Structural thermal barriers and methods

Abstract

A battery module and related methods are disclosed. In one example, the battery module includes a thermal isolation structure with a structural support plate and an aerogel layer. An example of the thermal isolation structure is shown including a module cover contact located on the top edge of the structural support plate.

Description

[Technical Field]

[0001] Priority claims This patent application claims priority to U.S. Provisional Patent Application No. 63 / 425,939, entitled "Structural Thermal Barriers and Methods," filed November 16, 2022, which is incorporated herein by reference in its entirety.

[0002] The present disclosure generally relates to materials, systems, and methods for preventing or mitigating thermal events, such as thermal runaway problems, in energy storage systems. In particular, the present disclosure provides thermal barrier materials. The present disclosure further relates to battery modules or packs having one or more battery cells that include the thermal barrier materials, as well as systems that include these battery modules or packs. The generally described embodiments may include aerogel materials. [Background technology]

[0003] Lithium-ion batteries (LIBs) are widely used in powering portable electronic devices such as mobile phones, tablets, laptops, power tools, and other high-current devices such as electric vehicles because of their high operating voltage, low memory effect, and high energy density compared to conventional batteries. However, safety concerns have arisen due to the susceptibility of LIBs to catastrophic failure under "abuse conditions," such as when rechargeable batteries are overcharged (charged beyond their design voltage), overdischarged, or operated or exposed to high temperatures and pressures. Summary of the Invention

[0004] Effective insulation and heat dissipation strategies are needed to address these and other technical challenges in LIBs to prevent the occurrence of cascading thermal runaway events. [Brief explanation of the drawings]

[0005] [Figure 1] 1 illustrates an isometric view of a battery module according to some embodiments. [Figure 2]2 shows a cross-sectional view of the battery module along line AA' of FIG. 1 according to some embodiments. [Figure 3] 1 illustrates selected portions of another battery module according to some embodiments. [Figure 4] 1 illustrates selected portions of another battery module according to some embodiments. [Figure 5A] 5 illustrates a cross-sectional view of a thermal isolation structure along line BB' of FIG. 4 according to some embodiments. [Figure 5B] 5 illustrates a cross-sectional view of a thermal isolation structure along line BB' of FIG. 4 according to some embodiments. [Figure 5C] 5 illustrates a cross-sectional view of a thermal isolation structure along line CC′ of FIG. 4 according to some embodiments. [Figure 5D] 5 illustrates a cross-sectional view of a thermal isolation structure along line CC′ of FIG. 4 according to some embodiments. [Figure 6] 4A illustrates a cross-sectional view of a selected portion 460 of the thermal isolation structure of FIG. 4 according to some embodiments. [Figure 7A] 1 illustrates an exploded view of an assembly of components of a thermal isolation structure according to some embodiments. [Figure 7B] 1 illustrates another exploded view of the assembly of components of a thermal isolation structure according to some embodiments. [Figure 8A] 1 illustrates an exploded view of components of a thermal isolation structure according to some embodiments. [Figure 8B] 8B illustrates the thermal isolation structure of FIG. 8A in an assembled state according to some embodiments. [Figure 9A] 1 illustrates an exploded view of components of a thermal isolation structure according to some embodiments. [Figure 9B] 9B illustrates the thermal isolation structure of FIG. 9A in an assembled state according to some embodiments. [Figure 10A] 1 illustrates a thermal isolation structure according to some embodiments. [Figure 10B] 1 illustrates another thermal isolation structure according to some embodiments. [Figure 10C] 1 illustrates another thermal isolation structure according to some embodiments. [Figure 11A] 1 illustrates components of a thermal isolation structure according to some embodiments. [Figure 11B] 1 illustrates components of a thermal isolation structure according to some embodiments. [Figure 11C] 1 illustrates assembled components of a thermal isolation structure according to some embodiments. [Figure 12A] 1 illustrates components of a thermal isolation structure according to some embodiments. [Figure 12B] 1 illustrates an isometric view of assembled components of a thermal isolation structure according to some embodiments. [Figure 12C] FIG. 12C illustrates an end view of the assembled components from FIG. 12B according to some embodiments. [Figure 13A] 1 illustrates selected components of a thermal isolation structure according to some embodiments. [Figure 13B] 1 illustrates an isometric view of assembled components of a thermal isolation structure according to some embodiments. [Figure 13C] FIG. 13C illustrates an end view of the assembled components from FIG. 13B according to some embodiments. [Figure 14A] 1 illustrates selected components of a thermal isolation structure according to some embodiments. [Figure 14B] 1 illustrates an isometric view of assembled components of a thermal isolation structure according to some embodiments. [Figure 14C] FIG. 14C illustrates an end view of the assembled components from FIG. 14B according to some embodiments. [Figure 14D] 14D shows a close-up view of the end of the assembled components within the dashed box of FIG. 14C according to some embodiments. [Figure 15A] 1 illustrates an exploded view of components of a thermal isolation structure according to some embodiments. [Figure 15B] 15B illustrates the thermal isolation structure of FIG. 15A in an assembled state according to some embodiments. [Figure 15C] 15B illustrates another embodiment of the thermal isolation structure of FIG. 15A in an assembled state including an additional component layer according to some embodiments. [Figure 16] 1 illustrates selected components of a thermal isolation structure according to some embodiments. [Figure 17A] 1 illustrates a thermal isolation structure according to some embodiments. [Figure 17B] 17B illustrates a cross-sectional view of a thermal isolation structure along line CC' of FIG. 17A according to some embodiments. [Figure 17C] 17C illustrates a selected portion of the thermal isolation structure within the dashed box of FIG. 17B according to some embodiments. [Figure 18] 1 illustrates a method of forming a battery module according to some embodiments. [Figure 19] 1 illustrates an electronic device according to some embodiments. [Figure 20] 1 illustrates an electric vehicle according to some embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0006] The following description and drawings sufficiently describe particular embodiments to enable those skilled in the art to practice them. Other embodiments may incorporate structural, logical, electrical, process, and other changes. Portions and features of some embodiments may be included in, or substituted for, portions and features of other embodiments. The claimed embodiments encompass all available equivalents of those claims.

[0007] The present disclosure is directed to an energy storage system including a plurality of battery cells and one or more thermal isolation structures disposed therebetween to prevent heat propagation and thermal runaway that may result in potential fire, overheating, combustion, or other problems associated with high temperatures within such battery modules.

[0008] The thermal isolation structure includes a structural support plate and one or more thermal isolation layers on a major surface of the structural support plate. The one or more thermal isolation layers prevent heat transfer between the battery cells, while the structural support plate provides mechanical support for the thermal isolation layers. The thermal isolation structure may further include an encapsulation film for encapsulating the one or more thermal isolation layers to prevent dust from entering the thermal isolation layers, a conductive layer for dissipating heat and preventing hot spots, and a module cover contact for positioning the thermal isolation structure within the battery module adjacent to the lid of the battery module housing.

[0009] Thermal isolation structures are discussed in detail below with respect to their materials, structure, components, and other relevant properties. Insulating, thermally conductive, elastic, and other materials, such as those described in the examples below, can be used in battery modules to compartmentalize individual battery cells or groups of battery cells within a battery device. Multiple battery cells bonded together are referred to as battery modules in this disclosure. However, the described devices and methods can be used with any of several types of multiple battery cell arrangements, which may be referred to as battery packs, battery systems, and the like.

[0010] thermal separation layer The thermal isolation layers described below can be used as the sole heat-resistant layer or in combination with other layers that provide additional functionality to the multi-layer construction, such as mechanical strength, compressibility, heat dissipation / conduction, etc. The thermal isolation layers described herein are responsible for ensuring containment and control of heat flow from heat-generating components in small spaces, providing safety and fire prevention for such products in the fields of electronics, industrial, and automotive technology.

[0011] In many embodiments of the present disclosure, the thermal isolation layer functions as a flame / fire deflector layer, either by itself or in combination with other materials that enhance its ability to contain and control heat flow. For example, the thermal isolation layer itself may be flame and / or hot gas resistant and may further include entrained particulate materials that modify or enhance heat containment and control. One aspect of a highly effective thermal isolation layer includes aerogels. Aerogels are characterized by their structure, i.e., low density, open cell structure, and large surface area (often over 900 m²).2 This paper describes a class of materials based on their pore sizes (e.g., pore sizes of 1 / g or more) and sub-nanometer scale. The pores may be filled with a gas, such as air. Aerogels can be distinguished from other porous materials by their physical and structural properties. Aerogel materials are exemplary insulating materials, but the invention is not limited thereto. Other thermal insulating material layers may also be used in the examples of this disclosure.

[0012] Selected examples of aerogel formation and properties are described below. In some examples, precursor materials are gelled to form a network of solvent-filled pores. The solvent is then extracted, leaving a porous matrix. A variety of different aerogel compositions are known, and they may 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.

[0013] Inorganic aerogels can generally be formed from metal oxide or metal alkoxide materials. The metal oxide or metal alkoxide materials can be based on the oxide or alkoxide of any metal capable of forming an oxide. 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 via the hydrolysis and condensation of silica-based alkoxides (e.g., tetraethoxysilane) or via the gelation of silicic acid or water glass. Other relevant inorganic precursor materials for silica-based aerogel synthesis include, but are not limited to, metal silicates such as sodium silicate or potassium silicate, alkoxysilanes, partially hydrolyzed alkoxysilanes, tetraethoxysilane (TEOS), partially hydrolyzed TEOS, condensation polymers of TEOS, tetramethoxysilane (TMOS), partially hydrolyzed TMOS, condensation polymers of TMOS, tetra-n-propoxysilane, partially hydrolyzed and / or condensation polymers of tetra-n-propoxysilane, polyethylsilicate, partially hydrolyzed polyethylsilicate, monomeric alkylalkoxysilanes, bis-trialkoxyalkyl or arylsilanes, polyhedral silsesquioxanes, or combinations thereof.

[0014] In certain embodiments of the present disclosure, prehydrolyzed TEOS, such as Silbond H-5 (SBH5, Silbond Corp), which is hydrolyzed to a water / silica ratio of about 1.9 to 2, may be used commercially or may be further hydrolyzed before being incorporated into the gelation process. Partially hydrolyzed TEOS or TMOS, such as polyethyl silicate (Silbond 40) or polymethyl silicate, may also be used commercially or may be further hydrolyzed before being incorporated into the gelation process.

[0015] Inorganic aerogels can also include gel precursors containing at least one hydrophobic group, such as alkyl metal alkoxides, cycloalkyl metal alkoxides, and aryl metal alkoxides, which can impart or improve certain properties to the gel, such as stability and hydrophobicity. Inorganic silica aerogels, specifically, can include hydrophobic precursors such as alkyl silanes or aryl silanes. The hydrophobic gel precursor may be used as the primary precursor material to form the framework of the gel material. However, hydrophobic gel precursors are more commonly used as co-precursors in combination with simple metal alkoxides to form amalgam aerogels. Hydrophobic inorganic precursor materials for silica-based aerogel synthesis include, but are not limited to, trimethylmethoxysilane (TMS), dimethyldimethoxysilane (DMS), methyltrimethoxysilane (MTMS), trimethylethoxysilane, dimethyldiethoxysilane (DMDS), methyltriethoxysilane (MTES), ethyltriethoxysilane (ETES), diethyldiethoxysilane, dimethyldiethoxysilane (DMDES), ethyltriethoxysilane, propyltrimethoxysilane, propyltriethoxysilane, phenyltrimethoxysilane, phenyltriethoxysilane (PhTES), hexamethyldisilazane, and hexaethyldisilazane. Any derivatives of any of the above precursors may also be used, particularly certain polymers of other chemical groups may be added to or crosslinked with one or more of the above precursors.

[0016] Organic aerogels are generally formed from carbon-based polymer precursors. Such polymeric materials include, but are not limited to, resorcinol formaldehyde (RF), polyimides, polyacrylates, polymethyl methacrylates, acrylate oligomers, polyoxyalkylenes, polyurethanes, polyphenols, polybutadienes, trialkoxysilyl-terminated polydimethylsiloxanes, polystyrenes, polyacrylonitriles, polyfurfural, melamine-formaldehyde, cresol formaldehyde, phenol-furfural, polyethers, polyols, polyisocyanates, polyhydroxybenzenes, polyvinyl alcohol dialdehyde, polycyanurates, polyacrylamides, various epoxies, agar, agarose, chitosan, and combinations thereof. As an example, organic RF aerogels are generally prepared from the sol-gel polymerization of resorcinol or melamine with formaldehyde under alkaline conditions.

[0017] Organic / inorganic hybrid aerogels are primarily composed of organically modified silica ("ormosil") aerogels. These ormosil materials contain organic components covalently bonded to the silica network. Ormosils are typically formed by the hydrolysis and condensation of an organically modified silane, R-Si(OX)3, with a conventional alkoxide precursor, Y(OX)4. In these formulas, X can represent, for example, CH3, CH5, CH7, or CH9; Y can represent, for example, Si, Ti, Zr, or Al; and R can be any organic fragment, such as methyl, ethyl, propyl, butyl, isopropyl, methacrylate, acrylate, vinyl, or epoxide. Additionally, the organic components in ormosil aerogels can be dispersed throughout the silica network or chemically bonded to it.

[0018] Aerogels can be formed from flexible gel precursors. Various flexible layers, including flexible fiber-reinforced aerogels, can be easily combined and shaped to obtain a preform that, when mechanically compressed along one or more axes, provides an object with high compressive strength along any of those axes.

[0019] One method of aerogel formation involves batch casting. Batch casting involves catalyzing an entire volume of sol to simultaneously induce gelation throughout that volume. Gel formation techniques involve adjusting the pH and / or temperature of a dilute metal oxide sol to a point where gelation occurs. Materials suitable for forming inorganic aerogels include oxides of most metals capable of forming oxides, such as silicon, aluminum, titanium, zirconium, hafnium, yttrium, and vanadium. Particularly preferred are gels formed primarily from alcoholic solutions of hydrolyzed silicate esters (alcogels) due to their ready availability and low cost. Organic aerogels can also be made from melamine formaldehyde, resorcinol formaldehyde, and the like.

[0020] In one example, the aerogel material may be monolithic or continuous throughout the structure or layer. In another example, the aerogel material may include a composite aerogel material having aerogel particles mixed with a binder. Other additives may be included in the composite aerogel material, including, but not limited to, surfactants that aid in the dispersion of the aerogel particles within the binder. The composite aerogel slurry may be applied to a support such as a mesh, felt, or web and then dried to form a composite aerogel structure.

[0021] Strengthening the thermal isolation layer The aerogel may be organic, inorganic, or a mixture thereof. In some examples, the aerogel includes silica-based aerogel. One or more layers within the thermal barrier may include a reinforcing material. The reinforcing material may be any material that provides resilience, compliance, or structural stability to the aerogel material. Examples of reinforcing materials include, but are not limited to, open-cell macroporous framework reinforcement materials, closed-cell macroporous framework reinforcement materials, open-cell membranes, honeycomb reinforcement materials, polymeric reinforcement materials, and fibrous reinforcement materials such as staple fibers, woven materials, nonwoven materials, needled nonwovens, battings, webs, mats, and felts.

[0022] Fiber reinforcement materials include polyester, polyolefin terephthalate, poly(ethylene) naphthalate, polycarbonate (e.g., rayon, nylon), cotton (e.g., Lycra manufactured by DuPont), carbon (e.g., graphite), polyacrylonitrile (PAN), oxidized PAN, pre-oxidized PAN, uncarbonized heat-treated PAN (e.g., manufactured by SGL Carbon), glass or glass fiber-based materials (e.g., S-glass, 901-glass, 902-glass, 475-glass, E-glass, etc.), silica-based fibers such as quartz (e.g., Quartz manufactured by Saint-Gobain), Q-felt (Johns Other fibers include polyamide fibers such as Manville (manufactured by Saffil), Durablanket (manufactured by Unifrax), Duraback (manufactured by Carborundum), Kevlar, Nomex, Sontera (all manufactured by DuPont), and Conex (manufactured by Taijin), polyolefins such as Tyvek (manufactured by DuPont), Dyneema (manufactured by DSM), and Spectra (manufactured by Honeywell), other polypropylene fibers such as Typar and Xavan (both manufactured by DuPont), fluoropolymers such as PTFE, which have trade names such as Teflon (manufactured by DuPont), Goretex (manufactured by WLGORE), and Nicalon (manufactured by COI). The range of materials may include, but are not limited to, silicon carbide fibers such as those manufactured by Epson Ceramics, ceramic fibers such as Nextel (manufactured by 3M), acrylic polymers, wool, silk, hemp, leather, suede fibers, PBO-Zylon fibers (manufactured by Tyobo), liquid crystal materials such as Vectan (manufactured by Hoechst), Cambrelle fibers (manufactured by DuPont), polyurethanes, polyamides, wood fibers, boron, aluminum, iron, stainless steel fibers, and other thermoplastics such as PEEK, PES, PEI, PEK, PPS, etc.

[0023] Glass or glass fiber-based fiber reinforced materials may be manufactured using one or more techniques. In certain embodiments, it is desirable to create them using a carding and cross-lapping or airlaid process. In exemplary embodiments, carded and cross-lapping glass or glass fiber-based fiber reinforced materials offer certain advantages over airlaid materials. In one embodiment, carded and cross-lapping glass or glass fiber-based fiber reinforced materials can provide a consistent material thickness for a given basis weight of the reinforced material. In certain additional embodiments, it is desirable to further needle the fiber reinforced material, which requires entanglement of the fibers in the z-direction to improve mechanical and other properties in the final aerogel composition.

[0024] structural support plate In addition to the thermal isolation layer, the structural support plate in combination with the thermal isolation layer is effective in protecting components adjacent to the battery stack (e.g., the passenger compartment of an electric vehicle) during a thermal runaway event. The structural support plate provides mechanical support for the thermal isolation layer. Furthermore, the structural support plate effectively protects the battery components and associated electrical devices from particle impact in a thermal runaway ejecta. Examples of rigid materials used in the structural support plate include, but are not limited to, mica, carbon fiber, graphite, silicon carbide, copper, stainless steel, aluminum, titanium, other metals, titanium alloys, other metal alloys, and combinations thereof.

[0025] Thermal Conduction Layer In addition to the thermal isolation layer, a thermally conductive layer in combination with the thermal isolation layer can be effective in directing unwanted heat to a desired external location, such as external heat dissipation fins, a heat dissipation enclosure, or other external structure for dissipating unwanted heat to the ambient air. In one example, one or more thermally conductive layers help dissipate heat from localized heat loads within a battery module or pack. Examples of highly thermally conductive materials include carbon fiber, carbon nanotubes, graphene, graphite, pyrolytic graphite sheets, silicon carbide, metals including, but not limited to, copper, stainless steel, aluminum, etc., as well as combinations thereof.

[0026] To aid in heat distribution and removal, in at least one embodiment, the thermally conductive layer is coupled to a heat sink. It is understood that there are various heat sink types and configurations, as well as different techniques for coupling the heat sink to the thermally conductive layer, and 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 material disclosed herein may be in thermal communication with an element of a battery module or pack's cooling system, such as a cold plate or cooling channel of the cooling system. In another example, the at least one thermally conductive layer may be in thermal communication with other elements of the battery pack, battery module, or battery system that can function as a heat sink, such as a wall of the pack, module, or system, or with other elements of the multilayer material disposed between battery cells. Thermal communication between the thermally conductive layer and the heat sink element within the battery system allows for the removal of excess heat from the cell(s) adjacent to the multilayer material to the heat sink, thereby reducing the impact, severity, or propagation of thermal events that may generate excess heat. In addition to removing heat, the thermally conductive layer may diffuse or dissipate heat from areas of high heat concentration to a larger area of ​​lower heat concentration.

[0027] In addition to the thermal insulating and thermally conductive layers, one or more elastic material layers may also be included adjacent to or between the cells. In one example, the elastic layer absorbs any volumetric expansion of one or more battery cells during normal operation. In one aspect, the cells may expand during charging and contract during discharging. In one example, the elastic layer may also absorb permanent volumetric expansion caused by degradation and / or thermal runaway of any of the battery cells. The elastic material layer may include, but is not limited to, foam, fiber, cloth, sponge, spring structure, rubber, polymer, etc.

[0028] Thermal isolation structure within the battery module FIG. 1 illustrates one embodiment of a battery module 100. The module 100 includes a stack of battery cells 102, also referred to hereinafter as cells. In one example, the stack of cells 102 includes lithium-ion cells 102. Several configurations of the lithium-ion cells 102 are possible. In one example, the stack of lithium-ion cells 102 includes lithium-ion pouch cells or prismatic cells, although the invention is not limited thereto. A heat sink 104 is shown located on the side of the battery module 100 and in thermal communication with the battery cells 102. In the embodiment of FIG. 1, the stack of battery cells 102 is located within a module housing 106. Further shown is a module cover 108 that encloses the stack of battery cells 102 within the module housing 106.

[0029] One or more thermal isolation structures 110 are shown between at least two cells in the stack of battery cells 102. In the embodiment of FIG. 1 , a thermal isolation structure 110 is included between each cell in the stack of battery cells 102, but the present invention is not so limited. In one example, a group of cells 102 is separated by one or more thermal isolation structures 110. The inclusion of one or more thermal isolation structures 110 provides an improved level of safety during a thermal runaway event in one or more of the cells 102. In the event of a thermal runaway event, the area affected by the destruction of a failed cell 102 is contained within the area between the thermal isolation structures 110 and / or the module housing 106. Improved thermal isolation structures 110 are desired to better isolate and protect adjacent areas within the battery module 100 during a thermal runaway event in one or more individual cells 102.

[0030] A heat sink 104 is shown in FIG. 1. Examples of the heat sink 104 include, but are not limited to, a passive heat sink, such as a metal plate, and an active heat sink, such as a fluid recirculation system that removes heat to a remote location. In the embodiment of FIG. 1, one or more thermal isolation structures 110 mate with the heat sink within a slot or other recess. In one example, the heat sink 104 is a separate component housed within the module housing 106. In one example, the heat sink 104 is integrated into the bottom surface of the module housing 106.

[0031] Figure 2 shows a cross-sectional view of the battery module 100 taken along line AA' in Figure 1. A thermal isolation structure 110 is shown including a structural support plate 112. The thermal isolation structure 110 also includes a module cover contact 114 located at an upper end of the structural support plate 112. A thermal isolation layer 118 is shown coupled to one side of the structural support plate 112. In the embodiment of Figure 2, a second thermal isolation layer 120 is shown coupled to the structural support plate 112 on the side opposite the thermal isolation layer 118.

[0032] As shown in FIG. 2 , at least some of the cells 102 are separated by a thermal isolation structure 110. A space 130 above the cells 102 within the module housing 106 and module cover 108 is shown. During a thermal runaway event, gas can be vented into the space 130 above the cells 102. In one example, the cells 102 include a vent (not shown) that directs gas specifically into the space 130. In such an event, it is desirable to contain the hot gas and prevent it from affecting adjacent cells 102. A module cover contact portion 114 of the thermal isolation structure 110 provides closure of the space 130 against the module cover 108. In one example, the module cover contact portion 114 includes a flat surface, although the invention is not so limited. Other shapes for the module cover contact portion 114 include a triangular shape, a rounded taper to the structural support plate 112, etc.

[0033] In one example, one or more components or portions of the thermal isolation structure 110 are formed from an expansion material. The expansion material expands in volume when exposed to heat. In one example, the module cover contact portion 114 includes an expansion material and / or an adhesive material. In one example, the structural support plate 112 includes an expansion material. In one example, the module cover contact portion 114 and the structural support plate 112 include an expansion material. In one example, the module cover contact portion 114 and the structural support plate 112 are integrally formed. In one example, the module cover contact portion 114 and the structural support plate 112 are separate components formed from different materials. Examples in which the module cover contact portion 114 and the structural support plate 112 are separate components formed from different materials are discussed in more detail below, particularly with respect to FIGS. 5A, 5B, and 6.

[0034] 2 , one or more of the thermal isolation structures 110 include tabs 126 that mate with mating features in the heat sink 104 or in the bottom of the module housing 106. The inclusion of the tabs 126 and the wide module cover contacts 114 provides a level of structural support that secures each thermal isolation structure 110 in place, improving the ability of each thermal isolation structure 110 to not shift from its position during a thermal runaway event of a cell 102. In one example, the inclusion of multiple thermal isolation structures 110 with module cover contacts 114 provides sufficient structural support to enable a smaller and lighter module housing 106 design.

[0035] In one example, by including one or more thermal isolation layers 118, 120, heat generated during a thermal runaway event remains isolated to the area of ​​the failed cell 102. However, high-temperature thermal isolation materials, such as aerogel materials, can be brittle. By fastening the one or more thermal isolation layers 118, 120 to the structural support plate 112, the composite thermal isolation structure 110 provides both mechanical stability from the structural support plate 112 and thermal isolation from the one or more thermal isolation layers 118, 120. The addition of the module cover contacts 114, as described, provides further structural stability for each thermal isolation structure 110 adjacent the space 130 above the cells 102.

[0036] In one example, a resilient pad 116 is included between the module cover contact 114 and the module cover 108. The inclusion of the resilient pad 116 accommodates some movement of the components of the battery module 100 due to thermal expansion or other mechanisms, while still maintaining the cell isolation benefits described above.

[0037] FIG. 3 illustrates another embodiment of a portion of a battery module 300. In the embodiment of FIG. 3, several cells 302 are shown. In this example, a heat sink 304 is included. Several thermal isolation structures 310 are shown to selectively isolate one or more cells 302 in the stack of cells. The thermal isolation structures 310 include a structural support plate 312 similar to the previous example. One or more thermal isolation layers 318 are shown coupled to the structural support plate 312. In the embodiment of FIG. 3, a protrusion height 340 of the thermal isolation structures 310 above the top surfaces of the cells 302 is shown. The structural support plate 312 and the thermal isolation layers 318 have the same protrusion height 340 in the embodiment illustrated in FIG. 3. The protrusion height 340 defines a space 350 in which gas emissions are contained during a thermal runaway event in a cell 302. The space 350 is defined by the protruding portion of the thermal isolation layer 318, the top of the battery cells 302 (in the XY plane away from the cold plate), and the module cover 108 (not shown).

[0038] FIG. 4 illustrates another embodiment of a portion of a battery module 400. In the embodiment of FIG. 4, several cells 402 are shown. In this example, a heat sink 404 is included. Several thermal isolation structures 410 are shown to selectively isolate one or more cells 402 in a stack of cells. The thermal isolation structures 410 include a structural support plate 412 similar to the previous example. One or more thermal isolation layers 418 are shown coupled to the structural support plate 412. In the embodiment of FIG. 4, a protrusion height 440 of the structural support plate 412 above the top surface of the cells 402 is shown. The protrusions 442 of the structural support plate 412 may have different shapes. In one embodiment, the protrusions 442 may be prisms having a thickness the same as the thickness of the structural support plate 412. In one embodiment, the protrusions 442 may be thicker than the structural support plate 412. In one embodiment, the protrusions 442 may have a semicircular, arched, triangular, or Y-shaped cross section. The different cross-sectional shapes help the structural support plate 412 press against the module housing cover, holding the thermal isolation structure 410 in place within the battery module. The thermal isolation layer 418 has a height equal to the height of the cell 402. The protrusion height 440 defines a space 450 where gas emissions are contained during a thermal runaway event in the cell 402. The space 450 is defined by the protruding portion of the structural support plate 412, the top of the battery cell 402 (in the XY plane away from the cold plate), and the module cover 108 (not shown).

[0039] Thermal isolation structure Figures 5A, 5B, 5C, and 5D illustrate select components of thermally isolating structure 510. Figures 5A and 5B show cross-sectional views of thermally isolating structure 510 along line BB' in Figure 4. Figures 5C and 5D show cross-sectional views of thermally isolating structure 510 along line CC' in Figure 4. Figure 5C is a cross-sectional view of thermally isolating structure 510 of Figure 5A along line DD'. Figure 5D is a cross-sectional view of thermally isolating structure 510 of Figure 5B along line EE'.

[0040] In the embodiment of FIG. 5A , thermal isolation structure 510 includes a structural support plate 512 and a module cover contact portion 514. A pair of thermal isolation layers 518 are shown on either side of structural support plate 512. Module cover contact portion 514 is a different material than structural support plate 512. In one example, module cover contact portion 514 includes an expansion material, while structural support plate 512 includes a material that is stiffer than the expansion material. In one example, structural support plate 512 includes a polymer or metal. Thermal isolation layer 518 can include an aerogel material, which can be fragile. The inclusion of a rigid structural support plate 512 helps support more fragile components, such as thermal isolation layer 518 and module cover contact portion 514.

[0041] As shown in Figure 5A, the major surface of the battery cell is indicated by dashed line 502. A thermal isolation layer 518 extends beyond at least one edge of the major surface area of ​​the battery cell 502. In one embodiment, the thermal isolation layer 518 extends beyond three edges of the major surface of the battery cell 502, as shown in Figures 5A and 5C, with the fourth edge of the battery cell 502 remaining in contact with a cold plate for heat transfer.

[0042] 5A and 5C, thermally isolating structure 510 includes a structural support plate 512 between two thermally isolating layers 518. A major surface of isolation layer 518 extends beyond at least one edge of structural support plate 512, leaving a gap between the two thermally isolating layers 518, as shown in FIG. 5C. Module cover contact portion 514 fills the gap and extends beyond the major surface of thermally isolating layer 518, as shown in FIG. 5A and 5C. In one example, module cover contact portion 514 includes an expansion material and structural support plate 512 includes a more rigid material.

[0043] 5B and 5D, the thermal isolation structure 510 includes a structural support plate 512 and a module cover contact 514 along at least one edge of the structural support plate 512. At least one edge of the major surface of the battery cell, indicated by the dashed box 502, extends beyond the maximum surface of the structural support plate 512. Three edges of the battery cell extend away from the major surface of the structural support plate 512 in the embodiment shown in FIG. 5B. The periphery of the battery cell (indicated by the dashed box 502) is between the periphery of the cover contact 514 and the periphery of the structural support plate 512 in the YZ plane.

[0044] As shown in FIG. 6 , the thermal isolation structure 510 can engage with a slot 507 on the side (surface parallel to the XZ plane) of the module housing 506 (only relevant portions are shown). The module housing 506 is similar to the module housing 106 of FIG. 1 . In addition to the side of the module housing 506 shown in FIG. 6 , the slot 507 can also be on the top (surface parallel to the XY plane) side of the module housing 506. The engagement defines the position of the thermal isolation structure 510 within the module housing 506, thereby maintaining the thermal isolation structure 510 in place during use of the battery module. An adhesive 509 or elastic material can be included in the slot 507 to help stabilize the thermal isolation structure 510 within the module housing 506.

[0045] Encapsulated thermal isolation structure FIG. 7A shows an exploded view 700 of one embodiment of the assembly of a thermal isolation layer 718. In one example, the material of the thermal isolation layer 718 includes aerogel. The aerogel material can be configured in several forms, as described above, and can be made with a variety of chemical options. An aerogel layer 701 is shown. The aerogel layer 701 can be fragile, allowing unwanted particles to shed from the layer 701. In the embodiment of FIG. 7A, a encapsulation film 704 is shown positioned to at least partially cover the aerogel layer 701. The encapsulation film encapsulates the thermal isolation layer 718 and prevents dust from escaping from the thermal isolation layer 718. In the embodiment of FIG. 7A, the encapsulation film 704 completely encases the aerogel layer 701 by folding the encapsulation film 704 around all sides of the aerogel layer 701. In one example, the encapsulation film 704 includes a pressure sensitive adhesive that allows the encapsulation film 704 to adhere to itself, allowing for wrapping without additional tape or other fasteners.

[0046] In one example, the thermal conductor layer 702 is wrapped with the aerogel layer 701 by the encapsulation film 704. One embodiment of the thermal conductor layer 702 includes a metal foil or graphite plate. Stainless steel foil is one embodiment of a metal foil, although other metals or other thermal conductors may also be used. The inclusion of the thermal conductor layer 702 helps to spread heat outward along the plane of the thermal conductor layer 702 from any localized hot spots on the battery cells that the thermal isolation layer 718 may adjoin. The inclusion of the thermal conductor layer 702 may also facilitate the conduction of heat from adjacent battery cells to an external heat sink, such as the heat sinks shown in the various examples above. In one embodiment, a structural support layer may be included to provide physical support to the aerogel layer 701. The structural support layer may be on the inside or outside of the encapsulation film 704. The structural support layer is more rigid than the aerogel. Examples of mechanical support layers may be metals, polymers, resins, rubber, mica, and graphite. The structural support layer can be the same as other structural support layers described herein, such as structural support layers 112, 312, 412, and 512.

[0047] In one example, after wrapping the aerogel layer 701, an adhesive layer 706 is attached to the encapsulation film 704. One embodiment of the adhesive layer 706 includes a pressure-sensitive adhesive layer. The embodiment of FIG. 7A further includes an emissive layer 708. The emissive layer 708 is longer than the adhesive layer 706 and provides a tab 712 that extends away from the encapsulated thermal isolation layer 718. In operation, the emissive layer 708 is removed by pulling on the tab 712, exposing the adhesive layer 706, which can then be used to attach the thermal isolation layer 718 to a structural support plate (e.g., 312, 412, 512), such as the support plates shown in other examples of this disclosure.

[0048] FIG. 7B shows another embodiment of an exploded view 720 of the thermal isolation layer 718. In the embodiment of FIG. 7B, a first conductor layer 722 and a second conductor layer 723 sandwich either side of an aerogel layer 721. Similar to the embodiment of FIG. 7A, one material for the conductor layers 722, 723 comprises a metal foil. Stainless steel foil is one embodiment of the metal foil, but other metals or other thermal conductors may also be used. Although foil is described, it is not limited to a particular foil thickness; conductor layers of various thicknesses may be used. A encapsulation film 724 is then used to cover all or a portion of the laminate stack of layers (722, 721, 723). In one embodiment, the encapsulation film 724 encapsulates the aerogel layer 721 and the conductive layer 722, leaving the conductive layer 723 outside the encapsulation film 724. 7A , at least one of conductor layers 722 and 723 may be replaced by a structural support layer, such as a mica layer, a polymer layer, and / or a resin layer. The structural support layer may be the same as other structural support layers described herein, such as structural support layers 112, 312, 412, and 512. In one embodiment, at least one of conductor layers 722 and 723 may be replaced by an adhesive layer, such as a pressure-sensitive adhesive (PSA) layer, to bond to encapsulation film 724 and aerogel layer 721. In one embodiment, adhesive layer 723 is a PSA layer on the outside of encapsulation film 724. Adhesive layer 723 adheres encapsulated aerogel layer 721 onto a structural support plate, such as structural support plate 312, 412, and 512.

[0049] One use of the encapsulation film 724, as described above, is to encapsulate airborne particles that may emerge from the aerogel layer 721. If conductor layers (722, 723) are included on one or both sides of the aerogel layer 721, the encapsulation film 724 may not be needed in addition to the conductor layers. In embodiments where one side of the aerogel layer 721 is covered with a conductor layer, only the opposite side of the aerogel layer 721 needs to be covered with the encapsulation film 724. In embodiments where both sides of the aerogel layer 721 are covered with conductor layers, only the edges of the laminated stack of layers (722, 721, 723) need to be encapsulated. In such configurations, one method may include sealing only the edges of the laminated stack of layers (722, 721, 723) with an adhesive or other edge cover. The edge cover may include, but is not limited to, rubber, resin, polymer film, etc.

[0050] In one example, a laminated stack of layers (722, 721, 723) as shown in FIG. 7B or a laminated stack of layers (702, 701) as shown in FIG. 7A is fabricated from a multilayer sheet, such as a roll. The aerogel layers (701, 721) are unfolded and laminated with one or more conductor layer rolls, and multiple rectangles, as shown in FIG. 7A or 7B, are cut from the laminated roll or larger sheet. In one example, the aerogel layers and conductor layers are adhered to each other before cutting. One embodiment of cutting from a roll or sheet includes die cutting. Another embodiment of cutting from a roll or sheet includes water jet cutting. Layer lamination tack is further described with respect to FIG. 16. After the laminated rectangles are cut, they can be partially or completely wrapped with a encapsulation film, as described above.

[0051] Alternative configurations of thermal isolation structures 8A and 8B show one embodiment of a thermally isolating structure 800 including one or more thermally isolating layers 818 and a structural support plate 812 as described in examples of the present disclosure. In the example of FIGS. 8A and 8B, a module cover contact portion 814 is bonded to or integral with the structural support plate 812. In the example of FIGS. 8A and 8B, a top of the module cover contact portion 814 is flush with a top of the thermally isolating layer 818. The major surfaces of the structural support plate 812 and the thermally isolating layer 818 have the same dimensions in the YZ plane. The thermally isolating structure 800 is a rectangular laminate.

[0052] 9A and 9B show one embodiment of a thermal isolation structure 900 including one or more thermal isolation layers 918 as described in examples of the present disclosure. The embodiment of Figures 9A and 9B includes tabs 926 configured to mate with mating features in a heat sink or in the bottom of a module housing, as described in examples above. In one embodiment, tabs 926 are attached to a structural support plate 912 and are in contact with thermal isolation layer 918.

[0053] 10A, 10B, and 10C illustrate an example of a thermal isolation structure including one or more thermal isolation layers as described in examples of the present disclosure. The thermal isolation structure 1000 includes a structural support plate 1012 and at least one thermal isolation layer 1018 attached to a major surface of the structural support plate 1012. At least one edge of the structural support plate 1012 extends beyond the periphery of the thermal isolation layer 1018. In one embodiment, the edge 1002 opposite the tab 1026 of the structural support plate 1012 extends away from the thermal isolation layer 1018. The edge 1002 is designed to prevent thermal runaway products from migrating to healthy battery cells within the battery module. The edge 1002 may be thicker than the thickness of the structural support layer 1012. The edge 1002 may have a square, rectangular, semicircular, arched, triangular, or Y-shaped cross-sectional shape. The different cross-sectional shapes help the structural support plate 1012 press against the cover of the module housing and hold the thermal isolation structure 1000 in place within the battery module. In one embodiment, the thickness of the structural support plate 1012 is the same as the thickness of the thermal isolation layer 1018.

[0054] 10B shows a thermal isolation structure 1020 including a structural support plate 1022 and at least one thermal isolation layer 1028 attached to a major surface of the structural support plate 1022. The thermal isolation layer 1028 is thinner than the structural support plate 1022. Compared to other types of thermal isolation layers, the thermal isolation layer 1018 provided in the present disclosure has a lower thermal conductivity, so the thin thermal isolation layer 1018 can provide sufficient thermal isolation. The thin thermal isolation layer saves space within the battery module, allowing more battery cells to be packed together for improved energy density.

[0055] 10C shows a thermal isolation structure 1040 that includes a structural support plate 1042 and at least one thermal isolation layer 1048 attached to a major surface of the structural support plate 1042. The thermal isolation layer 1048 is thinner than the structural support plate 1042. The thicker thermal isolation layer 1048 provides improved compression to accommodate volumetric changes of the battery cells during operation. Accommodating the volumetric changes improves the cycle life of the battery cells.

[0056] Alternative encapsulation of thermal isolation structures 11A-11C illustrate components of one embodiment of the assembly of a thermal isolation layer 1118. In one example, the material of the thermal isolation layer 1118 includes aerogel. The aerogel material can be configured in several forms, as described above, and can be made with a variety of chemical options. An aerogel layer 1101 is shown. The aerogel layer 1101 can be fragile, allowing unwanted particles to shed from the layer 1101. A encapsulation film 1104 positioned to at least partially cover the aerogel layer 1101 is shown in FIG. 11A. The encapsulation film 1104 in the embodiment of FIGS. 11A-11C encases the major surfaces (YZ plane) of the aerogel layer 1101 by folding the encapsulation film 1104 around the aerogel layer 1101, leaving only the edges exposed (in the XZ and XY planes). Alternatively, the encapsulation film 1104 may surround the edges of the aerogel layer 1101. Preformed weakened portions 1106 are shown formed in the sheet of containment film 1104 in Figure 1 IB to aid in folding. Examples of weakened portions 1106 include, but are not limited to, scores, cuts, wrinkles, press lines, etc.

[0057] 12A-12C illustrate an embodiment of a thermal isolation structure 1220 including one or more thermal isolation layers 1218 as described in examples of the present disclosure. In the example of FIGS. 12B and 12C, the module cover contact portion 1214 is bonded to or integral with the structural support plate 1212. FIG. 12A illustrates a encapsulation film 1204 similar to that shown in FIGS. 11A and 11B, but in a folded state prior to wrapping the assembly. In the embodiment of FIGS. 12B and 12C, the encapsulation film 1204 is shown wrapped around the thermal isolation layer 1218 and the structural support plate 1212. As described in the examples above, a tab 1226 is included that is configured to mate with a mating feature in a heat sink (not shown) or in the bottom of a module housing (not shown). A preformed weakened portion 1206 corresponds to the edge of the thermal isolation structure 1220.

[0058] 13A-13C illustrate one embodiment of a thermal isolation structure 1320 including one or more thermal isolation layers 1318 and a structural support plate 1312 as described in examples of the present disclosure. In the examples of FIGS. 13B and 13C, a module cover contact 1314 is bonded to or integral with the structural support plate 1312. A encapsulation film 1304 is shown wrapped around the thermal isolation layer 1318 and the structural support plate 1312. A encapsulation film 1304 similar to that of FIG. 12A is shown in FIG. 13A prior to wrapping the assembly. As described in the examples above, a tab 1326 is included that is configured to mate with a mating feature within a heat sink or the bottom of a module housing. One or more rigid layers 1306 are shown included in the thermal isolation structure 1320. Examples of the rigid layer 1306 include, but are not limited to, mica, resin, polymer, rubber, metal, etc. In one example, rigid layer 1306 provides an outer structure that further protects thermal isolation layer 1318, which may be fragile and prone to grains or dust being shaken off any exposed surface. In the embodiment of Figures 13A-13C, rigid layer 1306 is on the outer surface of thermal isolation structure 1320.

[0059] 14A-14D illustrate one embodiment of a thermal isolation structure 1420 including one or more thermal isolation layers 1418 and a structural support plate 1412 as described in examples of the present disclosure. In the example of FIGS. 14B and 14C, the module cover contact 1414 is bonded to or integral with the structural support plate 1412. A encapsulation film 1404 is shown wrapped around the thermal isolation layer 1418 and the structural support plate 1412. The encapsulation film 1404 is shown in FIG. 14A prior to wrapping the assembly. As described in the previous examples, a tab 1426 is included that is configured to mate with a mating feature within the heat sink or the bottom of the module housing. One or more rigid layers 1406 are shown included in the thermal isolation structure 1420. The rigid layer 1406 may be disposed outside the encapsulation film 1404. Examples of the rigid layer 1406 include, but are not limited to, mica, resin, polymer, rubber, metal, etc. In one example, rigid layer 1406 provides an exterior structure that further protects thermal isolation layer 1418, which may be fragile and prone to grains or dust being shaken off any exposed surfaces. In the embodiment of FIGS. 14A-14D, rigid layer 1406 is further encased in second encapsulation layer 1408. Second encapsulation layer 1408 protects rigid layer 1406 from external damage, such as scratches and moisture. Second encapsulation layer 1408 may comprise a different material than encapsulation layer 1404 to achieve its protective function. In one example, the combination of the two encapsulation layers forms a small gap 1428, shown in FIG. 14D, between layers 1404, 1408. In one embodiment, small gap 1428 has a triangular shape, one edge of which is the thickness of rigid layer 1406.

[0060] 15A-15C illustrate one embodiment of a thermally isolating structure 1520 including one or more thermally isolating layers 1518 and a structural support plate 1512 as described in examples of the present disclosure. A encapsulation film 1504 is shown wrapped around the thermally isolating layer 1518, leaving a portion of the structural support plate 1512 unwrapped. The unwrapped portion of the structural plate 1512 extends away from the thermally isolating layer 1518. The encapsulation film 1504 is shown in FIG. 15A prior to wrapping the assembly. A more rigid layer 1506 is shown included in the thermally isolating structure 1520. In one example, the rigid layer 1506 is wrapped over the encapsulation film 1504. Examples of the rigid layer 1506 include, but are not limited to, mica, resin, polymer, rubber, metal, and the like. In one example, the rigid layer 1506 provides an outer structure that further protects the thermally isolating layer 1518, which may be fragile and prone to grains or dust being shaken off any exposed surfaces. In the embodiment of FIGS. 15A-15C, stiff layer 1506 is on the exterior surface of thermal isolation structure 1520 outside of containment film 1504.

[0061] Figure 16 shows an embodiment of one or more stiff layers 1606 sandwiched between layers of containment film 1604. Using the illustration of Figure 16, sheets of the laminated containment film 1604 and stiff layer 1606 structure can be rolled or sheeted and then cut into components for assembly into thermal isolation structures as described in the examples above. As shown in the examples above, pre-fabricated weakened sections 1607, such as crimps, cuts, presses, etc., can be included to make wrapping easier.

[0062] Alternative module cover contacts 17A-17C illustrate one embodiment of a thermal isolation structure 1720 including one or more thermal isolation layers 1718 as described in examples of the present disclosure. In the embodiment of FIGS. 17A-17C, the module cover contact portion 1714 is located on the edge of the structural support plate 1712. Like the embodiments of FIGS. 5A, 5B, and 6, in the embodiment of FIGS. 17A-17C, the module cover contact portion 1714 is a separate material from the structural support plate 1712. While FIG. 17C illustrates a lap joint 1725 connecting the module cover contact portion 1714 to the structural support plate 1712, the invention is not so limited. The joint 1725 in other embodiments includes a butt joint, a finger joint, a dovetail joint, and / or other types of joints. In one embodiment, the module cover contact portion 1714 is overmolded onto the structural support plate 1712 to increase the durability of the connection therebetween. In one embodiment, the module cover contact portion includes a keyed portion that extends into a keyway in the structural support plate 1712 to improve connection. In one embodiment, the thickness of the module cover contact portion is the same as the thickness of the structural support plate 1712. In one embodiment, the thickness of the module cover contact portion 1714 can be greater than the thickness of the structural support plate 1712. In one embodiment, the module cover contact portion 1714 can have a semicircular, arched, triangular, or Y-shaped cross-section. The different thicknesses and cross-sectional shapes help the structural support plate 1712 press against the cover of the module housing and hold the thermal isolation structure 1720 in place within the battery module.

[0063] In one example, module cover contact portion 1714 comprises an expansion material, while structural support plate 1712 comprises a more rigid material. In one embodiment, structural support plate 1712 comprises a metal, such as aluminum, stainless steel, titanium, other metals, or metal alloys. In one embodiment, structural support plate 1712 comprises mica, graphite, plastic, polymer, rubber, or other material that is more rigid than thermal isolation layer 1718. In the embodiment of FIGS. 17A-17C, the width of module cover contact portion 1714 is substantially the same as the width of structural support plate 1712.

[0064] Figure 18 shows a flow diagram of a manufacturing method. In operation 1802, several lithium-ion cells are stacked. In operation 1804, one or more aerogel layers are encapsulated. In operation 1806, one or more aerogel layers are laminated to one or more sides of a structural support. In operation 1808, a thermal isolation structure is stacked between at least some of the cells in the stack of lithium-ion cells. In operation 1810, a module cover is contacted with the top surface of the structural support.

[0065] Battery modules such as those described above are used in several electronic devices. Figure 19 shows an exemplary electronic device 1900 including a battery module 1910. The battery module 1910 is coupled to functional electronics 1920 by circuitry 1912. In the illustrated embodiment, the battery module 1910 and circuitry 1912 are housed in a housing 1902. A charging port 1914 is shown coupled to the battery module 1910 to facilitate recharging the battery module 1910 when needed.

[0066] In one example, functional electronics 1920 includes devices such as semiconductor devices with transistors and memory circuits, including, but not limited to, telephones, computers, display screens, navigation systems, etc.

[0067] FIG. 20 illustrates another electronic system utilizing a battery module including a multi-layer thermal barrier as described above. An electric vehicle 2000 is illustrated in FIG. 20. The electric vehicle 2000 includes a chassis 2002 and wheels 2022. In the illustrated embodiment, each wheel 2022 is coupled to a drive motor 2020. A battery module 2010 is shown coupled to the drive motor 2020 by circuitry 2006. A charge port 2004 is shown coupled to the battery module 2010 to facilitate recharging the battery module 2010 when needed.

[0068] Examples of electric vehicles 2000 include, but are not limited to, consumer vehicles such as cars and trucks. Commercial vehicles such as tractors and semi-trucks are also within the scope of the present invention. While a four-wheeled vehicle is shown, the present invention is not so limited. Two-wheeled vehicles, such as motorcycles and scooters, are also within the scope of the present invention.

[0069] In order to more fully describe the methods and apparatus disclosed herein, a non-limiting list of embodiments is provided herein.

[0070] Aspect 1. A thermal isolation structure for a battery module, comprising: a structural support plate having a first width; a module cover contact portion located at an upper end of the structural support plate; and a thermal isolation layer coupled to at least one side of the structural support plate.

[0071] Aspect 2. The thermal isolation structure of Aspect 1, wherein the thermal isolation layer comprises an aerogel material.

[0072] Aspect 3. The thermal isolation structure of Aspect 1, wherein the structural support plate comprises an expandable material.

[0073] Aspect 4. The thermal isolation structure of Aspect 1, wherein the module cover contact portion comprises an expansion material.

[0074] Aspect 5. The thermal isolation structure of aspect 1, wherein the thermal isolation layer comprises two aerogel thermal isolation layers, the two aerogel thermal isolation layers being bonded to either side of the structural support plate.

[0075] Aspect 6. The thermal isolation structure of aspect 5, wherein the two aerogel thermal isolation layers are each at least partially covered with an encapsulation film.

[0076] Aspect 7. A battery module comprising: a stack of lithium ion cells located within a module housing; a thermal isolation structure between at least two cells in the stack of lithium ion cells, the thermal isolation structure including a structural support plate, a module cover contact located on an upper end of the structural support plate, and an aerogel layer bonded to at least one side of the structural support plate; and a module cover on the stack of lithium ion cells in contact with the module cover contact, the module cover enclosing the stack of lithium ion cells within the module housing.

[0077] Embodiment 8. The battery module of embodiment 7, wherein the aerogel layer is at least partially covered with an encapsulation film.

[0078] Embodiment 9. The battery module of embodiment 8, further comprising a metal foil layer wrapped with the aerogel layer.

[0079] Embodiment 10. The battery module of embodiment 7, further comprising a heat sink coupled to an edge of the stack of lithium ion cells.

[0080] Aspect 11. The battery module of aspect 7, wherein the thermal isolation structure includes a plurality of thermal isolation structures, each of which is included between each cell in the stack of lithium ion cells.

[0081] Aspect 12. The battery module of aspect 11, wherein the sides of the structural support plate mate with the sides of the module housing.

[0082] Aspect 13. The battery module of aspect 12, wherein the bottom of the structural support plate mates with a heat sink on the bottom of the module housing.

[0083] Embodiment 14. The battery module of embodiment 7, wherein the structural support plate comprises a first material for a central body portion and a second material for the module cover contact portion.

[0084] Embodiment 15. The battery module of embodiment 14, wherein the second material comprises an expansion material.

[0085] Aspect 16. A method of forming a battery module, the method comprising: stacking several lithium ion cells; and forming a thermal isolation structure, the thermal isolation structure comprising encapsulating one or more aerogel layers; and laminating the one or more aerogel layers to one or more sides of a structural support; stacking the thermal isolation structure between at least some cells in the stack of lithium ion cells; and contacting a module cover with a top surface of the structural support.

[0086] Embodiment 17. The method of embodiment 16, wherein encapsulating one or more aerogel layers comprises laminating the one or more aerogel layers to one or more sides of the structural support prior to encapsulation.

[0087] Embodiment 18. The method of embodiment 16, wherein encapsulating one or more aerogel layers comprises encapsulating the one or more aerogel layers prior to laminating them to one or more sides of the structural support.

[0088] Embodiment 19. The method of embodiment 16, wherein encasing the one or more aerogel layers comprises wrapping a flexible film around all sides of the one or more aerogel layers.

[0089] Aspect 20. The method of aspect 16, wherein laminating the one or more aerogel layers to one or more sides of a structural support comprises attaching the one or more aerogel layers to the structural support using a pressure-sensitive adhesive.

[0090] Aspect 21. The method of aspect 16, wherein contacting a module cover with the upper surface of the structural support includes disposing a medium-elasticity pad between the module cover and the upper surface of the structural support.

[0091] The above description is intended to be illustrative, not limiting. For example, the above examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments may be employed, such as by one of ordinary skill in the art who reviews the above description. The Abstract is provided to enable the reader to quickly grasp the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be construed as intending that any unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter lies in less than all features of a particular disclosed embodiment. Accordingly, it is contemplated that the following claims are incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment, and that such embodiments can be combined with each other in various combinations or variations. The scope of the invention should be determined with reference to the appended claims, along with the full range of equivalents to which such claims are entitled.

[0092] While the inventive subject matter has been generally described with reference to particular aspects, various modifications and changes can be made to these embodiments without departing from the broader scope of the disclosed embodiments. Such embodiments of the inventive subject matter may be referred to herein, individually or collectively, by the term "invention" for convenience only, and this is not intended to intentionally limit the scope of this application to any single disclosure or inventive concept where multiple inventions are in fact disclosed.

[0093] The embodiments illustrated herein are described in sufficient detail to enable those skilled in the art to practice the teachings disclosed. Other embodiments may be utilized and derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of the present disclosure. Therefore, the detailed description is not to be construed in a limiting sense, and the scope of various embodiments is defined only by the appended claims, along with the full range of equivalents to which such claims are entitled.

[0094] As used herein, the term "or" may be interpreted in either an inclusive or exclusive sense. Furthermore, 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 particular operations are illustrated in the context of specific exemplary configurations. Other allocations of functionality are contemplated and may be included within the scope of various embodiments of the present disclosure. In general, structures and functionality that are represented as separate resources in an aspect configuration may be implemented as a combined structure or resource. Similarly, structures and functionality that are 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 embodiments of the present disclosure, as expressed by the appended claims. Accordingly, the specification and drawings should be regarded in an illustrative and not a restrictive sense.

[0095] The foregoing description, for purposes of illustration, has been set forth with reference to specific embodiments. However, the foregoing illustrative description is not intended to be exhaustive or to limit possible embodiments to the precise forms disclosed. Many modifications and variations are possible in light of the above teachings. The embodiments were chosen and described to best explain the principles involved and their practical application, thereby enabling those skilled in the art to best utilize various embodiments, with their various modifications, as suited to the particular uses intended.

[0096] It is also understood that terms such as "first" and "second" may be used herein to describe various elements, but these elements should not be limited by these terms. These terms are used only to distinguish one element from another. For example, a first contact portion can be referred to as a second contact portion, and similarly, a second contact portion can be referred to as a first contact portion, without departing from the scope of the present embodiment. Although the first contact portion and the second contact portion are both contact portions, they are not the same contact portion.

[0097] The terms used in describing the embodiments herein are for the purpose of describing particular embodiments only and are not intended to be limiting. As used in the description of the embodiments and the accompanying examples, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. The term "and / or," as used herein, is also understood to refer to and encompass any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms "comprise" and / or "comprising," as used herein, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0098] As used herein, the term "if" may be interpreted to mean "when" or "upon" or "in response to determining" or "in response to detecting," depending on the context. Similarly, the phrase "if it is determined" or "if [a stated condition or event] is detected" may be interpreted to mean "upon determining" or "in response to determining" or "upon detecting [the stated condition or event]" or "in response to detecting [the stated condition or event]," depending on the context.

Claims

1. A thermal isolation structure for a battery module, comprising: a structural support plate having a first width; a module cover contact portion located at an upper end of the structural support plate; a thermal isolation layer coupled to at least one side of the structural support plate; The thermal isolation structure.

2. The thermal isolation structure of claim 1 , wherein the thermal isolation layer comprises an aerogel material.

3. The thermal isolation structure of claim 1 , wherein the structural support plate comprises an expansion material.

4. The thermal isolation structure of claim 1 , wherein the module cover contact portion comprises an expansion material.

5. 2. The thermal isolation structure of claim 1, wherein the thermal isolation layer comprises two aerogel thermal isolation layers, the two aerogel thermal isolation layers being bonded to either side of the structural support plate.

6. The thermal isolation structure of claim 5 , wherein the two aerogel thermal isolation layers are each at least partially covered with an encapsulation film.

7. A battery module, a stack of lithium-ion cells located within a module housing; a thermal isolation structure between at least two cells in the stack of lithium ion cells, a structural support plate; a module cover contact portion located at an upper end of the structural support plate; the thermal isolation structure including an aerogel layer bonded to at least one side of the structural support plate; a module cover on the stack of lithium ion cells in contact with the module cover contacts, the module cover enclosing the stack of lithium ion cells within the module housing; and The battery module.

8. 8. The battery module of claim 7, wherein the aerogel layer is at least partially covered with an encapsulation film.

9. The battery module of claim 8 , further comprising a metal foil layer wrapped with the aerogel layer.

10. 8. The battery module of claim 7, further comprising a heat sink coupled to an edge of the stack of lithium-ion cells.

11. 8. The battery module of claim 7, wherein the thermal isolation structure comprises a plurality of thermal isolation structures, each of the plurality of thermal isolation structures being included between each cell in the stack of lithium-ion cells.

12. The battery module of claim 11 , wherein a side of the structural support plate mates with a side of the module housing.

13. The battery module of claim 12 , wherein the bottom of the structural support plate mates with a heat sink on the bottom of the module housing.

14. 8. The battery module of claim 7, wherein the structural support plate comprises a first material for a central body portion and a second material for the module cover contact portion.

15. The battery module of claim 14 , wherein the second material comprises an expansion material.

16. 1. A method of forming a battery module, comprising: By stacking several lithium-ion cells, forming a thermal isolation structure, encapsulating one or more aerogel layers; laminating the one or more aerogel layers to one or more sides of a structural support; stacking the thermal isolation structure between at least some cells in the stack of lithium ion cells; contacting a module cover with a top surface of the structural support; The method comprising:

17. 17. The method of claim 16, wherein encapsulating one or more aerogel layers comprises encapsulating the one or more aerogel layers after laminating them to one or more sides of the structural support.

18. 17. The method of claim 16, wherein encapsulating one or more aerogel layers comprises encapsulating the one or more aerogel layers prior to laminating them to one or more sides of the structural support.

19. 17. The method of claim 16, wherein encapsulating one or more aerogel layers comprises wrapping a flexible film around all sides of the one or more aerogel layers.

20. 17. The method of claim 16, wherein laminating the one or more aerogel layers to one or more sides of a structural support comprises attaching the one or more aerogel layers to the structural support using a pressure sensitive adhesive.

21. 17. The method of claim 16, wherein contacting a module cover with the top surface of the structural support comprises disposing a medium resilience pad between the module cover and the top surface of the structural support.

Images