Structure for thermal insulation and conduction

Abstract

Battery module comprising: a support frame with a pair of opposing cavities for receiving batteries; a central separator area between the pair of opposing cavities; and a thermal insulation layer included within the central separator area.

Description

Technical FieldThe present disclosure relates generally to materials and systems for preventing or containing thermal events, such as thermal runaway, in energy storage systems. In particular, the present invention provides materials for thermal barriers. The present disclosure further relates to a battery module(s) having one or more battery cells and including the thermal barrier materials, and systems including these battery modules or packs. Examples that are generally described may include aerogel materials.General State of the ArtLithium ion batteries (LIBs) are frequently used for the power supply of portable electronic devices such as mobile phones, tablets, laptops, power tools and other high-power devices such as electric vehicles because of their high working voltage, low memory effects and high energy density compared to conventional batteries. Safety is a problem, however, because LIBs are susceptible to total failures under "abuse conditions", such as when a rechargeable battery is overcharged (charged beyond the intended voltage), overdischarged, operated at, or exposed to, high temperatures and high pressure. To prevent the occurrence of thermal runaway chain reactions, efficient isolation and heat dissipation strategies are needed to address this and other technical challenges of LIB.Brief Description of the DrawingsFIG. 1 shows a battery system according to some example aspects. FIG. 2 shows a side view of a battery module according to some example aspects. FIG. 3 shows another battery module according to some example aspects. FIG. 4 shows another battery module according to some example aspects. FIG. 5A illustrates a battery module according to some example aspects. FIG. 5B shows a battery module according to some example aspects. FIG. 5C illustrates a battery module according to some example aspects. FIG. 6 shows another battery module according to some example aspects. FIG. 7A illustrates another battery module according to some example aspects. FIG. 7B shows another battery module according to some example aspects. FIG. 8 shows another battery module according to some example aspects. FIG. 9 shows a portion of a separator according to some example aspects. FIG. 10 shows another portion of a separator according to some example aspects. FIG. 11 illustrates an electronic device according to some example aspects. FIG. 12 shows an electric vehicle according to some example aspects.DESCRIPTION OF ASPECTSThe following description and drawings illustrate specific aspects sufficient to enable those skilled in the art to practice the same. Other aspects may involve structural, logical, electrical, process and other changes. Portions and features of some aspects may be included or replaced in those other aspects. Aspects set forth in the claims include all available equivalents of those claims.Insulating materials as described in Examples below may be used as a single heat resistant layer or in combination with other layers that provide additional function to a multi-layer configuration, such as mechanical strength, compressibility, heat dissipation / conduction, etc. Insulation layers described herein are responsible for reliably holding and controlling heat flows from heat-generating parts in small spaces and for providing safety and preventing fire propagation for such products in the field of electronic, industrial and automotive engineering.In many aspects of the present disclosure, the insulation layer functions as a flame / fire resistant layer, either alone or in combination with other materials that improve performance in restricting and controlling heat flow. For example, the insulation layer itself may be resistant to flames and / or hot gases and may further contain entrained particulate materials that modify or enhance heat control.Thermal Barrier Insulating MaterialsAn example of a high-efficiency insulation layer includes an aerogel. Aerogels, by virtue of their structure, describe a class of materials, namely low density, open cell structures, large surfaces (often 900 m 2 / g or higher) and pore sizes in the sub-nanometer range. The pores may be filled with gases such as air. Aerogels may differ from other porous materials in their physical and structural properties. Although an aerogel material is an exemplary insulating material, the invention is not limited thereto. Other thermal insulation material layers may also be used in aspects of the present disclosure.Selected examples of aerogel formation and properties are described. In several examples, a precursor material is gelled to form a network of pores filled with solvent. The solvent is then extracted and a porous matrix remains. A variety of aerogel compositions are known, which can be inorganic, organic and inorganic / organic hybrids. Inorganic aerogels are generally based on metal alkoxides and include materials such as silica, zirconia, alumina and other oxides. Organic aerogels include, but are not limited to, urethane aerogels, resorcinol-formaldehyde aerogels, and polyimide aerogels.Inorganic aerogels may be formed from metal oxide or metal alkoxide materials. The metal oxide or metal alkoxide materials may be based on oxides or alkoxides of any metal that can form oxides. Such metals include, but are not limited to, silicon, aluminum, titanium, zirconium, hafnium, yttrium, vanadium, cerium, and the like. Inorganic silica aerogels are traditionally made by hydrolysis and condensation of silica-based alkoxides (such as tetraethoxysilane) or by gelling silica or water glass. Other relevant inorganic precursor materials for silica-based aerogel synthesis include, but are not limited to, metal silicates such as sodium or potassium silicate, alkoxysilanes, partially hydrolyzed alkoxysilanes, tetraethoxysilane (TEOS), partially hydrolyzed TEOS, condensed polymers of TEOS, tetramethoxysilane (TMOS), partially hydrolyzed TMOS, condensed polymers of TMOS, tetra-n-propoxysilane, partially hydrolyzed and / or condensed polymers of tetra-n-propoxysilane, polyethyl silicates, partially hydrolyzed polyethy silicates, monomeric alkylalkoxysilanes, bistrialkoxyalkyl- or arylsilanes, polyhedral silasesquioxanes, or combinations thereof.In certain aspects of the present disclosure, prehydrolysed TEOS, such as Silbond H-5 (SBH5, Silbond Corp), hydrolyzed at a water / silica ratio of about 1.9-2 may be used as commercially available or further hydrolyzed prior to incorporation into the gelling process. Partially hydrolyzed TEOS or TMOS, such as polyethysilicate (Silbond 40) or polymethylsilicate, may also be used as commercially available or may be further hydrolyzed prior to incorporation into the gelling process.The 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 may impart or improve certain properties such as stability and hydrophobicity to the gel. Inorganic silica aerogels may in particular contain hydrophobic precursors such as alkylsilanes or arylsilanes. As primary precursor materials, hydrophobic gel precursors may be used to form the framework of a gel material. More often, however, hydrophobic gel precursors are used as co-precursors in combination with simple metal alkoxides in the formation of amalgam aerogels. Hydrophobic inorganic precursor materials for silica-based aerogel synthesis include, but are not limited to, trimethyldimethoxysilane (TMS), dimethyldimethoxysilane (DMS), methyltrimethoxysilane (MTMS), trimethylethoxysilane, dimethyldiethoxysilane (DMDS), methyltriethoxysilane (MTES), ethyltriethoxysilane (ETES), diethyldiethoxysilane, dimethyldiethoxysilane (DMDS), ethyltriethoxysilane, propyltrimethoxysilane, propyltriethoxysilane, phenyltrimethoxysilane, phenyltriethoxysilane (PhTES), hexamethyldisilazane and hexaethyldisilazane, and the like. Any derivatives of any of the above precursors may be used, and specifically certain polymeric or other chemical groups may be added to or cross-linked to one or more of the above precursors.Organic aerogels are generally formed from carbon-based polymeric precursors. Such polymeric materials include, but are not limited to, resorcinol formaldehyde (RF), polyimide, polyacrylate, polymethyl methacrylate, acrylate oligomers, polyoxyalkylene, polyurethane, polyphenol, polybutadian, trialkoxysilyl terminated polydimethylsiloxane, polystyrene, polyacrylonitrile, polyfurfural, melamine formaldehyde, cresol formaldehyde, phenol furfural, polyether, polyol, polyisocyanate, polyhydroxybenzene, polyvinyl alcohol dialdehyde, polycyanurates, polyacrylamides, various epoxides, agar, agarose, chitosan, and combinations thereof. For example, organic RF aerogels are typically prepared by the sol-gel polymerization of resorcinol or melamine with formaldehyde under alkaline conditions.Organic / inorganic hybrid aerogels consist mainly of (organically modified) silicon dioxide ("ormosil") aerogels. These ormosil materials include organic components covalently bonded to a silica network. The formation of ormosils is typically effected by hydrolysis and condensation of organically modified silanes, R--Si(OX) 3, with conventional alcoholate precursors, Y(OX) 4. In these formulas, X may be, for example, CH 3, C 2 H 5, C 3 H 7, C 4 H 9 Y may be, for example, Si, Ti, Zr, or Al; and R may be any organic fragment such as methyl, ethyl, propyl, butyl, isopropyl, methacrylate, acrylate, vinyl, epoxy, and the like. The organic components in ormosil aerogel may also be dispersed or chemically bonded throughout the silica network.Aerogels may be formed from flexible gel precursors. Various flexible layers, including flexible fiber reinforced aerogels, can be readily combined and formed into preforms which upon mechanical compression along one or more axes yield compression resistant bodies along any of these axes.One method of aerogel formation includes batch casting. Batch casting involves catalyzing an entire volume of sol to simultaneously induce gelation in that entire volume. Gelling techniques involve adjusting the pH and / or temperature of a diluted metal oxide sol to a point where gelation occurs. Suitable materials for forming inorganic aerogels include oxides of most metals that can form oxides, such as silicon, aluminum, titanium, zirconium, hafnium, yttrium, vanadium, and the like. Especially preferred, due to their ready availability and low cost, are gels formed predominantly from alcohol solutions of hydrolyzed silicate esters (alkogel). Organic aerogels may also be made from melamine formaldehyde, resorcinol formaldehyde, and the like.As mentioned above, an aerogel may be organic, inorganic, or a mixture thereof. In some examples, the aerogel includes a silica-based aerogel. One or more layers in a thermal barrier may include a reinforcing material. The reinforcement material may be any material that imparts elasticity, conformability, or structural stability to the aerogel material. Examples of reinforcement materials include, but are not limited to, open cell macroporous scaffold reinforcement materials, closed cell macroporous scaffold reinforcement materials, open cell membranes, honeycomb reinforcement materials, polymeric reinforcement materials, and fiber reinforcement materials such as discrete fibers, fabrics, nonwovens, needled nonwovens, batts, braids, mats, and felts.The reinforcing material may be selected from organic polymer-based fibers, inorganic fibers, carbon-based fibers, or a combination thereof. The inorganic fibers are selected from glass fibers, rock fibers, metal fibers, boron fibers, ceramic fibers, basalt fibers, or combinations thereof. In some examples, the reinforcement material may include a reinforcement including a plurality of material layers.Overview of Carrier Frame StructuresIn some aspects, the structures described herein provide numerous advantages for the assembly and operation of battery packs. In some aspects, the use of a support frame as described below may provide a dimensionally stable and durable frame for receiving battery cells, particularly pouch cells, having a flexible outer structure containing the electrochemically active materials. This type of structure enables modern manufacturing techniques and also precise dimensions of the battery pack and its components. In some aspects, the support frame itself, a central separator therein, and / or other structures improve the operation and safety of battery packs by providing effective thermal management. As used herein, thermal management may include one or more of: cooling (e.g., by conduction, convection, forced, or passive cooling) and insulation.In addition to thermal insulation layers, in some aspects, thermally conductive layers in combination with thermal insulation layers are effective to conduct undesired heat to a desired external location, such as external heat dissipation fins, a heat dissipating housing, or other external structure to dissipate undesired heat to external ambient air. In one example, one or more thermally conductive layers assist in dissipating heat from a localized thermal load within a battery module or pack. Examples of high thermal conductivity materials include carbon fiber, graphite, silicon carbide, metals including, but not limited to, copper, stainless steel, aluminum, and the like, and combinations thereof.To assist in the distribution and dissipation of heat, in at least one aspect, the thermally conductive layer is coupled to a heat sink. It should be appreciated that there are a variety of heat sink types and configurations, as well as various techniques for coupling the heat sink to the thermally conductive layer, and that the present disclosure is not limited to the use of any one type of heat sink / coupling technique. For example, at least one thermally conductive layer of the multilayer materials disclosed herein may be in thermal communication with an element of a cooling system of a battery module or pack, such as a cooling plate or a cooling channel of the cooling system. As another example, at least one thermally conductive layer of the multilayer materials disclosed herein may be in thermal communication with other elements of the battery pack, battery module, or battery system that may function as a heat sink, such as the walls of the pack, module, or system, or with other of the multilayer materials disposed between battery cells. Thermal bonding between the thermally conductive layer of the multi-layer materials and the heat sink elements within the battery system may allow excess heat to be dissipated from the one or more cells located adjacent to the multi-layer material to the heat sink, thereby reducing the effect, severity, or spread of a thermal event that may generate excess heat.Illustrations and Aspects of Carrier Frame StructuresFIG. 1 shows an example of a battery system 100. The system 100 includes one or more battery modules 102. In the example of FIG. 1, each module includes a carrier frame and two batteries, as indicated by dashed square 106. On one side of the system 100, a heat sink 104 is shown in thermal communication with the battery modules 102.FIG. 2 shows a cross-section of a portion of a battery module 200 similar to the battery module 102 in dashed square 106 of FIG. 1 The battery module 200 includes a carrier frame 202, a central separator 208, a first battery 210, and a second battery 212 as shown.In some aspects, the support frame 202 provides, in some aspects, physical confinement for pouch cells having a flexible outer surface. The flexible outer surface of the pouch cell presents a challenge in assembly, without a limiting structure, that is overcome by the aspects described herein.The support frame 202 may also provide additional advantages, such as managing thermal conditions within a battery pack. These include, among other things, preventing a cell from heating other cells in a module and also providing conduction paths for dissipating excess heat generated by the batteries, among other advantages described below.In some aspects, the carrier frame 202 includes a first cavity 204 and a second cavity 206. The first cavity 204 and the second cavity 206 may be disposed on opposite sides of the central separator 208 in some aspects. In this way, the first cavity 204 and the second cavity 206 may be configured and sized (e.g., based on the dimensions of the central separator 208 and other features of the support frame 202) to receive the first battery 210 and the second battery 212.In some aspects, the first battery 210 and the second battery 212 are shown disposed at least partially within a first cavity 204 and the second cavity 206. In one example, the batteries 210, 210 are lithium ion pouch cells, although the invention is not so limited. While lithium ion pouch cells are frequently used in battery modules for electric vehicles, other examples of batteries that may be supported by the support frame 202 (e.g., by dimensioning and configuring the structure defining the first cavity 204 and the second cavity 206) include, but are not limited to, prismatic cells and cylindrical cells.FIG. 3 shows a battery module 300 similar to the battery module 102 of FIG. 1. The module 300 includes a support frame 302, a first cell 310 in a corresponding first cavity, a second cell 312 in a corresponding second cavity, a central separator 320, a thermal insulation layer 322, a first metal plate 324, a second metal plate 326, a first heat sink 330, and a second heat sink 332.Generally speaking, the battery module 300 uses conductive materials (e.g., metals, graphite) as the support frame 302. Conductive materials may also be used in some components of the central separator 320 and the heat sinks 330, 332 to conduct heat away from the cells 310, 312 and into the heat sinks 330, 332. The inclusion of the thermal barrier layer 322 provides some level of security in the event of thermal runaway in one or more of the cells 310, 312 by reducing heat transfer between adjacent cells. At the same time, the thermal conduction from the opposing metal plates 324 and 326 and the support frame 302 helps to cool the cells 310, 312. In this way, the central separator 320 provides both cooling to improve battery performance and safety through the thermal insulation layer 322.As described above, the support frame 302 and the central separator 320 are sized and configured to define the first cavity and the second cavity, both of which are occupied by corresponding first and second cells 310, 312 in FIG. 3. The description of the support frame, the central separator, and the first and second cavities, as well as other features discussed above, applies equally to the corresponding features in the module 300.In some aspects, as described above, the first cell 310 and the second cell 312 are respectively disposed within the first cavity and the second cavity.In some aspects, the central separator 320 functions as a heat sink and heat transfer barrier, thereby conducting heat away from hot spots within a cell and preventing the undesired transfer of heat from one cell to another. By either or both of these mechanisms, the central separator 320 prevents the propagation of thermal events from one cell to another. In some aspects, the central separator 320 may have sufficient mechanical integrity to resist the destructive effects of ejection material from a cell (e.g., cell 310, 312) upon thermal runaway (for 30 seconds, for 1 minute, for 5 minutes), thereby preventing the ejection material from damaging and / or igniting an adjacent cell.In one aspect, the central separator 320 of the module 300 is a multi-component structure. Aspects where a central separator 320 is made from multiple layers can more efficiently achieve multiple design objectives than single layer configurations. For example, because the central separator 320 includes a thermal insulation layer 322 disposed between opposing metal plates 324 and 326, the central separator 320 may prevent the undesired transfer of heat between cells, facilitate the conductive transfer of heat from one or more cells to a heat sink, and provide additional protection to the cells from the harmful effect of ejection material of an adjacent cell that results in a thermal runaway.In some aspects, the thermal insulation layer 322 has a low thermal conductivity (e.g., on the order of 40 milliwatts / meter-kelvin) to prevent undesired heat transfer between adjacent cells. In some aspects, the thermal insulation layer 322 may be made of an aerogel material and / or a reinforced aerogel material. Other thermal insulation materials also fall within the scope of the invention including, but not limited to, ceramic (woven and / or non-woven) fiber materials, polymeric materials (e.g., oxidized polyacrylonitrile (O-PAN), (woven and / or non-woven) glass fibers.In some aspects, opposing metal plates 324 and 326 may be made of a known thermal conductor. In some aspects, the opposing metal plates 324, 326 may have a thermal conductivity of at least 50 watts / meter Kelvin. In some aspects, the opposing metal plates 324, 326 may be made of metals including, but not limited to, aluminum, copper, steel, or any other known thermal conductor. In some aspects, opposing metal plates 324 and 326 may include graphite plates, graphite or carbon coated metal plates, polymeric plates filled with metallic or conductive particles and / or metallic or conductive fibers, or other analogous composites.As stated above, one aspect of the metal plates 324, 326 is to dissipate heat from the cells. In some aspects, the first heat sink 330 and the second heat sink 332 are shown in thermal contact with the support frame 302, and more specifically, with the metal plates 324, 326 of the central separator 320. In this way, the heat generated in the cells 310, 312 may be transferred to one or more heat sinks 330, 332, thereby reducing the likelihood of thermal runaway in one or more of the cells 310, 312.FIG. 4 shows a battery system 400 similar to the battery system 100 of FIG. 1 and similar to the battery module 300 of FIG. 3. As with one or both of these previously described examples, the system 400 includes a first cell 410, a second cell 412, a support frame 402, and a central separator 420, and a heat sink 430.Analogous to the example described above, the system 400 includes a first cavity and a second opposing cavity, similar to aspects described above. As in FIG. 3, these two cavities are occupied by corresponding cells 410, 412 and are not visible in the view shown in FIG. 4.In some aspects, each of the modules described herein may include a single heat sink, as illustrated in FIG. 4. The single heat sink 430 is in thermal communication with "L" shaped metal plates 424, 426 that provide a conduction path that dissipates heat generated by the cells 410, 412.In some aspects, any of the modules described herein may alter the insulating properties of the central separator 420 by including one or more air gaps 428, 429 adjacent to the thermal insulation layer 422 as shown in FIG. 4. Thus, in this configuration (any one or more aspects thereof may be combined with any other module described herein), the central separator 420 includes an insulating layer 422 with opposing major surfaces at least partially exposed by a corresponding air gap 428, 429. The air gaps 428, 429 are at least partially defined by the insulation layer 422 on one side and a portion of the "L-shaped" metal plates 424, 426 on another side.In one embodiment, the central separator 420 is part of (i.e., integrally formed with, attached to, mounted on) the support frame 402. The support frame 402 may be an assembly of the metal plates 424, 426 and optionally the central separator 420. The central separator 420 in FIG. 4 includes a thermal insulation layer 422 included between opposing metal plates 424 and 426. The foregoing descriptions of the materials used to make the thermal insulation layer and metal plates apply equally to the analogous elements in Figure 4.The central separator 420 further includes one or more air gaps 428, 429 between the thermal insulation layer 422 and the opposing metal plates 424 and 426. The inclusion of one or more air gaps 428, 429 provides improved thermal insulation between the first cell 410 and the second cell 412, while still providing thermal conduction through the opposing metal plates 424 and 426 and the support frame 402 to a heat sink 430. In this way, the configuration of the central separator 420 shown in FIG. 4 (and therefore the system 400 as a whole) may provide additional thermal insulation between adjacent cells, thereby reducing heat transfer between adjacent cells and thus reducing the risk of thermal runaway of a cell causing thermal runaway in an adjacent cell.FIG. 5A shows a side view of a portion of a battery module 520 similar to the battery modules described above. The module 520 includes a battery 522 and a central separator 521, first fins 526, second fins 527. The central separator 521 consists (at least partially) of a thermal insulation element 524 and a printed circuit board 530.Those of ordinary skill in the art having the benefit of the present disclosure will appreciate that the central separator 521 may be included between two batteries in a module as shown in FIGS. 3 and 4, although the invention is not so limited. In one example, the thermal insulation 422 includes an aerogel material. Other thermal insulation materials are also within the scope of the invention.In one example, one or more fins 526 are included in the circuit board 530. In some aspects, the one or more fins 526 are integrally formed with the circuit board 530, whether formed from the circuit board itself 530 or separately formed and later mounted on the circuit board 530. Regardless of the continuity and / or connection between the circuit board 530 and the one or more fins 526, these two components are associated with one another such that thermal energy ("heat") can be transferred from one to the other.In one example, the fins 526 are part of a regular patterned pattern. In one example, the sipes 526 are part of an irregular structured pattern. For example, as illustrated in FIG. 5B, a second sipe 527 has a different size and shape than sipe 526 as indicated by the respective dimensions (e.g., sipe height) β and α. In one aspect, β is greater than α. In one aspect, β and α are each less than a thickness γ of the circuit board 530.FIG. 5C further shows a top view 500 of the circuit board 530 and the fins 526, 527. In the example of FIG. 5C, the patterned pattern includes a longitudinal orientation indicated by arrows 504, which, in operation, preferentially directs heat toward a heat sink, such as the heat sink described in FIGS. 3 and 4. In one example, the longitudinal orientation is perpendicular to the largest surface area of the heat sink. In one example, coolant in the form of a liquid or gas, such as air, may be used to flow through the fins 526 to provide additional cooling capacity. In one example, the circuit board 530 and the patterned pattern are concentrated or disposed only over known hotspots on batteries in a module. In one example, the patterned pattern is anisotropic and concentrates heat dissipation from known hotspots to batteries in a module. In other examples, the circuit board 530 and the patterned pattern cover an entire area adjacent to a battery in a module.FIG. 6 shows a side view of a portion of a battery module 620. The module 620 includes a battery 622 and a central separator 621. One of ordinary skill in the art having the benefit of the present disclosure will appreciate that the central separator 621 may be included between two batteries in a module as shown in FIGS. 3, 4, and 5A, although the invention is not so limited. The central separator 621 includes a circuit board 630 having a patterned pattern. In the example of FIG. 6, the patterned pattern includes fins 626 and gaps 624.FIG. 6 also shows a top view 600 of the circuit board 630 and the lamellae 626. The circuit board 630 is shown in thermal communication with a heat sink 602. In the example of FIG. 6, the patterned pattern includes a longitudinal orientation indicated by arrows 604, which, in operation, preferentially conducts heat toward the heat sink 602.FIG. 7A shows a battery module 700 similar to the battery module 102 of FIG. 1. The module 700 includes a first battery 710 and a second battery 712. A central separator 711 is shown between the first battery 710 and the second battery 712. In one example, the central separator 711 may be used as part of a support frame, similar to other described examples. The central separator 711 includes opposing metal plates 702, 704 with a thermal insulation layer 708 between the opposing metal plates 702, 704. In an example, the thermal insulation 708 includes an aerogel material. Other thermal insulation materials are also within the scope of the invention. A number of fins 706 are shown as part of a patterned pattern on the opposing metal plates 702, 704. Fins 706 may be oriented as described in the above examples to preferentially conduct heat toward a heat sink, such as the heat sink described in FIGS. 3 and 4, during operation.The fins 706 in FIG. 7A are offset from each other to provide a larger compression range of the thermal insulation layer without contact between the patterned patterns. In operation, the batteries 712, 712 may expand and require space for them. In one example, the thermal insulation layer 708 is elastic and can compress and expand as needed as the opposing metal plates 702, 704 flex to accommodate expansion and contraction. The offset of the fins allows additional expansion and contraction while still conducting heat to a heat sink as described.FIG. 7B shows a battery module 720 similar to the battery module 102 of FIG. 1. The module 720 includes a first battery 722 and a second battery 724. A central separator 721 is shown between the first battery 722 and the second battery 724. In one example, the central separator 721 may be used as part of a support frame, similar to other described examples.In the example of FIG. 7B, opposing metal plates are omitted and only a number of fins 726 are used to conduct heat to a heat sink during operation. A thermal insulation 728 is shown between the structured pattern of the fins 726. In an example, the thermal insulation 708 includes an aerogel material. Other thermal insulation materials are also within the scope of the invention. As shown in FIGS. 7A, 7B, and 5A, 5B, 5C, in selected examples, thermal insulation is incorporated into the patterned pattern. Similar to the example of FIG. 7A, the fins 726 in FIG. 7B are offset from each other to provide a greater compression range of the thermal insulation layer without contact between the patterned patterns.FIG. 8 shows a side view of a portion of a battery module 820 similar to the battery module 102 of FIG. 1. the module 820 includes a battery 822 and a central separator 821. One of ordinary skill in the art having the benefit of the present disclosure will appreciate that the central separator 821 may be included between two batteries in a module as shown in other examples, although the invention is not so limited. The central separator 821 includes a circuit board 830 having a patterned pattern. In the example of FIG. 8, the patterned pattern includes fins 826 and gaps 824. In the example of FIG. 8, a thermal insulation 825 is shown between the structured pattern of the lamellae 826. In one example, the thermal insulator 825 includes an aerogel material. Other thermal insulation materials are also within the scope of the invention. The thermal insulation 825 inserts itself into the structured pattern.FIG. 8 further shows a top view 800 of the circuit board 830 and the lamellae 826. The circuit board 830 is shown in thermal communication with a heat sink 802. In the example of FIG. 8, the patterned pattern includes a longitudinal orientation similar to the orientations described in other examples, which preferentially directs heat toward the heat sink 802 during operation.FIGS. 9 and 10 show further examples of structured patterns that may be used as components of the described central separators. FIG. 9 shows a side view of a portion of a battery module 920. FIG. 9 further shows a top view 900 of a circuit board 902 having a number of fins 904. In the example of FIG. 9, the number of fins 904 includes rounded tops. FIG. 10 shows a side view of a portion of a battery module 1020. FIG. 10 further shows a top view 1000 of a circuit board 1002 having a number of cavities 1004. In FIG. 10, a circuit board 1002 is shown having a number of cavities 1004 forming a patterned pattern. In one example, patterned patterns as described provide additional expansion and contraction with a central separator to enable expansion and contraction of the battery.Battery modules as described above are used in a variety of electronic devices. FIG. 11 illustrates an example electronic device 1100 that includes a battery module 1110. The battery module 1110 is coupled to functional electronics 1120 via a circuit 1112. In the example shown, the battery module 1110 and the circuit 1112 are contained within a housing 1102. A charging port 1114 is shown coupled to the battery module 1110 to enable recharging of the battery module 1110 when needed.In an example, the functional electronics 1120 include devices such as semiconductor devices with transistors and memory circuits. Examples include, but are not limited to, telephones, computers, screens, navigation systems, etc.FIG. 12 illustrates another electronic system that utilizes battery modules that include multilayer thermal barriers as described above. In FIG. 12, an electric vehicle 1200 is illustrated. The electric vehicle 1200 includes a chassis 1202 and wheels 1232. In the example shown, each wheel 1232 is coupled to a drive motor 1220. A battery module 1210 is shown coupled to the drive motors 1220 by the circuit 1206. A charging port 1204 is shown coupled to the battery module 1210 to enable recharging of the battery module 1210 when needed.Examples of electric vehicles 1200 include, but are not limited to, consumer vehicles such as cars, trucks, etc. Commercial vehicles such as tractors and semi-trailers are also within the scope of the invention. Although a four-wheel vehicle is shown, the invention is not limited thereto. For example, two-wheel vehicles such as motorcycle and scooter also fall within the scope of the invention.For a better illustration of the devices disclosed herein, a non-limiting list of aspects is provided herein:Example 1 includes a battery module. The module includes a support frame having a pair of opposing cavities for receiving batteries, a central separator region between the pair of opposing cavities, and a thermal insulation layer included within the central separator region.Example 2 includes the battery module of example 1, wherein the thermal insulation layer includes an aerogel material.Example 3 includes the battery module of any of Examples 1-2, wherein the central separator includes opposing metal plates with the thermal insulation layer between the opposing metal plates.Example 4 includes the battery module of any of Examples 1-3, wherein the thermal insulation layer is elastic and wherein the opposing metal plates are flexible.Example 5 includes the battery module of any of Examples 1-4, further including an air gap between the thermal insulation layer and the central separator region.Example 6 includes the battery module of any of Examples 1-5, wherein the support frame and the central separator region include metal.Example 7 includes the battery module of any of Examples 1-6, wherein the support frame and the central separator region are a one-piece metal casting.Example 8 includes a battery module. The module includes a support frame having a pair of opposing cavities, a pair of pouch batteries in the pair of opposing cavities, a central separator between the pair of opposing cavities, the central separator including a patterned pattern in one or more opposing major surfaces of the central separator, and a thermal insulation layer included between the pair of opposing cavities.Example 9 includes the battery module of example 8, wherein the patterned pattern includes fins.Example 10 includes the battery module of any of Examples 8-9, wherein the fins include rounded tops.Example 11 includes the battery module of any of Examples 8-10, wherein the patterned pattern includes an array of circular voids.Example 12 includes the battery module of any of Examples 8-11, wherein the thermal insulation layer inserts into the patterned pattern.Example 13 includes the battery module of any of Examples 8-12, further including a heat sink in thermal communication with a side of the support frame, and wherein the patterned pattern includes a longitudinal orientation that preferentially directs heat towards the heat sink during operation.Example 14 includes the battery module of any of Examples 8-13, wherein the thermal insulation layer includes an aerogel material.Example 15 includes the battery module of any of Examples 8-14, wherein the central separator includes opposing metal plates with the thermal insulation layer between the opposing metal plates.Example 16 includes the battery module of any of Examples 8-15, wherein the patterned pattern is included on inner surfaces of each of the opposing metal plates.Example 17 includes the battery module of any of Examples 8-16, wherein the patterned pattern on each of the opposing metal plates is offset from one another to provide a greater compression range of the thermal insulation layer without contact between the patterned patterns.Example 18 includes the battery module of any of Examples 8-17, wherein the thermal insulation layer inserts into the patterned pattern on each of the opposing metal plates.The foregoing description is intended to be illustrative and not limiting. For example, the examples described above (or one or more aspects thereof) may be used in combination with each other. Other aspects may be used, such as by one of ordinary skill in the art after review of the foregoing description. The Abstract is intended to allow the reader to quickly take an image of the nature of the technical disclosure. It is submitted in the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, various features may be summarized in the foregoing detailed description to further emphasize the disclosure. This is not to be interpreted as meaning that an unclaimed disclosed feature is essential to any claim. Rather, the inventive subject matter may lie in less than all features of a particular aspect disclosed. The following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a distinct aspect, and it is contemplated that these aspects may be combined in various combinations or permutations. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.Although an overview of the inventive subject matter has been described with reference to specific example aspects, various modifications and changes may be made to these aspects without departing from the broader scope of aspects of the present disclosure. Such aspects of the inventive subject matter may be referred to herein, individually or collectively, by the term "invention" for convenience without the scope of this application being intended to be intentionally limited to a single disclosure or concept of the invention if more than one(s) is actually disclosed.The aspects illustrated herein are described in sufficient detail to enable those skilled in the art to practice the teachings disclosed herein. Other aspects may be utilized and derived therefrom such that structural and logical substitutions and changes may be made without departing from the scope of this disclosure. The detailed description is therefore not to be taken in a limiting sense, and the scope of various aspects is defined only by the appended claims, along with all equivalents to which such claims are entitled.As used herein, the term "or" may be construed as either inclusive or exclusive. Additionally, multiple instances may be provided for resources, operations, or structures described herein as a single instance. Moreover, boundaries between various resources, operations, modules, engines, and data stores are somewhat arbitrary, and certain operations are depicted in a context of certain illustrative configurations. Other assignments of functionality are provided and may fall within the scope of various aspects of the present disclosure. In general, structures and functionalities represented as separate resources in the example configurations may be implemented as a combined structure or resource. Likewise, structures and functionalities represented as a single resource may be implemented as separate resources. These and other variations, modifications, additions and improvements are within the scope of the present disclosure as set forth in the appended claims. The specification and drawings are, accordingly, to be regarded in an illustrative and non-limiting sense.The foregoing description has been described for purposes of explanation with reference to certain example aspects. However, the foregoing illustrative discussions are not intended to be exhaustive or to limit the possible example aspects to the precise forms disclosed. Many modifications and variations are possible in light of the above teachings. The example aspects were chosen and described in order to best explain the principles involved and their practical application, to enable one skilled in the art to best utilize the various example aspects with various modifications as are suited to the particular application contemplated.It should be understood that although the terms "first," "second," etc. may be used herein to describe different elements, these elements are not intended to be limited by these terms. These terms are used only to distinguish one element from another. For example, a first contact could be referred to as a second contact, and likewise, a second contact could be referred to as a first contact, without departing from the scope of the present example aspects. The first contact and the second contact are each contacts, but they are not the same contact.The terminology used herein in the description of example aspects is for the purpose of describing specific examples only and is not intended to be limiting. As used herein in the description of the example aspects and the accompanying examples, the singular forms "a", "an" and "the / s" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It is also understood that the term "and / or" as used herein refers to and includes all possible combinations of one or more of the associated listed items. Further, it is understood that the terms "comprise" and / or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one / more other features, integers, steps, operations, elements, and / or components, and / or groups thereof.As used herein, the term "if" may be construed as "when" or "at", or "responsive to determining" or "responsive to detecting", depending on the context. Similarly, the phrase "when determined" or "when [a specified condition or event] is detected" may be understood to mean "upon determination that" or "in response to the determination" or "upon detection [of the specified condition or event]" or "in response to detection [of the specified condition or event]", depending on the context.

Claims

A battery module, comprising: a support frame having a pair of opposing cavities for receiving batteries; a central separator region between the pair of opposing cavities; and a thermal insulation layer included within the central separator region.The battery module of claim 1, wherein the thermal insulation layer includes an aerogel material.The battery module of claim 1, wherein the central separator region includes opposing metal plates with the thermal insulation layer between the opposing metal plates.The battery module according to claim 3, wherein the thermal insulation layer is elastic, and wherein the opposing metal plates are flexible.The battery module of claim 1, further comprising an air gap between the thermal insulation layer and the central separator region.The battery module of claim 1, wherein the support frame and the central separator region include metal.The battery module of claim 1, wherein the support frame and the central separator region are a one-piece metal casting.A battery module comprising: a support frame having a pair of opposing cavities; a pair of pouch batteries in the pair of opposing cavities; a central separator between the pair of opposing cavities, the central separator including a patterned pattern in one or more opposing major surfaces of the central separator; and a thermal insulation layer included between the pair of opposing cavities.The battery module of claim 8, wherein the patterned pattern includes fins.The battery module of claim 9, wherein the fins include rounded tops.The battery module of claim 8, wherein the patterned pattern includes an array of circular cavities.The battery module of claim 8, wherein the thermal insulation layer inserts into the patterned pattern.The battery module of claim 8, further comprising a heat sink in thermal communication with a side of the support frame, and wherein the patterned pattern comprises a longitudinal orientation that preferentially directs heat towards the heat sink during operation.The battery module of claim 8, wherein the thermal insulation layer includes an aerogel material.The battery module of claim 8, wherein the central separator includes opposing metal plates with the thermal insulation layer between the opposing metal plates.The battery module of claim 15, wherein the patterned pattern is included on inner surfaces of each of the opposing metal plates.The battery module of claim 16, wherein the patterned pattern on each of the opposing metal plates is offset from each other to provide a greater compression range of the thermal insulation layer without contact between the patterned patterns.The battery module of claim 17, wherein the thermal insulation layer inserts into the patterned pattern on each of the opposing metal plates.

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