Graphite foil as an active heating and passive cooling material in a battery pack

Abstract

Temperature control element for an electrochemical cell, comprising: two or more structural elements, and one or more anisotropic elements arranged between the two or more structural elements, wherein the one or more anisotropic elements each comprise one or more anisotropic materials selected from the group consisting of: graphite, graphene, carbon nanotubes (CNTs), crystalline materials, cohesive powder and combinations thereof, wherein the temperature control element is configured to be in a heat transfer relationship with the electrochemical cell to heat and / or cool the electrochemical cell, wherein the temperature control element further comprises one or more tabs in electrical connection with the one or more anisotropic elements, wherein the one or more tabs each comprise one or more made of copper, aluminum, nickel, nickel-plated copper, stainless steel and aluminum alloys.

Description

[0001] The present invention relates to a temperature control element for an electrochemical cell, comprising two or more structural elements and one or more anisotropic elements arranged between the two or more structural elements.

[0002] The present disclosure relates to the use of an anisotropic material or element, such as graphite, e.g. in the form of a foil, as a heating material or element (e.g. active heating) and as a cooling material or element (e.g. passive cooling), e.g. within a battery pack containing one or more electrochemical cells, to create controllable temperature ranges within the battery and / or the pack (e.g. isotherms and other desired thermal patterns and / or gradients) which can, e.g., prevent and / or minimize lithium plating, uneven wear, drying and overheating, and improve performance over a wide temperature range.

[0003] Electrochemical energy storage devices, such as lithium-ion batteries, can be used in a wide variety of products, including automotive products such as start-stop systems (e.g., 12V start-stop systems), battery-assisted systems (µBAS), hybrid electric vehicles (HEVs), and electric vehicles (EVs). Typical lithium-ion batteries contain electrodes, a separator, and an electrolyte. However, in solid-state or semi-solid-state batteries, the separator and the solid electrolyte can be a single component. Lithium-ion batteries can also incorporate various terminal (e.g., tab) and packaging or casing materials (e.g., pouch). In electrochemical cells, such as those found in lithium-ion batteries, one of the two electrodes serves as the positive electrode or cathode, and the other serves as the negative electrode or anode.

[0004] Rechargeable lithium-ion batteries function by reversibly conducting lithium ions back and forth between the negative and positive electrodes. For example, lithium ions can move from the positive to the negative electrode during charging and in the opposite direction during discharging. A separator and / or electrolyte may be placed between the negative and positive electrodes. The electrolyte is suitable for conducting lithium ions (or sodium ions in the case of sodium-ion batteries) between the electrodes and, like the two electrodes, can be in solid, liquid, or solid-liquid form. In solid-state batteries, which contain a solid electrolyte positioned between solid electrodes, the electrolyte can physically separate the electrodes, thus eliminating the need for a separate separator.

[0005] Operating electrochemical cells, including batteries, at elevated temperatures can lead to capacity loss, power degradation, and, under certain circumstances, thermal runaway. Conversely, operating at excessively low temperatures can result in increased resistance, increased deposits or plating, and reduced capacity. Maintaining the desired operating temperature range maximizes cell efficiency and lifespan. However, in certain cases, such as due to current flow paths, common algorithmic heating solutions tend to heat areas around and between the battery terminals more rapidly than the bottom and / or sides of the battery. Such uneven heat distribution can potentially make the cell bottom and sides more susceptible to lithium plating as the cell heats up, and can lead to weak / strong characteristics at different locations within the battery.In lithium-ion battery packs where batteries or cells are electrically connected (e.g., in parallel or in series), for example in a stack to increase overall power, cells located in the inner positions within the pack may have a higher thermal resistance than cells located in the outer positions. Such temperature differences within a pack can lead to a degradation in performance due to differences in the cells. Therefore, mechanisms and materials (e.g., temperature control systems) for electrochemical cells or batteries and battery packs containing one or more electrically connected batteries or cells are desirable.

[0006] From US Patent 2019 / 0013556A1, a composite panel is known which comprises a thermally conductive panel, a first insulating panel covering one surface of the thermally conductive panel, and a second insulating panel covering another surface of the thermally conductive panel and sealing the thermally conductive panel between the first and second insulating panels. The thermally conductive panel has a first through-hole, and the composite panel has an insulating laminated section in which the first insulating panel is stacked onto the second insulating panel to seal an inner wall surface of the first through-hole. The insulating laminated section has a second through-hole provided within the first through-hole, with a hole diameter smaller than that of the first through-hole.

[0007] CN 1 06 571 484 A describes battery electrodes, in particular rechargeable lithium battery electrodes, with active materials containing an inorganic binder for cohesion between the electrode materials and for adhesion to a current collector.

[0008] A heat-dissipating surface structure is described in WO 2014 / 208 930 A1, which has a heat-dissipating layer with a first surface and a second surface, wherein the heat-dissipating layer contains graphene and metal particles, with an adhesive layer arranged on a first surface of the heat-dissipating layer and a protective layer arranged on a second surface of the heat-dissipating layer.

[0009] According to the invention, a temperature control element for an electrochemical process is provided in various aspects.

[0010] The temperature control element is provided for the electrochemical cell. It can contain two or more structural elements and one or more anisotropic elements arranged between these structural elements. The one or more anisotropic elements can each comprise one or more anisotropic materials selected from the following group: graphite, graphene, carbon nanotubes (CNTs), crystalline materials, cohesive powder, and combinations thereof. The temperature control element is configured to be in a heat transfer relationship with the electrochemical cell to heat and / or cool it. The temperature control element also includes one or more tabs electrically connected to the one or more anisotropic elements. The one or more tabs can each comprise one or more of copper, aluminum, nickel, nickel-plated copper, stainless steel, and aluminum alloys.

[0011] In one aspect, the one or more tabs can define one or more tab layers. For example, a first tab layer can be arranged between the one or more anisotropic elements and a first structural element of the two or more structural elements, and a second tab layer can be arranged between the one or more anisotropic elements and a second structural element of the two or more structural elements. Each tab layer of the one or more tab layers can comprise a first part located at a first terminal end and a second part located at a second terminal end separated from the first terminal end, such that a gap can be defined in a central region between the first part and the second part of each tab layer of the one or more tab layers.

[0012] In one aspect, the one or more anisotropic elements and the one or more tabs can define a heating element.

[0013] In one aspect, the two or more structural elements may each contain one or more of mica, asbestos, marble, porcelain, glass, shellac, resin, rubber, cotton yarn, paper, linen, rayon and plastic.

[0014] In one aspect, at least one of the two or more structural elements may also contain one or more adhesive materials, which may be selected from the group consisting of: polyethylene terephthalate (PET), polypropylene (PP), polyethylene (PE), polytetrafluoroethylene (PTFE) and combinations thereof.

[0015] In one aspect, the two or more structural elements can be first structural elements, and the temperature control element can also contain one or more second structural elements arranged between adjacent anisotropic elements.

[0016] In one aspect, the one or more anisotropic elements can define one or more films. Each film can have a thickness ranging from more than or equal to approximately 1 µm to less than or equal to approximately 10,000 µm.

[0017] In one aspect, the temperature control element can also contain one or more insulating materials, the one or more films can each have a multitude of folds, and the one or more insulating materials can be arranged between the folds of the one or more films that define the one or more anisotropic elements.

[0018] In one aspect, the one or more anisotropic elements comprise a first grouping of anisotropic elements containing one or more first anisotropic materials, and a second grouping of anisotropic elements containing one or more second anisotropic materials. Each of the first and second groupings of anisotropic elements can be controlled independently.

[0019] In one aspect, the two or more structural elements are one or more first structural elements, and the temperature control element further comprises one or more second structural elements arranged between the first grouping of anisotropic elements and the second grouping of anisotropic elements.

[0020] In several aspects, this disclosure provides an example of a battery pack with a temperature control system that includes one or more temperature control elements. The battery pack contains a plurality of electrochemical cells arranged in a stack, defining the battery pack. Each temperature control element of the one or more temperature control elements comprises two or more structural elements and one or more anisotropic elements positioned between the two or more structural elements. The one or more anisotropic elements may each comprise one or more anisotropic materials selected from the group consisting of: graphite, graphene, carbon nanotubes (CNTs), crystalline materials, cohesive powder, and combinations thereof.The temperature control elements can be at least one of the following: (i) arranged between the electrochemical cells of the stack; (ii) arranged around the electrochemical cells of the stack; or (iii) both (i) and (ii).

[0021] In one aspect, each of the temperature control elements can also contain one or more tabs electrically connected to the one or more anisotropic elements. The one or more tabs can each contain one or more of copper, aluminum, nickel, nickel-plated copper, stainless steel, and aluminum alloys.

[0022] In one aspect, the one or more anisotropic elements and the one or more tabs of each temperature control element can define a heating element.

[0023] In one aspect, the two or more structural elements of each temperature control element may contain one or more of the following elements: mica, asbestos, marble, porcelain, glass, shellac, resin, rubber, cotton yarn, paper, linen, rayon and plastic; and the one or more adhesives may be selected from the group consisting of: polyethylene terephthalate (PET), polypropylene (PP), polyethylene (PE), polytetrafluoroethylene (PTFE) and combinations thereof.

[0024] In one aspect, the one or more anisotropic elements of each temperature control element can comprise a first grouping of anisotropic elements containing one or more first anisotropic elements, and a second grouping of anisotropic elements containing one or more second anisotropic elements. Each of the first and second groupings of anisotropic elements can be controlled independently.

[0025] In one aspect, each temperature control element of the one or more temperature control elements can be controlled independently.

[0026] In one aspect, one or more temperature control elements can define one or more films. Each of these films can have a multitude of folds. Individual electrochemical cells of the stack can be arranged between the folds of the one or more films to define the one or more temperature control elements.

[0027] In one aspect, the one or more temperature control elements can define different layers, and individual electrochemical cells of the stack can be arranged between the different layers.

[0028] In various aspects, a temperature control element for an electrochemical cell is provided. The temperature control element comprises two or more coated structural elements and one or more anisotropic elements arranged between the two or more structural elements. Each structural element can be coated with one or more adhesive layers. The one or more anisotropic elements can comprise a first grouping of anisotropic elements with one or more first anisotropic materials and a second grouping of anisotropic elements with one or more second anisotropic materials. The one or more first anisotropic materials and the one or more second anisotropic materials can each be selected from the group consisting of: graphite, graphene, carbon nanotubes (CNTs), crystalline materials, cohesive powder, and combinations thereof.Each of the first and second groups of anisotropic elements can be controlled independently. The temperature control element can be configured to be in a heat transfer relationship with the electrochemical cell to heat and / or cool the electrochemical cell.

[0029] Further areas of application will become apparent from the description given here. The description and specific examples in this summary serve only for illustration and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The drawings described here serve only to illustrate selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure. Fig. Figure 1 is a schematic representation of an example of an electrochemical battery cell for the cyclic movement of lithium ions; Fig. Figure 2 is a schematic representation of an exemplary battery pack with a large number of battery modules; Fig. Figure 3A is a schematic cross-sectional representation of an exemplary temperature control element according to various aspects of the present disclosure; Fig. Figure 3B is a schematic cross-sectional representation of an exemplary structural layer with one or more supporting adhesive coatings; Fig. Figure 4 is a schematic cross-sectional representation of another example of a temperature control element according to various aspects of the present disclosure; Fig. Figure 5 is a schematic representation from top to bottom of another example of a temperature control element with different thermal zones according to various aspects of the present disclosure; Fig. Figure 6 is a schematic cross-sectional representation of an exemplary battery pack with a plurality of battery cells and temperature control elements according to various aspects of the present disclosure; Fig. Figure 7 is a schematic cross-sectional representation of another exemplary battery pack with a plurality of battery cells and temperature control elements according to various aspects of the present disclosure; Fig. 8A is a profile of a cell temperature (°C) for a conventional electrochemical cell over a period of sixty minutes; and Fig. 8B is a profile of a cell temperature (°C) for an electrochemical cell with temperature control elements according to various aspects of the present disclosure.

[0031] The corresponding reference symbols designate corresponding parts in the different views of the drawings. DETAILED DESCRIPTION

[0032] Exemplary embodiments are given so that this disclosure is thorough and conveys its full scope to those skilled in the art. Numerous specific details are listed, such as examples of specific compositions, components, devices, and processes, to provide a thorough understanding of the embodiments of this disclosure. It is clear to those skilled in the art that specific details need not be used, that exemplary embodiments can be realized in many different forms, and that none of them should be designed in such a way as to limit the scope of the disclosure. In some exemplary embodiments, known processes, known device structures, and known technologies are not described in detail.

[0033] The terminology used here serves only to describe certain exemplary embodiments and is not intended to be restrictive. As used here, the singular forms "a," "an," and "the" can also include the plural forms unless the context clearly indicates otherwise. The terms "comprises," "comprehensive," "containing," and "exhibiting" are inclusive and therefore specify the presence of indicated features, elements, compositions, steps, integers, processes, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, processes, elements, components, and / or groups thereof.Although the open term "comprehensive" is to be understood as a non-restrictive term used to describe and claim the various embodiments set forth herein, the term can alternatively be understood, under certain aspects, as a more restrictive term, such as "consisting of" or "consisting substantially of". Therefore, for each given embodiment that mentions compositions, materials, components, elements, features, integers, processes and / or process steps, the present disclosure expressly includes embodiments that consist of, or consist substantially of, such mentioned compositions, materials, components, elements, features, integers, processes and / or process steps.In the case of "consisting of", the alternative embodiment excludes all additional compositions, materials, components, elements, features, integers, operations and / or process steps, whereas in the case of "consisting substantially of", all additional compositions, materials, components, elements, features, integers, operations and / or process steps that substantially affect the basic and novel features are excluded from such an embodiment, but all compositions, materials, components, elements, features, integers, operations and / or process steps that do not substantially affect the basic and novel features may be included in the embodiment.

[0034] All procedural steps, processes, and procedures described here are not to be interpreted as necessarily having to be carried out in the discussed or depicted order, unless they are expressly designated as such. It is also understood that additional or alternative steps may be applied, unless otherwise specified.

[0035] When a component, element, or layer is described as "on," "interacting," "connected," or "coupled" with another element or layer, it may be directly on, interacting, connected, or coupled with that other component, element, or layer, or there may be intervening elements or layers. Conversely, when an element is described as "directly on," "directly interacting with," "directly connected with," or "directly coupled with" another element or layer, there must be no intervening elements or layers. Other words used to describe the relationship between elements should be interpreted similarly (e.g., "between" versus "directly between," "next to" versus "directly beside," etc.).As used here, the term “and / or” includes all combinations of one or more of the related listed elements.

[0036] Although the terms first, second, third, etc., may be used here to describe different steps, elements, components, areas, layers, and / or sections, these steps, elements, components, areas, layers, and / or sections should not be restricted by these terms unless otherwise specified. These terms should only be used to distinguish one step, element, component, area, layer, or section from another. Terms such as "first," "second," and other numerical terms, when used here, do not imply any sequence or order unless clearly indicated by the context.Thus, a first step, element, component, area, layer or section discussed below could be referred to as a second step, element, component, area, layer or section without deviating from the teachings of the exemplary embodiments.

[0037] Spatially or temporally relative terms such as "before," "after," "inside," "outside," "under," "below," "down," "above," "above," and the like may be used here for the sake of simplicity to describe the relationship of one element or feature to one or more other elements or features, as illustrated in the figures. Spatially or temporally relative terms may also be intended to encompass different orientations of the device or system in use or operation, in addition to the orientation shown in the figures.

[0038] Throughout this entire disclosure, numerical values ​​represent approximate measures or limits for ranges that include minor deviations from the stated values ​​and embodiments with approximately the stated value, as well as those with exactly the stated value. Unlike the working examples at the end of the detailed description, all numerical values ​​of parameters (e.g., of quantities or conditions) in this specification, including the appended claims, are to be understood as being modified in all cases by the term "approximately," regardless of whether "approximately" actually precedes the numerical value or not. "Approximately" means that the stated numerical value permits a slight inaccuracy (with some approximation to the accuracy of the value; approximately or quite close to the value; almost).Unless otherwise understood in engineering with this ordinary meaning, the imprecision indicated by "approximately" means, at a minimum, deviations that may arise from ordinary procedures for measuring and using such parameters. For example, "approximately" may include a variation of less than or equal to 5%, optionally less than or equal to 4%, optionally less than or equal to 3%, optionally less than or equal to 2%, optionally less than or equal to 1%, optionally less than or equal to 0.5%, and, in certain aspects, optionally less than or equal to 0.1%.

[0039] Furthermore, the disclosure of ranges includes the disclosure of all values ​​and further subdivided ranges within the entire range, including the endpoints and the subranges specified for the ranges.

[0040] Exemplary embodiments are now described in more detail with reference to the attached drawings.

[0041] Electrochemical cells or batteries, which can be used in vehicles such as automobiles, motorcycles, boats, tractors, buses, motorhomes, caravans, off-road vehicles, snowmobiles, aircraft, and tanks, can be exposed to a wide operating temperature range, e.g., temperatures greater than or equal to approximately -20 °C to less than or equal to approximately 60 °C. Accordingly, current technology offers systems and methods for controlling the operating temperature of electrochemical cells or batteries and battery packs containing one or more electrically connected (e.g., in series or parallel) electrochemical cells or batteries. In particular, current technology, as further explained below, relates to the use of an anisotropic material or element, such as graphite, e.g., in the form of a film, as a heating material or element (e.g., an active heating element) and as a cooling material or element (e.g., a heat sink).a passive cooling element) to create controllable temperature ranges within the battery and / or pack (e.g. isotherms and other desired thermal patterns and / or gradients) which can, for example, prevent lithium plating and improve temperature performance over a wide temperature range.

[0042] As a non-restrictive background, an exemplary schematic representation of an electrochemical cell or battery 20 (also referred to as a battery comprising at least one electrochemical cell) that cyclically moves ions is shown in Fig. Figure 1 shows that unless explicitly stated otherwise, the term "ions" as used herein refers to lithium ions or sodium ions. For example, an electrochemical cell that cyclically moves sodium ions has similar components to battery 20, which cyclically moves lithium ions, but replaces the lithium and lithium ions with sodium and sodium ions in corresponding components.

[0043] The battery 20 contains a negative electrode (i.e., an anode) 22, a positive electrode (i.e., a cathode) 24, and a separator 26 (for example, a microporous polymeric separator) arranged between the two electrodes 22 and 24. An electrolyte 30 is located throughout the separator 26 and optionally in the negative electrode 22 and the positive electrode 24. A current collector 32 for the negative electrode may be positioned at or near the negative electrode 22, and a current collector 34 for the positive electrode may be positioned at or near the positive electrode 24. Although not shown, the current collector 32 for the negative electrode and the current collector 34 for the positive electrode may be coated on one or both sides, as is known in the art. In certain aspects, the current collectors 32 and 34 may be coated on both sides with an electrodeactive material / electrode layer.The current collector 32 for the negative electrode and the current collector 34 for the positive electrode each collect free electrons and move them to and from an external circuit 40 (as indicated by the block arrows). For example, an interruptible external circuit 40 and a load device 42 can connect the negative electrode 22 (via the current collector 32 of the negative electrode) and the positive electrode 24 (via the current collector 34 of the positive electrode). In this way, the current collectors 32 and 34 can define tabs (not shown) that are in electrical contact with battery terminals (not shown).

[0044] The battery 20 can generate an electric current during discharge through reversible electrochemical reactions that occur when the external circuit 40 is closed (to connect the negative electrode 22 and the positive electrode 24) and the negative electrode 22 contains a relatively larger amount of lithium than the positive electrode 24. The chemical potential difference between the positive electrode 24 and the negative electrode 22 drives the electrons generated by the oxidation of the lithium stored at the negative electrode 22 through the external circuit 40 towards the positive electrode 24. Lithium ions, also generated at the negative electrode 22, are simultaneously transported to the positive electrode 24 through the electrolyte 30 contained in the separator 26.The electrons flow through the external circuit 40, and the lithium ions migrate through the separator 26, which contains the electrolyte solution 30, to form lithium deposited at the positive electrode 24. As mentioned above, the electrolyte 30 is also typically present in the negative electrode 22 and the positive electrode 24. The electric current flowing through the external circuit 40 can be utilized and passed through the load device 42 until the available lithium in the negative electrode 22 is depleted and the capacity of the battery 20 has decreased.

[0045] While the load device 42 can be any number of known electrically powered devices, some specific examples of power-consuming load devices are given as non-restrictive examples, such as an electric motor for a hybrid or all-electric vehicle, a laptop computer, a tablet computer, a mobile phone, and cordless power tools or devices. The load device 42 can also be a power-generating device that charges the lithium-ion battery 20 for the purpose of energy storage. In certain other variations, the electrochemical cell can be a supercapacitor, e.g., a lithium-ion-based supercapacitor.

[0046] The battery 20 can be charged or recharged at any time by connecting an external power source to it, thus reversing the electrochemical reactions that occur during battery discharge. Connecting an external electrical energy source to the battery 20 promotes a reaction, such as the non-spontaneous oxidation of stored lithium, at the positive electrode 24, generating electrons and lithium ions. The lithium ions flow through the electrolyte 30, via the separator 26, back to the negative electrode 22, replenishing it with lithium (e.g., stored lithium) for use during the next battery discharge cycle. Thus, a complete discharge followed by a complete charge is considered a cycle in which lithium ions are cyclically moved between the positive electrode 24 and the negative electrode 22.The external power source that can be used to charge the battery 20 can vary depending on the size, design, and specific end application of the battery 20. Some notable and exemplary external power sources include an AC-DC converter connected to an AC power supply via a wall socket, and a motor vehicle alternator. Accordingly, the lithium-ion battery 20 can generate an electrical current for the load device 42, which can be operationally connected to the external power circuit 40.

[0047] In many lithium-ion battery configurations, the current collector 32 for the negative electrode, the negative electrode 22, the separator 26, the positive electrode 24, and the current collector 34 for the positive electrode are each manufactured as relatively thin layers (e.g., from a few micrometers to a fraction of a millimeter or less thick), defining a respective cell. These cells are then assembled in electrically parallel layers to obtain a suitable electrical energy and power package. Furthermore, the separator 26 acts as an electrical insulator by being inserted between the negative electrode 22 and the positive electrode 24 to prevent physical contact and thus the occurrence of a short circuit.If the electrolyte 30 is a liquid or a semi-solid, the separator 26, in addition to providing a physical barrier between the two electrodes 22, 24, is porous and acts like a sponge, containing the electrolyte 30 in a network of open pores during the lithium ion cycle to facilitate the function of the battery 20.

[0048] The battery 20 may contain a variety of other components in certain aspects, which, although not shown here, are nevertheless familiar to those skilled in the art. For example, the battery 20 may contain a casing, seals, terminal caps, tabs, battery terminals, and any other conventional components or materials that may be located within the battery 20, including those between or around the negative electrode 22, the positive electrode 24, and / or the separator 26. As mentioned above, the size and shape of the battery 20 may vary depending on the specific applications for which it is designed. Battery-powered vehicles and portable consumer electronics devices are two examples where the battery 20 is most likely to be designed according to different size, capacity, and performance specifications.

[0049] In various aspects, the battery 20, for example, can also be connected in a stack with other similar lithium-ion cells or batteries via series or parallel electrical connections to generate a higher output voltage, energy, and power when required by the load device 42. For example, a plurality of cells or batteries 20 can be stacked to define a battery module 50, and a plurality of battery modules 50 can be operationally connected in series or parallel to define a battery pack 100, as shown in Fig. 2 shown. As experts will recognize, each battery module 50 can contain one or more cells or batteries 20 (as in Fig. (shown in Figure 1), and the 100 battery pack can contain two or more 50 battery modules. As shown in Figure 1. Fig. As shown in Figure 2, the battery pack 100 can, for example, contain two or more battery modules 50. Fig. Figure 2 shows the central battery module 50 with dashed lines and is intended to illustrate that the central battery module 50 is optional or can consist of any number of further battery modules 50, such as only greater than or equal to one to less than or equal to approximately fifty battery modules 50.

[0050] The battery pack 100 comprises a first side face 70, defined by a first cell wall 54 of a first edge battery module 50 of the plurality, a opposite second side face 72, defined by a second cell wall 56 of a last edge battery module 50 of the plurality, and opposite first and second stack edges 74, 76, defined by the first and second cell edges 58, 60 of each battery module 50 of the plurality. The first and second stack edges 74, 76 are orthogonal to the first and second side faces 70, 72. The battery pack 100 also comprises opposite first and second stack ends 78, 80, defined by the first and second cell ends 62, 64 of each battery module 50 of the plurality. Each battery module 50 can contain tabs 66 which generally extend outwards from at least one of the first and second cell ends 62, 64 of each battery module 50 of the plurality.In certain aspects, each battery module 50 comprises two tabs 66, one of which is connected to at least one anode 22 and the other tab 66 to at least one cathode 24. The two tabs 66 may be located at opposite cell ends 62, 64 of each battery module 50 of the plurality. In other cases, the two tabs may both be arranged at a single end, the single end being either the first cell end 62 or the second cell end 64 of the respective battery module 50. Although the tabs 66 of each battery 20 in . Fig. Since 2 are shown exposed, they can of course be connected, e.g. with a busbar as a non-restrictive example.

[0051] With renewed reference to Fig. 1. The positive electrode 24, the negative electrode 22, and the separator 26 can each contain an electrolyte solution or electrolyte system 30 within their pores, capable of conducting lithium ions between the negative electrode 22 and the positive electrode 24. Any suitable electrolyte 30, whether in solid, liquid, or gel form, that can conduct lithium ions between the negative electrode 22 and the positive electrode 24 can be used in the lithium-ion battery 20. In certain aspects, the electrolyte 30 can be a non-aqueous liquid electrolyte solution containing a lithium salt dissolved in an organic solvent or a mixture of organic solvents. Numerous conventional non-aqueous liquid solutions containing electrolyte 30 can be used in the lithium-ion battery 20.

[0052] A non-restrictive list of lithium salts that can be dissolved in an organic solvent to form the non-aqueous liquid electrolyte solution includes lithium hexafluorophosphate (LiPF6), lithium fluorosulfonylimide (LiN(FSO2)2) (LiFSI), lithium perchlorate (LiClO4), lithium tetrachloroaluminate (LiAlCl4), lithium iodide (Lil), lithium bromide (LiBr), lithium thiocyanate (LiSCN), lithium tetrafluoroborate (LiBF4), lithium tetraphenylborate (LiB(C6H5)4), lithium hexafluoroarsenate (LiAsF6), lithium trifluoromethanesulfonate (LiCF3SO3), lithium bis(trifluoromethanesulfonimide) (LiTFSI) (LiN(CF3SO2)2) and combinations thereof.

[0053] These and other similar lithium salts can be dissolved in a variety of organic solvents, including, but not limited to, various alkyl carbonates, such as cyclic carbonates (e.g., ethylene carbonate (EC), propylene carbonate (PC), butylene carbonate (BC), fluoroethylene carbonate (FEC)), linear carbonates (e.g., dimethyl carbonate (DMC), diethyl carbonate (DEC), ethyl methyl carbonate (EMC)), aliphatic carboxylic esters (e.g., methyl formate, methyl acetate, methyl propionate), γ-lactones (e.g., γ-butyrolactone, γ-valerolactone), chain ethers (e.g., 1,2-dimethoxyethane (DME), 1,2-diethoxyethane, ethoxymethoxyethane), cyclic ethers (e.g., tetrahydrofuran, 2-methyltetrahydrofuran, 1,3-dioxolane (DOL)), sulfur compounds (e.g., sulfolane), and combinations thereof. of this. In various aspects, the electrolyte can contain more than or equal to approximately 0.5 M to less than or equal to approximately 4.0 M of one or more lithium salts.

[0054] The separator 26 acts as both an electrical insulator and a mechanical support. In one embodiment, a microporous polymeric separator 26 comprises a polyolefin. The polyolefin can be a homopolymer (derived from a single monomer component) or a heteropolymer (derived from more than one monomer component), which can be either linear or branched. If a heteropolymer is derived from two monomer components, the polyolefin can adopt any copolymer chain arrangement, including that of a block copolymer or a statistical copolymer. Similarly, if the polyolefin is a heteropolymer derived from more than two monomer components, it can also be a block copolymer or a statistical copolymer. In certain aspects, the polyolefin can be polyethylene (PE), polypropylene (PP), or a mixture of PE and PP.

[0055] If the separator 26 is a microporous polymeric separator, it can be a single layer or a multilayer laminate that can be produced using either a dry or wet process. For example, in one embodiment, a single layer of the polyolefin can form the entire microporous polymer separator 26. In other embodiments, the separator 26 can be a fibrous membrane with a multitude of pores extending between the opposing surfaces and can, for example, have a thickness of less than one millimeter. As another example, several discrete layers of similar or dissimilar polyolefins can be assembled to form the microporous polymer separator 26. The polyolefins can be homopolymers (derived from a single monomer component) or heteropolymers (derived from more than one monomer component), which can be either linear or branched.If a heteropolymer is derived from two monomer components, the polyolefin can adopt any copolymer chain arrangement, including that of a block copolymer or a statistical copolymer. Similarly, if the polyolefin is a heteropolymer derived from more than two monomer components, it can also be a block copolymer or a statistical copolymer. In certain aspects, the polyolefin can be polyethylene (PE), polypropylene (PP), a mixture of PE and PP, or multilayer structured porous films of PE and / or PP. The microporous polymer separator 26 can contain other polymers besides the polyolefin, such as, but not limited to, polyethylene terephthalate (PET), polyvinylidene fluoride (PVDF), and / or a polyamide. Furthermore, the porous separator 26 can be blended with a ceramic material or its surface can be coated with a ceramic material.

[0056] For example, a ceramic coating may contain aluminum oxide (Al2O3), silicon dioxide (SiO2), titanium oxide (TiO2) or combinations thereof.

[0057] Commercially available porous membranes include CELGARD. ® 2500 (a single-layer polypropylene separator) and CELGARD ® 2320 (a three-layer polypropylene / polyethylene / polypropylene separator), both of which are available from Celgard LLC. The polyolefin layer and any other optional polymer layers can further be incorporated as a fiber layer into the microporous polymer separator 26 to help impart suitable structural and porosity properties to the microporous polymer separator 26. Various conventionally available polymers and commercial products for the fabrication of the separator 26 are considered, as are the many fabrication processes that can be used to produce such microporous polymer separators 26.

[0058] Alternatively, the porous separator 26 and the electrolyte 30 can be replaced by a solid electrolyte (SSE) (not shown) that functions as both an electrolyte and a separator, as known in the prior art. The SSE can be positioned between the positive electrode 24 and the negative electrode 22. The SSE facilitates the transfer of lithium ions while mechanically separating and electrically isolating the negative and positive electrodes 22 and 24 from each other. As a non-limiting example, SSEs can be LiTi₂(PO₄)₃, LiGe₂(PO₄)₃, or Li₇La₃Zr₂O. 12 , Li3xLa 2 / 3 -xTiO3, Li3PO4, Li3N, Li4GeS4, Li 10 GeP2S 12 , Li2S-P2S5, Li6PS5Cl, Li6PS5Br, Li6PS5I, Li3OCl, Li 2,99 Ba 0,005 ClO, Li5La3M2O 12 , where M is niobium (Nb) or tantalum (Ta)), Li2O-La2O3-M2O5, where M is niobium (Nb) or tantalum (Ta), LiAlTi(PO4)2, or LISICON materials such as Li 2+2x Zn 1-xGeO4 or Li (3+x) Ge x V (1-x) O4, where x can be 0 and 1 for example, and can contain any combination thereof. In certain variations, the SSE can be selected from the group consisting of: Li5La3M2O 12 , where M is niobium (Nb) or tantalum (Ta)), Li2O-La2O3-M2O5, where M is niobium (Nb) or tantalum (Ta), LiAlTi(PO4)2, or LISICON materials such as Li 2+2x Zn 1-x GeO4 or Li (3+x) Ge x V (1-x) O4, where x can be 0 and 1, and combinations thereof.

[0059] The negative electrode 22 can be formed from a lithium host material capable of functioning as the negative terminal of a lithium-ion battery. The negative electrode 22 can therefore contain the electrodeactive material and optionally another electrically conductive material, as well as one or more polymeric binder materials to structurally hold the particles of the electroactive lithium host material together.

[0060] In certain variations, the active material of the negative electrode can contain lithium, such as lithium metal.

[0061] In certain variations, the negative electrode 22 is a film or layer formed from lithium metal or a lithium alloy. Other materials can also be used to form the negative electrode 22, e.g., lithium-silicon and silicon-containing binary and ternary alloys and / or tin-containing alloys, such as Si-Sn, SiSnFe, SiSnAl, SiFeCo, SnO2, and the like. In certain alternative embodiments, lithium-titanium anode materials are considered, such as Li 4+x Ti5O 12 , where 0 ≤ x ≤ 3, including lithium titanate (Li4Ti5O) 12 ) (LTO). Thus, negative electroactive materials for the negative electrode 22 can be selected from the group consisting of: lithium, graphite, silicon, silicon-containing alloys, tin-containing alloys and combinations thereof.

[0062] Such active materials for the negative electrode can optionally be mixed with an electrically conductive material that provides an electron conduction path, and / or with at least one polymeric binder material that enhances the structural integrity of the negative electrode 22. As a non-restrictive example, the negative electrode 22 can contain an active material that includes electroactive material particles (e.g., graphite particles) mixed with a polymeric binder material selected from the group consisting of polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), ethylene propylene diene monomer (EPDM) rubber, carboxymethoxyl cellulose (CMC), nitrile butadiene rubber (NBR), lithium polyacrylate (LiPAA), sodium polyacrylate (NaPAA), sodium alginate, lithium alginate, and combinations thereof, to name a few examples.Other suitable electrically conductive materials can be carbon-based materials or conductive polymers. Carbon-based materials can include, as a non-limiting example, particles of KETCHEN™ carbon black, DENKA™ carbon black, acetylene carbon black, carbon black, and the like. Conductive metal particles can include nickel, gold, silver, copper, aluminum, and the like. Examples of conductive polymers are polyaniline, polythiophene, polyacetylene, polypyrrole, and the like. In certain aspects, mixtures of conductive materials can also be used.

[0063] A negative electrode may contain the active material of the negative electrode in a proportion of more than approximately 60 wt.% of the total weight of the electrode, optionally more than or equal to approximately 65 wt.%, optionally more than or equal to approximately 70 wt.%, optionally more than or equal to approximately 75 wt.%, optionally more than or equal to approximately 80 wt.%, optionally more than or equal to approximately 85 wt.%, optionally more than or equal to approximately 90 wt.% and in certain variations optionally more than or equal to approximately 95% of the total weight of the electrode.

[0064] The binder can be present in the negative electrode 22 in more than or equal to approximately 1 wt.% to less than or equal to approximately 20 wt.%, optionally more than or equal to approximately 1 wt.% to less than or equal to approximately 10 wt.%, optionally more than or equal to approximately 1 wt.% to less than or equal to approximately 8 wt.%, optionally more than or equal to approximately 1 wt.% to less than or equal to approximately 7 wt.%, optionally more than or equal to approximately 1 wt.% to less than or equal to approximately 6 wt.%, optionally more than or equal to approximately 1 wt.% to less than or equal to approximately 5 wt.%, or optionally more than or equal to approximately 1 wt.% to less than or equal to approximately 3 wt.% of the total weight of the electrode.

[0065] In certain variations, the negative electrode 22 contains the electrically conductive material in a proportion of less than or equal to approximately 20 wt.%, optionally less than or equal to approximately 15 wt.%, optionally less than or equal to approximately 10 wt.%, optionally less than or equal to approximately 5 wt.%, optionally less than or equal to approximately 1 wt.%, or optionally greater than or equal to approximately 0.5 wt.% to less than or equal to approximately 8 wt.% of the total weight of the negative electrode. While the electrically conductive materials may be described as powders, these materials may lose their powdery character after incorporation into the electrode, with the associated particles of the additional electrically conductive materials becoming part of the resulting electrode structure.

[0066] The current collector 32 for the negative electrode can be made of copper (Cu) or another suitable electrically conductive material known to those skilled in the art.

[0067] The positive electrode 24 can be formed from a lithium-based active material containing a transition metal and capable of undergoing sufficient lithium insertion and removal or alloying and dealloying while acting as the positive terminal of the battery 20.

[0068] In various aspects, the positive electrode 24 can be a layered oxide cathode, a spinel cathode, or a polyanion cathode. For example, layered oxide cathodes (e.g., rock salt layered oxides) comprise one or more positive electroactive lithium-based materials selected from LiNi. x Mn y Co 1-x-y O2 (where 0 ≤ x ≤ 1 and 0 ≤ y ≤ 1), LiNi x Mn 1-x O2 (where 0 ≤ x ≤ 1), Li 1+xMO2 (where M is one of Mn, Ni, Co and Al and 0 ≤ x ≤ 1) (for example LiCoO2 (LCO), LiNiO2, LiMnO2, LiNi 0,5 Mn 0,5 O2, NMC111, NMC523, NMC622, NMC721, NMC811, NCA). Spinel cathodes contain one or more positive electroactive lithium-based materials selected from LiMn2O4 (LMO) and LiNi. 0,5 Mn 1,5O4. Olivine-type cathodes contain one or more positive electroactive materials based on lithium, such as LiV₂(PO₄)₃, LiFePO₄, LiCoPO₄, and LiMnPO₄. Tavorite-type cathodes contain, for example, LiVPO₄F. Borate-type cathodes contain, for example, one or more LiFeBO₃, LiCoBO₃, and LiMnBO₃. Silicate-type cathodes contain, for example, Li₂FeSiO₄, Li₂MnSiO₄, and LiMnSiO₄F. In further variations, the positive electrode 24 can contain one or more other positive electroactive materials, such as one or more dilithium (2,5-dilithiooxy) terephthalate and polyimide. The positive electroactive material can optionally be coated (e.g., with LiNbO₃ and / or Al₂O₃) and / or doped (e.g., with one or more magnesium (Mg), aluminum (Al), and manganese (Mn)).

[0069] The active materials of the positive electrode can be powder compositions. These materials can be mixed with an optional electrically conductive material (e.g., electrically conductive particles) and a polymeric binder. The binder can both hold the electroactive material of the positive electrode together and impart ionic conductivity to the positive electrode.The polymeric binder may include polyvinylidene fluoride (PVDF), poly(vinylidene chloride) (PVC), poly((dichloro-1,4-phenylene)ethylene), carboxymethoxylcellulose (CMC), nitrile butadiene rubber (NBR), fluorinated urethanes, fluorinated epoxides, fluorinated acrylics, copolymers of halogenated hydrocarbon polymers, epoxides, ethylene propylene diamine termonomer rubber (EPDM), hexafluoropropylene (HFP), ethylene acrylic acid copolymer (EAA), ethylene vinyl acetate copolymer (EVA), EAA / EVA copolymers, PVDF / HFP copolymers, polyvinylidene fluoride (PVDF), lithium polyacrylate (LiPAA), sodium polyacrylate (NaPAA), sodium alginate, lithium alginate, or combinations thereof.

[0070] Electrically conductive materials can be graphite, other carbon-based materials, conductive metals, or conductive polymer particles. Carbon-based materials can include, as non-limiting examples, particles of KET-CHEN™ carbon black, DENKA™ carbon black, acetylene carbon black, carbon black, carbon nanotubes, and the like. Conductive metal particles can include nickel, gold, silver, copper, aluminum, and the like. Examples of conductive polymers are polyaniline, polythiophene, polyacetylene, polypyrrole, and the like. In certain aspects, mixtures of electrically conductive materials can also be used.

[0071] A positive electrode may contain the active material of the positive electrode in a proportion of more than approximately 60 wt.% of the total weight of the electrode, optionally more than or equal to approximately 65 wt.%, optionally more than or equal to approximately 70 wt.%, optionally more than or equal to approximately 75 wt.%, optionally more than or equal to approximately 80 wt.%, optionally more than or equal to approximately 85 wt.%, optionally more than or equal to approximately 90 wt.% and in certain variations optionally more than or equal to approximately 95% of the total weight of the electrode.

[0072] The binder can be present in the positive electrode 24 in more than or equal to approximately 1 wt.% to less than or equal to approximately 20 wt.%, optionally more than or equal to approximately 1 wt.% to less than or equal to approximately 15 wt.%, optionally more than or equal to approximately 1 wt.% to less than or equal to approximately 10 wt.%, optionally more than or equal to approximately 1 wt.% to less than or equal to approximately 5 wt.%, or optionally more than or equal to approximately 1 wt.% to less than or equal to approximately 3 wt.% of the total weight of the electrode.

[0073] In certain variations, the positive electrode 24 contains the electrically conductive material to less than or equal to approximately 20 wt.%, optionally less than or equal to approximately 10 wt.%, optionally less than or equal to approximately 5 wt.%, optionally less than or equal to approximately 3 wt.%, optionally greater than or equal to approximately 1 wt.% to less than or equal to approximately 20 wt.% of the total weight of the positive electrode, optionally greater than or equal to approximately 1 wt.% to less than or equal to approximately 10 wt.% of the total weight of the positive electrode, or optionally greater than or equal to approximately 0.5 wt.% to less than or equal to approximately 8 wt.% of the total weight of the positive electrode.While the electrically conductive materials can be described as powders, these materials can lose their powdery character after being incorporated into the electrode, with the associated particles of the additional electrically conductive materials becoming part of the resulting electrode structure.

[0074] As described above, current technology offers systems and methods for controlling the operating temperature of electrochemical cells or batteries and battery packs containing one or more electrically connected (e.g. in series or parallel) electrochemical cells or batteries. Fig. Figure 3A shows an example of a temperature control or regulation element, or temperature control element 300, which can actively heat and passively cool. The temperature control element 300 comprises one or more first elements, layers, or films 310A, 310B, which comprise anisotropic thermally and / or electrically conductive materials arranged between two or more structural elements or layers 320A, 320B. As shown, for example, the temperature control element 300 comprises two first layers 310A, 310B, which are arranged (i.e., embedded) between a first structural layer 320A and a second structural layer 320B. In certain cases, although not shown, the temperature control element 300 may include further layers, such as a third structural layer 320C, which is arranged between the lower first layer 310A and the upper first layer 310B.

[0075] Anisotropic refers to materials that possess a physical property with different values ​​when measured in different directions. For example, graphite sheets can be manufactured to have a much higher thermal conductivity in the xy-plane than in the z-plane, causing heat to spread laterally, unlike most metals where heat spreads uniformly in all directions. Thus, anisotropic thermally and / or electrically conductive materials can be good heat conductors, and when an electric field is applied in one direction, such a material can become a heater that does not remain electrically activated due to the material's directional arrangement. Anisotropic thermally and / or electrically conductive materials can include graphite, graphene, carbon nanotubes (CNTs), crystalline materials (e.g.,The device comprises boron arsenide), one or more cohesive powders (cohesive powders are particles that form aggregates or agglomerates due to attractive forces between particles, which tend to increase with smaller particle sizes, e.g., particles with an average particle size below 100 µm) and / or other conductive inert carbons. Examples of suitable cohesive powders are graphite flakes and / or metal powders compressed to act as an integral, continuous thermal and / or electrical conductor.

[0076] Experts will understand that such anisotropic thermally and / or electrically conductive materials can be treated with one or more known techniques, e.g., passivation to prevent corrosion, changes in thermal / electrical conductivity, and the like; coating with known materials (e.g., silicone, polyethylene terephthalate (PET), etc., and / or known oxide layers (i.e., protective layers)) to improve physical properties, mechanical strength, and the like, and to reduce material failure due to temperature changes; and / or making them amenable to improvements, e.g., to various desirable properties. Furthermore, experts will recognize that such anisotropic thermally and / or electrically conductive materials are not typically used for individually / regionally controlled heating elements.

[0077] The one or more first layers 310A, 310B, including the anisotropic thermally and / or electrically conductive materials, can each have a thickness of approximately 1 µm or greater than or equal to approximately 10,000 µm. The thickness of the one or more first layers 310A, 310B, including the anisotropic thermally and / or electrically conductive materials, can be selected to achieve, for example, the desired thermal and electrical conductivity and / or mechanical strength, as well as a balance between preferred weight, size, and cost. In certain aspects, the one or more first layers 310A, 310B can have the same thickness as certain cell plates (not shown) to minimize the impact on the overall battery thickness (not shown).

[0078] Experts will understand that in various aspects, the one or more first layers 310A, 310B, including the anisotropic thermally and / or electrically conductive materials, may also contain one or more known additives, such as fillers and / or binders. For example, the one or more first layers 310A, 310B may contain one or more thermally conductive additives that fine-tune the resistance of the one or more first layers 310A, 310B, for example, to improve the generation of self-heating. Such thermally conductive additives may also improve the manufacturability of the one or more first layers 310A, 310B. The one or more thermally conductive additives may be polymers and / or polymers in combination with metal compounds, for example, as composites, as shown in the following table: Table 1. Examples of thermally conductive material additives Firma Polymer Marke WärmeleitfähigkeitW(m·K) -1 COOLPOLY® LCP D5506 10 PPS E5101 20 PPS E5108 10 PC E4505 4 Laticonther PPS Lati80 / 50 10 PA6 Lati62GR / 70 15 DSM PA46 Tanyl-TC153 8 PA46 Stanyl-TC551 14 PA46 Stanyl-RC154 - Albis PPSGF46 TedurR9519 - PP66 AlcomTCE10 10 PA6 AlcomTCE10 10 PBT AlcomTCE10 10 Ticona PPS FortronPPS - LCP ZeniteLCP - Sabic PPS OTF2A 2,2 PPS OTF2B 1,05

[0079] Such polymeric materials can be mixed with one or more metal compounds, such as BeO (219 W(m·K) -1 ), MgO (36 W(m·K) -1 ), Al2O3 (30 W(m·K) -1 ), CaO (15 W(m·K) -1 ), NiO (12 W(m·K) -1 ), AlN (320 W(m·K) -1 ) and / or SiN (270 W(m·K) -1 ).

[0080] The structural layers 320A and 320B are selected based on the performance requirements for the respective device. For example, if the temperature control elements 300 are to be in close proximity to battery cells, as in Fig. As shown in Figure 3A, the type and application of the battery cells and battery pack (e.g., automotive, military, commercial, low voltage, high voltage) and the battery's sensitivity to, for example, electromagnetic interference (EMI) and noise injection, as well as the probability of crashes, crushing, deformation, radiation exposure, etc., will guide the selection of the appropriate structural layers 320A and 320B. In various cases, the structural layers 320A and 320B can provide the temperature control element 300 with sufficient mechanical strength, flexibility, and electrical insulation. The structural layers 320A and 320B can minimize or eliminate potential mechanical damage to one or more of the first layers 310A and 310B.

[0081] The structural layers 320A and 320B can be formed from a material including mica, asbestos, marble, porcelain, glass, shellac, resin, rubber, cotton yarn, paper, linen, rayon, and / or plastic. In various aspects, the structural layers 320A and 320B may also contain a single- or double-sided adhesive that provides sufficient mechanical strength, flexibility, and electrical insulation. The single- or double-sided adhesive can be sprayed, poured, applied, etc., to one or more exposed surfaces of the structural layers 320A and 320B. As described in Fig. As shown in Figure 3B, for example, one or more first adhesives can be arranged as a first coating 322 on a first surface 324 of the first structural layer 320A; and one or more second adhesives can be arranged as a second coating 326 on a second surface 328 of the first structural layer 320A. The single- or double-sided adhesive(s) can comprise, for example, polyethylene terephthalate (PET), polypropylene (PP), polyethylene (PE), and / or polytetrafluoroethylene (PTFE).

[0082] The temperature control element 300 also includes one or more tab layers 330A, 330B, 330C, which establish both an electrical (ohmic) and a thermal connection with the one or more first layers 310A, 310B. The tab layers 330A, 330B, 330C contain a relatively mechanically high-strength, electrically conductive material, such as copper, aluminum, nickel, nickel-plated copper, stainless steel, and / or aluminum alloys. The tab layers 330A, 330B, 330C can be arranged between one or more of the first layers 310A, 310B and / or between the one or more first layers 310A, 310B and the one or more structural layers 320A, 320B. In particular, the tabs 330A, 330B, 330C along a length 340 of the first layers 310A, 310B can be coextensive or have the same area, or not, but can, as in Fig. 3A shows that the first layers 310A and 310B are arranged only at their terminal ends 302 and 304, such that a gap 342 is defined in the central region between each respective tab 330A, 330B, and 330C in a single plane. As shown in Fig. As shown in Figure 3A, for example, a first tab layer 330A can be arranged between the first structural layer 320A and the first layer 310A; a second tab layer 330B can be arranged between the first layer 310A and the first layer 310B; a third tab layer 330C can be arranged between the first layer 310B and the second structural layer 320B. As described above, the tab layers 330A, 330B, 330C can extend over the length of one or more first layers 310A, 310B and / or one or more structural layers 320A, 320B and substantially overlap this surface. In certain other cases, as in Fig. As shown in Figure 3A, each tab layer 330A, 330B, 330C can contain a first part or section 332 and a second part or section 334. As shown, the first part 332 of each tab layer 330A, 330B, 330C can be arranged on a first side 302 of the temperature control element 330, extending, for example, from this side, and the second part 334 of each tab layer 330A, 330B, 330C can be arranged on a second side 304 of the temperature control element 330, extending, for example, from this side.

[0083] Fig. Figure 4 shows another example of a temperature control element 400 that can actively heat and passively cool an electrochemical cell. The temperature control element 400 comprises a first element 410 that is arranged between two or more structural elements or layers 420A, 420B. For example, as shown, the first element 410 can be arranged between a first structural layer 420A and a second structural layer 420B.

[0084] The structural layers 420A and 420B provide the temperature control element 400 with sufficient mechanical strength, flexibility, and electrical insulation. These layers can contain materials such as mica, asbestos, marble, porcelain, glass, shellac, resin, rubber, cotton yarn, paper, linen, rayon, and / or plastic. As experts know, in certain aspects, the structural layers 420A and 420B may also contain a single- or double-sided adhesive, which likewise provides sufficient mechanical strength, flexibility, and electrical insulation. This single- or double-sided adhesive includes, for example, polyethylene terephthalate (PET), polypropylene (PP), polyethylene (PE), and / or polytetrafluoroethylene (PTFE). The structural layers 420A and 420B provide the temperature control element 400 with mechanical strength and minimize or eliminate potential mechanical damage to the first element 410.

[0085] The first element 410 is formed from a film or sheet 412 having a multitude of folds (e.g., where the film or sheet 412 undergoes a change in direction of approximately 180°) that wrap around one or more insulating layers 414. In other words, the one or more insulating layers 414 are arranged between the folds of the film 412. The film 412 comprises one or more anisotropic thermally and / or electrically conductive materials and can have a thickness of greater than or equal to approximately 1 µm to less than or equal to approximately 10,000 µm. The anisotropic thermally and / or electrically conductive materials can include graphite, graphene, carbon nanotubes (CNTs), crystalline materials (e.g., boron arsenide), cohesive powder, and / or other conductive inert carbons. The one or more insulating layers 414 can contain known insulating materials.

[0086] The temperature control element 400 also contains one or more tabs 430A, 430B, which establish both an electrical (ohmic) and a thermal connection with the film 412. The tabs 430A, 430B comprise a relatively high-strength, electrically conductive material, as described above in connection with the tabs 330A, 330B, 330C in Fig. 3A described, such as copper, aluminum, nickel, nickel-plated copper, stainless steel and / or aluminum alloys. The tabs 430A, 430B can be arranged between the first element 410 and one or more structural layers 420A, 420B. For example, as described in Fig. Figure 4 shows a first tab 430A between the first element 410 and a first structural layer 420A and a second tab 430B between the first element 410 and a second structural layer 420B.

[0087] Fig. Figure 5 shows another example of a temperature control element 500 that is capable of actively heating and passively cooling when arranged in a heat transfer relationship with an electrochemical cell. The temperature control element 500 comprises two or more independently controlled temperature zones or ranges 510A, 510B. As shown, the temperature control element 500 can, for example, have a first temperature control element 510A and a second temperature control element 510B. Each of the temperature zones 510A, 510B contains, similar to the one in Figure 5, a temperature control element 510A, 510B, a temperature control element 510A, 510B, and a temperature control element 510A, 510B, 510A ... Fig. 3A shown temperature control element 300 and / or the one in Fig. 4. Temperature control element 400 shown, one or more first elements or layers of anisotropic thermally and / or electrically conductive materials arranged between two or more structural layers and one or more panels. Each temperature zone 510A, 510B may also contain one or more insulating layers, e.g., similar to those in Fig. 4 insulating layers shown 414.

[0088] Although not shown, experts will recognize that each of the temperature zones 510A, 510B has a similar configuration to the one in Fig. 3A shown temperature control element 300 and / or the one in Fig. The temperature control element shown in section 400 can have this configuration. In contrast to the configurations of the... Fig. 3A and Fig. 4 contains the in Fig. However, the temperature control element 500 shown has a plurality of temperature zones 510A, 510B which can be controlled independently of one another. As shown, the plurality of temperature zones 510A, 510B can be separated by an electrically insulating material 520 and enclosed by or arranged between one or more structural elements or layers 530.

[0089] The electrically insulating material 520 may comprise known insulating materials familiar to those skilled in the art. The structural layers 530 provide the temperature control element 500 with sufficient mechanical strength, flexibility, and electrical insulation. The structural elements 520 may include, for example, mica, asbestos, marble, porcelain, glass, shellac, resin, rubber, cotton yarn, paper, linen, rayon, and / or plastic. In certain aspects, the structural layers 520 may also include a single- or double-sided adhesive that likewise exhibits sufficient mechanical strength, flexibility, and electrical insulation. The single- or double-sided adhesive includes, for example, polyethylene terephthalate (PET), polypropylene (PP), polyethylene (PE), and / or polytetrafluoroethylene (PTFE).

[0090] Temperature control elements with an anisotropic material or element, such as graphite, e.g. in the form of a film, as a heating material or element (e.g. active heating) and a cooling material or element (e.g. passive cooling), such as only the example in Fig. 3A shown temperature control element 300 and / or the one in Fig. 4 shown temperature control element 400 and / or the one in Fig. The 5 temperature control elements 500 shown can be integrated into a battery module and / or a battery pack in different ways (as in Fig. 2) can be integrated. For example, in certain cases, such as in Fig. Figure 6 shows that individual temperature control elements 610 are arranged between one or more cells 620 within a battery pack 600. Each cell of the one or more cells 620 can be a battery 20, as shown in the example of Fig. 1 is described. Each temperature control element 610 of the multitude can be a temperature control element 300, as described in Fig. 3A shown, and / or a temperature control element 400, as shown in Fig. 4 shown, and / or a temperature control element 500, as shown in Fig. 5 shown, be. The in Fig. The 6 asterisks shown (*) are intended to illustrate that the battery pack 600 can contain any number of alternating cells 620 and temperature control elements 610.

[0091] As shown, each of the temperature control elements 610 can be electrically connected to a field-effect transistor and / or pulse-width modulation and / or a mechanical connector 612 and controlled independently by them. In this way, the temperature control elements 610 can be used to apply different temperature controls to different areas of the battery pack 600, thus enabling flexible zone control, e.g., to combat the spread from a blown cell and to control specific areas within the battery pack.

[0092] The use of temperature control elements 610 with anisotropic thermally and / or electrically conductive materials. For example, graphite can be used, whereby the specific resistance of the graphite can generate an active, uniformly heating solution for warming the cells 620 when current is passed through the graphite. Additionally, the same property can be used for passive cooling of the cells 620 by dissipating heat through the anisotropic nature of the graphite (e.g., anisotropic thermal conductivities along axes). In various cases, the connection between the anisotropic element and the insulating structural element can minimize or prevent heat propagation before and after the heat reaches the insulation, thus preventing heat transfer. Furthermore, the non-combustibility of the anisotropic thermally and / or electrically conductive materials provides protection in the event of a cell breakdown. For example, the anisotropic material (e.g.,Graphite preferentially transfers heat in the xy-plane, thus slowing down heat transfer in the z-plane to neighboring cells in order to reduce the peak temperature and thereby attenuate and / or prevent inflammation of a neighboring cell. Fig. Figure 6 shows an example with a singular element where the heat / temperature would be essentially the same at all points of the solution (assuming that the materials, thicknesses, etc. are homogeneous). Fig. As explained in more detail below, section 7 enables preferential heating by allowing discrete control of different areas of the battery. For example, the inner (central) cells heat and cool differently than the outer (distal) cells.

[0093] As in Fig. As shown in Figure 7, a temperature control element 710 can be wrapped around one or more cells 720 of a battery pack 700. In other words, the one or more cells 720 are arranged between the folds of the temperature control element 710. Each cell of the one or more cells 720 can be a battery 20, as in the context of Fig. 1 described. Each temperature control element 610 of the multitude can be in Fig. 3A shown temperature control element 300 and / or one in Fig. 4 shown temperature control element 400 and / or one in Fig. The temperature control element 500 shown in section 5 is shown. The one in Fig. The seven asterisks (*) shown are intended to illustrate that the battery pack 700 can contain any number of alternating cells 720 and temperature control elements 710. As shown, the temperature control element 710 can be electrically connected to and controlled by a field-effect transistor and / or a pulse-width modulation and / or a mechanical connector 712.

[0094] Embodiments of the present technology are explained in more detail with reference to the following non-restrictive example. Example

[0095] Fig. Figures 8A-8B show cell temperature (°C) profiles for example cells over a period of sixty minutes.

[0096] Fig. Figure 8A shows the temperature profile for a conventional electrochemical cell (e.g., bare cell), where 830 represents the positive battery terminal, 832 the negative battery terminal, and 834 the cell center. Fig. 8A represents the x-axis 810 the test time in minutes and the y-axis 820 the cell temperature (°C).

[0097] Fig. Figure 8B shows the temperature profile for an electrochemical cell incorporating a temperature control element according to various aspects of the present disclosure, where 870 represents the positive battery terminal, 872 the negative battery terminal, and 874 the cell center. Fig. 8B represents the x-axis 850 as the test time in minutes and the y-axis 860 as the cell temperature (°C).

[0098] As in Fig. As shown in Figure 8A, the bare cell lasted less than a minute, and the temperatures inside the cell show that the tab thermocouple is much hotter than the reference cell, which was manufactured in accordance with various aspects of the present disclosure, as shown in Fig. 8B is shown. More precisely, as in Fig.As shown in Figure 8B, the electrochemical cell, which included the temperature control element according to various aspects of the present disclosure, ran for approximately 20 minutes before the temperature delta of 20 °C was exceeded. Furthermore, the temperatures within the cell for the positive terminal 870, the negative terminal 872, and the cell center 874 are much narrower. The narrower temperatures result in more uniform wear within the cell and between the cells in the comparison cell, which was manufactured according to various aspects of the present disclosure, leading to improved performance and, in particular, improved reliability and safety.

[0099] The foregoing description of the embodiments serves for illustration and description purposes. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not restricted to that particular embodiment, but are optionally interchangeable and may be used in a selected embodiment, even if they are not specifically shown or described. The embodiment may also be varied in many ways. Such variations are not to be considered outside the scope of the disclosure, and all such modifications are to be included within the scope of protection of the disclosure.

Claims

[1] Temperature control element for an electrochemical cell, comprising: two or more structural elements, and one or more anisotropic elements arranged between the two or more structural elements, wherein the one or more anisotropic elements each comprise one or more anisotropic materials selected from the group consisting of: graphite, graphene, carbon nanotubes (CNTs), crystalline materials, cohesive powder and combinations thereof, wherein the temperature control element is configured to be in a heat transfer relationship with the electrochemical cell to heat and / or cool the electrochemical cell, wherein the temperature control element further comprises one or more tabs in electrical connection with the one or more anisotropic elements, wherein the one or more tabs each comprise one or more made of copper, aluminum, nickel, nickel-plated copper, stainless steel and aluminum alloys. [2] Temperature control element according to claim 1, wherein the one or more tabs define one or more tab layers, wherein a first tab layer is arranged between the one or more anisotropic elements and a first structural element of the two or more structural elements, and a second tab layer is arranged between the one or more anisotropic elements and a second structural element of the two or more structural elements, and wherein each tab layer of the one or of the multiple tab layers comprises a first part located at a first terminal end and a second part located at a second terminal end separated from the first terminal end, such that a gap is defined in a central region between the first part and the second part of each tab layer of the one or of the multiple tab layers. [3] Temperature control element according to claim 1, wherein the one or more anisotropic elements and the one or more tabs form a heating element. [4] Tempering element according to claim 1, wherein the two or more structural elements each comprise one or more of mica, asbestos, marble, porcelain, glass, shellac, resin, rubber, cotton yarn, paper, linen, rayon and plastic. [5] Temperature control element according to claim 4, wherein at least one of the two or more structural elements further comprises one or more adhesives selected from the group consisting of: polyethylene terephthalate (PET), polypropylene (PP), polyethylene (PE), polytetrafluoroethylene (PTFE) and combinations thereof. [6] Temperature control element according to claim 1, wherein the two or more structural elements are first structural elements and the temperature control element further comprises one or more second structural elements arranged between adjacent anisotropic elements. [7] Temperature control element according to claim 1, wherein the one or more anisotropic elements define one or more films with a plurality of folds and wherein the temperature control element further comprises one or more insulating materials and the one or more insulating materials are arranged between the folds of the one or more films defining the one or more anisotropic elements. [8] Tempering element according to claim 1, wherein the one or more anisotropic elements comprise a first grouping of anisotropic elements comprising one or more first anisotropic materials and a second grouping of anisotropic elements comprising one or more second anisotropic materials, wherein each of the first and second groupings of anisotropic elements is controlled independently. [9] Temperature control element according to claim 8, wherein the two or more structural elements are one or more first structural elements and the temperature control element further comprises one or more second structural elements arranged between the first grouping of anisotropic elements and the second grouping of anisotropic elements.

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