks are also within the scope of this invention. Although four-wheeled vehicles are shown, this invention is not limited thereto. In one embodiment, two-wheeled vehicles such as motorcycles and scooters are also within the scope of this invention.

[0168] To better illustrate the methods and apparatus disclosed herein, a non-limiting list of implementations is provided herein:

[0169] Implementation scheme 1 includes a battery module. This battery module includes a lithium-ion battery cell stack, individual battery cells including electrical terminals, vents on each battery cell in the lithium-ion battery cell stack, vents defining venting directions, and at least one channel communicating with the vents from the lithium-ion battery cell stack, wherein the channel is configured to redirect exhaust gas from the venting direction to the channel direction.

[0170] Implementation scheme 2 includes the battery module of implementation scheme 1, and further includes multiple cover layers located on one side of the lithium-ion battery cell stack including electrical terminals, wherein the electrical terminals pass through openings in one or more of the multiple layers.

[0171] Implementation scheme 3 includes any of the battery modules in implementation schemes 1-2, wherein one or more of the multiple covering layers include aerogel.

[0172] Implementation scheme 4 includes any of the battery modules in implementation schemes 1-3, and also includes battery management circuitry located in one or more multiple overlays.

[0173] Implementation scheme 5 includes any of the battery modules in implementation schemes 1-4, wherein the channel is defined by space in one or more multiple overlay layers.

[0174] Implementation scheme 6 includes any of the battery modules in implementation schemes 1-5, wherein the channels are filled with sacrificial material.

[0175] Implementation scheme 7 includes any of the battery modules in implementation schemes 1-6, wherein the channel is a separate component included in multiple layers.

[0176] Implementation scheme 8 includes an electric vehicle. The electric vehicle includes a vehicle chassis, multiple wheels coupled to the vehicle chassis, multiple wheels driven by one or more electric motors, and a battery module connected to the one or more electric motors. The battery module includes a lithium-ion battery cell stack, individual battery cells including electrical terminals, vents on each battery in the lithium-ion battery cell stack, vents defining venting directions, and channels communicating with the vents from the lithium-ion battery cell stack, wherein the channels are configured to redirect exhaust gas from the venting direction back to the channel direction.

[0177] Implementation scheme 9 includes the electric vehicle of implementation scheme 8, wherein the lithium-ion battery cell stack is at least partially encapsulated in a module housing.

[0178] Implementation scheme 10 includes any of the electric vehicles in implementation schemes 8-9, wherein the lithium-ion battery cells are arranged in a single row.

[0179] Implementation scheme 11 includes any of the electric vehicles in implementation schemes 8-10, wherein the lithium-ion battery cells are arranged in multiple rows.

[0180] Implementation scheme 12 includes any of the electric vehicles in implementation schemes 8-11, wherein the lithium-ion battery cell stack includes multiple battery packs and the channel includes a main vent with multiple sub-vents.

[0181] Implementation scheme 13 includes any of the electric vehicles in implementation schemes 8-12, wherein the passageway is oriented toward the side leading to the electric vehicle.

[0182] Implementation scheme 14 includes any of the electric vehicles in implementation schemes 8-13, wherein the passageway is oriented to the bottom of the electric vehicle.

[0183] Implementation scheme 15 includes a method of constructing a battery module. The method includes stacking a plurality of lithium-ion battery cells, each battery cell including electrical terminals and a vent, the vent defining a venting direction, covering the terminal surfaces of the plurality of lithium-ion battery cells with a first layer, wherein the electrical terminals pass through the first layer, and the opening of the vent is included in the first layer and configured to allow exhaust gas to pass through the first layer, and forming a channel communicating with the opening of the vent, wherein the channel is configured to redirect the exhaust gas from the venting direction to the channel direction.

[0184] Implementation scheme 16 includes the method of implementation scheme 15, wherein the constituting channel includes arranging space in multiple layers on the terminal surface.

[0185] Implementation scheme 17 includes any of the methods in implementation schemes 15-16, wherein constituting the channel includes an opening that couples a metal tube to an adjacent vent.

[0186] Implementation scheme 18 includes any of the methods in implementation schemes 15-17, wherein the terminal surfaces of a plurality of lithium-ion battery cells are covered with a first layer, including coverage with an aerogel layer.

[0187] The above description is intended to be illustrative and not restrictive. In one embodiment, the above embodiments (or one or more embodiments thereof) may be used in combination with each other. For example, other embodiments may be used by those skilled in the art after reading the above description. An abstract is provided to comply with patent law and to enable the reader to quickly determine the nature of the technical disclosure, and this submitted abstract should be understood not to be used to interpret or limit the scope or meaning of the claims. Furthermore, in the above detailed description section, features may be combined to simplify this disclosure, which should not be construed as an intention that any unclaimed disclosed feature is necessary for any claim. Rather, the subject matter of the utility model may exist with fewer than all the features of a particular disclosed example. Therefore, the appended claims are hereby incorporated into the detailed description, wherein each claim exists as a separate example, and it is contemplated that such examples may be combined or arranged in various ways. The scope of this utility model should be determined by reference to the full scope of the appended claims and the equivalents conferred by such claims.

[0188] Although an overview of the subject matter of this utility model has been described with reference to specific examples, various modifications and changes may be made to such examples without departing from the broader scope of this disclosure. Such examples of the subject matter of this utility model may be referred to herein individually or collectively by the term "utility model" for convenience only, and if more than one is disclosed in fact, it is not intended to voluntarily limit the scope of this application to any single disclosure or utility model concept.

[0189] The examples shown herein have been described in sufficient detail to enable those skilled in the art to practice the disclosed teachings. Other examples may be used and derived from them, and structural and logical substitutions and changes may be made without departing from the scope of this disclosure. Therefore, the specific embodiments should not be construed as limiting, and the scope of the various examples is defined only by the full scope of the appended claims and their equivalents.

[0190] As used herein, the term "or" may be interpreted as inclusive or exclusive. Furthermore, multiple instances of a resource, operation, or structure described herein may be provided as a single instance. Additionally, the boundaries between various resources, operations, modules, drives, and data storage are somewhat arbitrary, with specific operations described within the text of a particular illustrative configuration. Other functional assignments are foreseeable and fall within the scope of various instances of this disclosure. Generally, structures and functions presented as separate resources in an implementation configuration may be presented as combined structures or resources. Similarly, structures and functions presented as single resources may be presented as separate resources. Such and other changes, modifications, additions, and improvements fall within the scope of instances of this disclosure as shown in the appended claims. Therefore, the specification and drawings should be considered illustrative rather than restrictive.

[0191] For ease of explanation, specific examples have been referenced in the foregoing description. However, the illustrative discussion above is not intended to be exhaustive or to limit possible examples to the precise forms disclosed. Many modifications and variations can be made in light of the foregoing teachings. The examples were chosen and described in order to best explain the principles involved and their practical applications, thereby enabling others skilled in the art to best utilize the examples and make various modifications to suit their specific intended uses.

[0192] It should also be understood that although the terms "first," "second," etc., may be used herein to describe various elements, such elements should not be limited by such terms. These terms are used only to distinguish one element from another. In one embodiment, a first contact portion may be referred to as a second contact portion, and similarly, a second contact portion may be referred to as a first contact portion, without departing from the scope of this example. Both the first and second contact portions are contact portions, but they are not the same contact portion.

[0193] The terminology used in the description of the examples herein is for the purpose of describing specific instances only and is not intended to be limiting. As used in the description of the examples and the accompanying examples, the singular forms “a,” “an,” and “described” also include the plural forms, unless otherwise expressly stated in the text. It should also be understood that the term “and / or” as used herein designates and covers any and all possible combinations of one or more of the associated listed items. It should also be understood that when the terms “comprising” and / or “including” are used in this specification, the presence of the stated feature, integral, step, operation, element, and / or component is specified, but the presence or addition of the stated feature, integral, step, operation, element, component, and / or group thereof is not excluded.

[0194] As used herein, depending on the context, the term "if" may be interpreted as "when" or "when" or "in response to determination" or "in response to detection." Similarly, depending on the context, the phrases "if determination" or "if [the condition or event] is detected" may be interpreted as "when determination" or "in response to determination" or "when [the condition or event] is detected" or "in response to detection."

Claims

1. A battery module, characterized by, A battery module comprising: a stack of lithium ion battery cells; a vent on each battery cell of the stack of lithium ion battery cells, each vent defining a vent direction; a multi-layered cover on one side of the stack of lithium ion battery cells; and at least one channel embedded in the multi-layered cover; wherein the at least one channel communicates with the vents from the stack of lithium ion battery cells, and wherein the channel is configured to redirect vented gases from the vent direction to a channel direction. The multi-layered cover comprises one or more layers selected from:

2. The battery module of claim 1, wherein, a first layer comprising apertures aligned with the vents of the stack of lithium ion battery cells to accommodate thermal runaway ejecta; a second layer defining the channel to direct thermal runaway ejecta, wherein the channel is aligned with the apertures of the first layer; a third layer having no apertures and no channel; and a fourth layer providing additional protection.

3. The battery module of claim 2, wherein: the first layer is disposed in contact with a top surface of the stack of lithium ion battery cells; the second layer is disposed between the first layer and the third layer; and the fourth layer is disposed between the first layer and the second layer or between the second layer and the third layer.

4. The battery module of claim 2, wherein: the first layer is an insulating layer, a resilient layer, a rigid layer, or a combination thereof to direct the thermal runaway ejecta through the apertures away from the stack of lithium ion battery cells to the channel; the second layer is an insulating layer, a resilient layer, or a rigid layer to accommodate the channel; the third layer is a rigid layer to protect components above the battery module; and the fourth layer is an insulating layer, a resilient layer, or a rigid layer to provide thermal, fire, and electrical resistance. One or more layers of the multi-layered cover are connected by an adhesive, stitching, glue, or heat pressing. The channel spans a length of the second layer.

5. The battery module of claim 2, wherein, The second layer comprises a plurality of individual sheets arranged at a common level within the multi-layered cover.

6. The battery module of claim 2, wherein, The channel direction is perpendicular to the vent direction.

7. The battery module of claim 2, wherein, Each of the stack of lithium ion battery cells comprises an electrical terminal, and at least one of the first layer or the second layer further comprises an aperture to accommodate the electrical terminal.

8. The battery module of claim 2, wherein, Each of the stack of lithium ion battery cells comprises an electrical terminal that creates a vertical space, and at least a portion of the multi-layered cover fills the vertical space.

9. The battery module of claim 2, wherein, The first layer is coplanar with the electrical terminal.

10. The battery module of claim 2, wherein, The battery module further comprises an electronic device, wherein the electronic device comprises a busbar, a battery management circuit, an electrical connector, an electrical connection, an electrical terminal, or a combination thereof, and wherein the electronic device is embedded in the multi-layered cover.

11. The battery module of claim 10, wherein, The electrical connector couples the electrical terminals together, and the fourth layer separates the channel from the electrical connector or the battery management circuit.

12. The battery module of claim 2, wherein, The fourth layer is disposed between the electronic device and the vent channel to provide additional protection.

13. The battery module of claim 12, wherein, A battery module comprising:

14. The battery module of claim 13, wherein, a stack of lithium ion battery cells, each battery cell comprising an electrical terminal; 15. A battery module, characterized by a vent on each battery cell of the stack of lithium ion battery cells, each vent defining a vent direction; and a tube communicating with the vents of the stack of lithium ion battery cells, wherein the tube is configured to redirect vented gases and flames away from the vent direction. ​ ​ 16. The battery module of claim 15, wherein, The battery module includes a plurality of cover layers, wherein the tube is disposed in the plurality of cover layers.

17. The battery module of claim 15, wherein, The battery module further includes a plurality of cover layers embedded with channels, and wherein the tube is sized and configured within the channels.

18. The battery module of claim 17, wherein, The plurality of cover layers has a resilient layer, and wherein the tube is located in the resilient layer.

19. The battery module of claim 15, wherein, The middle portion of the tube has an angled turn that directs the vented gas and flame outside the enclosure.

20. The battery module of claim 15, wherein, Either or both ends of the tube have an angled turn that directs the vented gas and flame outside the enclosure.

21. The battery module of claim 15, wherein, The tube has a straight through port and no turn to direct the vented gas and flame.

22. The battery module of claim 15, wherein, The tube includes a plurality of sub-channels and a main channel port, the sub-channels being in communication with the vent and feeding into the main channel port.

23. A battery housing, characterized by Comprising: one or more battery modules located within the battery enclosure; Each of the battery modules has: vents on each cell of a stack of lithium ion cells, each vent defining a venting direction; a plurality of cover layers located on each of the stack of lithium ion cells; and a tube embedded in the plurality of cover layers to provide a venting solution for the plurality of modules.

24. The battery case of claim 23, wherein, The tube directs thermal runaway ejecta to a side or bottom of the enclosure.

25. The battery case of claim 23, wherein, The tube is a branch tube that provides a venting solution for the one or more battery modules.

26. The battery case of claim 25, wherein, The branch tube includes a main trunk and sub-channels feeding into the main trunk, wherein the sub-channels are configured to redirect vented gas from the venting direction to a direction perpendicular to the venting direction.

27. The battery case of claim 23, wherein, The plurality of cover layers of the one or more battery modules includes a first layer and a second layer for each of the one or more battery modules.

28. The battery case of claim 23, wherein, The plurality of cover layers of the one or more battery modules includes a third layer and a fourth layer common to the one or more battery modules.

29. The battery case of claim 28, wherein, The enclosure includes an opening located at a bottom wall of the enclosure box.

30. The battery case of claim 28, wherein, The enclosure has a wall and an enclosure cover, and wherein the plurality of cover layers is disposed between the wall and the stack of lithium ion cells or between the enclosure cover and the stack of lithium ion cells.

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