Materials, systems, and methods for encapsulating thermal barrier materials

Abstract

To provide a material and a system for managing a thermal runaway problem of an energy storage system.SOLUTION: An insulating barrier for use in an electrical energy storage system, the insulating barrier comprising: at least one insulating layer; a support member surrounding at least a portion of the insulating layer, wherein the support member includes at least one alignment element coupled with an alignment guide; and an encapsulating layer at least partially surrounding the insulating layer, wherein the encapsulating layer contacts at least a portion of the support member.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 218,205, filed July 2, 2021, entitled "Materials, Systems, and Methods for Mitigation of Electrical Energy Storage Thermal Events," and U.S. Provisional Patent Application No. 63 / 284,917, filed December 1, 2021, entitled "Materials, Systems, and Methods for Encapsulating Materials," the contents of which are incorporated herein by reference in their entireties.

[0002] The present disclosure relates generally to materials, systems, and methods for encapsulation. In particular, the present disclosure relates to materials, systems, and methods for encapsulating thermal barriers used between battery cells or modules in energy storage systems. The present disclosure further relates to encapsulating aerogel thermal barriers. The present disclosure also relates to battery modules or battery packs with one or more battery cells that include an encapsulated thermal barrier material, as well as systems that include those battery modules or battery packs. [Background technology]

[0003] Rechargeable batteries, such as lithium-ion batteries, have found wide application in power-driven energy storage systems. Lithium-ion batteries (LIBs) are widely used to power portable electronic devices, such as cell phones, tablets, laptops, and power tools, and also to power other high-current devices, such as electric vehicles, due to their high operating voltage, low memory effect, and high energy density compared to conventional batteries. However, safety concerns remain because LIBs are susceptible to catastrophic failure under "severe conditions," such as when rechargeable batteries are overcharged (charged beyond their design voltage), overdischarged, or operated or exposed to high temperatures and pressures. As a result, the narrow operating temperature range and charge / discharge rates limit the use of LIBs, as they can fail due to rapid self-heating or thermal runaway events when exposed to conditions outside their design range.

[0004] Thermal runaway can occur when the internal reaction rate increases to the point where more heat is generated than can be removed, resulting in a further increase in both reaction rate and heat generation. During thermal runaway, high temperatures trigger a chain of exothermic reactions in the battery, causing the battery temperature to rise rapidly. Often, when thermal runaway occurs in one battery cell, the generated heat causes cells in close proximity to the cell experiencing thermal runaway to heat up quickly. Each cell added to the thermal runaway reaction traps additional energy to continue the reaction, causing thermal runaway propagation within the battery pack and ultimately resulting in a catastrophic accident resulting in a fire or explosion. Rapid heat dissipation and effective blocking of heat transfer paths can be effective measures to reduce the dangers posed by thermal runaway propagation.

[0005] Based on an understanding of the mechanisms that lead to battery thermal runaway, many approaches have been explored with the goal of reducing safety hazards through rational design of battery components. To prevent such cascading thermal runaway events from occurring, LIBs are typically designed to either keep the stored energy low enough, utilize sufficient insulating material between cells within a battery module or pack, or insulate cells from thermal events that may occur in adjacent cells, or a combination of these. The former severely limits the amount of energy that can potentially be stored in such devices. The latter limits the effective energy density by restricting the manner in which closed cells can be arranged.

[0006] Currently, several different means are utilized to maximize energy density while taking precautions to prevent cascading thermal runaway. One approach is to incorporate a substantial amount of insulation between cells or clusters of cells. This approach is generally considered desirable for safety reasons. However, with this approach, the ability of the insulating material to contain heat combined with the volume of insulation required dictates an upper limit to the energy density that can be achieved.

[0007] Another approach is through the use of phase change materials. These materials undergo an endothermic phase change when a certain elevated temperature is reached. The endothermic phase change absorbs some of the heat being generated, thus cooling the localized area. Typically, for electrical storage devices, these phase change materials rely on hydrocarbon materials such as waxes and fatty acids. While these systems are effective at cooling, they are themselves flammable and thus are not useful for preventing thermal runaway if an ignition occurs within the storage device.

[0008] The incorporation of expansion materials is another approach to preventing cascading thermal runaway. These materials expand above a specified temperature, producing chars that are designed to be lightweight and provide thermal insulation when needed. While these materials can be effective in providing insulating benefits, the expansion of the material must be considered in the design of the storage device.

[0009] Aerogel materials have also been used as thermal barrier materials. Aerogel thermal barriers offer many advantages over other thermal barrier materials. Some of these benefits include favorable resistance to heat and fire propagation while minimizing the thickness and weight of the materials used. Aerogel thermal barriers also have favorable properties related to compressibility, compressive resilience, and compliance. The light weight and low stiffness of some aerogel-based thermal barriers can make them difficult to install between battery cells, especially in mass-production situations. Furthermore, aerogel thermal barriers tend to generate particulate matter (dust) that can be harmful to electrical storage systems, creating manufacturing challenges.

[0010] Many different materials are available, each with many different properties, both desirable and undesirable, which would be advantageous to encapsulate the thermal barrier material and provide additional protection to both the battery cell and the thermal barrier, while simplifying the manufacturing process. Summary of the Invention

[0011] It is an object of the present disclosure to obviate or mitigate at least one of the disadvantages of the aforementioned methods and materials described above. The support members provided herein are designed to improve the encapsulation and handling of thermal barriers used in battery modules or battery packs.

[0012] In an aspect of the present disclosure, an insulating barrier for use in an electrical energy storage system includes at least one insulating layer, a support member surrounding at least a portion of the insulating layer, and an encapsulation layer at least partially surrounding the insulating layer, the encapsulation layer contacting at least a portion of the support member.

[0013] The support member may be a single support member made of a single piece of material, or may be made of two or more support pieces joined together to form the support member. In some embodiments, the support member includes two support members positioned on opposite sides of the insulating layer. In other embodiments, the support member surrounds the periphery of the insulating barrier. In other embodiments, the support member is substantially U-shaped.

[0014] To provide support for the insulating layer, the support member can be formed from a material having a flexural modulus greater than that of the insulating layer. In aspects of the present disclosure, the support member should have a flexural modulus greater than 100 MPa. In some embodiments, the support member is made of a material different from the material used for the insulating layer. In preferred embodiments, the support member is made of a polymeric material. In some embodiments, the support member can include an expansion material. In some embodiments, the support member has a thickness less than that of the insulating layer.

[0015] The insulating layer can be made of any material useful for reducing heat transfer between battery cells. Generally, the insulating layer has a thermal conductivity through its thickness dimension of less than about 50 mW / m·K at 25° C. and less than about 60 mW / m·K at 600° C. In a preferred embodiment, the insulating layer comprises an aerogel.

[0016] The encapsulation layer covers at least a portion of the insulating layer. In some embodiments, the encapsulation layer comprises a polymeric material. In some embodiments, the encapsulation layer comprises a metal layer embedded in a polymeric material. The encapsulation layer, in some embodiments, includes an extension that extends beyond a portion of the support member. In use, the extension contacts the inner surface of the housing containing the insulating barrier.

[0017] In one embodiment, the encapsulation layer is attached to the support member. Alternatively, the encapsulation layer surrounds the insulating layer and the support member. The encapsulation layer is then sealed to form a housing that at least partially surrounds the insulating layer.

[0018] In an embodiment of the present disclosure, the insulating barrier includes one or more adhesive pads bonded to the encapsulation layer. The adhesive pads can provide a cushion between adjacent battery cells and can adhere to adjacent battery cells to prevent shifting of the insulating barrier relative to the battery cells during manufacturing and use.

[0019] In another aspect of the present disclosure, the support member includes one or more alignment elements coupled with the alignment guides. During manufacture and use of the battery module, the battery cells and insulating barriers can be aligned by using the alignment guides in combination with the alignment elements.

[0020] In another aspect of the present disclosure, an insulating barrier for use in an electrical energy storage system includes at least one insulating layer, a support member surrounding at least a portion of the insulating layer, and an encapsulation layer at least partially surrounding the insulating layer. In this aspect of the disclosure, the support member includes an intumescent material. The encapsulation layer includes a thermally conductive material and contacts at least a portion of the support member.

[0021] In another embodiment of the present disclosure, an insulating barrier for use in an electrical energy storage system includes at least one insulating layer, a support member surrounding at least a portion of the insulating layer, and an encapsulation layer surrounding at least a portion of the insulating layer. One or more sealing tabs are coupled to the support member. The sealing tab is made of a shape-memory material, such as a shape-memory nickel-titanium alloy. When exposed to heat, the sealing tab extends away from the support member. In this manner, the sealing tab creates a barrier between the battery cells and can suppress or prevent heat propagation from a runaway battery cell. In this embodiment of the present disclosure, the sealing tab is in a first position during normal battery operation. In the first position, the sealing tab is substantially stationary relative to the support member. When exposed to heat, the sealing tab moves to a second position and extends away from the support member, and the sealing tab moves from the first position to the second position when exposed to heat.

[0022] In another aspect of the present disclosure, a method for encapsulating an insulating layer includes surrounding at least a portion of the insulating layer with a support member and forming an encapsulation layer over at least a portion of the insulating layer and the support member. The encapsulation layer contacts at least a portion of the support member. In specific embodiments, at least a portion of the encapsulation layer is attached to at least a portion of the support member. In some embodiments, the encapsulation layer is attached to at least a portion of the support member by heating the encapsulation layer while the encapsulation layer is in contact with the support member. During this process, the encapsulation layer is held in contact with the support member by a heating element. Alternatively, the encapsulation layer can be attached to the support member by an adhesive.

[0023] In another embodiment, forming the encapsulation layer includes covering at least a portion of the insulating layer and the support member with the encapsulation layer and connecting two or more separate portions of the encapsulation layer together to form a housing that encloses at least a portion of the insulating layer and the support member. During this process, the two or more separate portions of the encapsulation layer are attached together by heating the two or more separate portions while the two or more separate portions are in contact. In any embodiment of forming an encapsulation layer over the insulating layer, the encapsulation layer may partially or completely surround the insulating layer and the support member.

[0024] In aspects of the present disclosure, at least one metal layer is disposed between two or more separate portions of the encapsulation layer. In some embodiments, the at least one metal layer can be embedded between two or more separate portions of the encapsulation layer. In some embodiments, the process includes forming a bend in the at least one metal layer to provide an extension that extends from the insulating layer. In some embodiments, the two or more separate portions are held together by a pair of elements on opposite sides of the two or more separate portions, and at least one of the elements is heated.

[0025] In another aspect of the present disclosure, a battery module includes a plurality of battery cells and one or more insulating barriers disposed between adjacent battery cells as described herein.

[0026] In another aspect, a device or vehicle provided herein comprises a battery module or battery pack according to any one of the above aspects. In some embodiments, the device is a laptop computer, a PDA, a mobile phone, a tag scanner, an audio device, a video device, a display panel, a video camera, a digital camera, a desktop computer, a military portable computer, a military telephone, a laser range finder, a digital communication device, a secret intelligence sensor, an electronically integrated garment, a night vision device, a power tool, a calculator, a radio, a remote control device, a GPS device, a handheld and portable television, a car starter, a flashlight, a sound device, a portable heating device, a portable vacuum cleaner, or a portable medical tool. In some embodiments, the vehicle is an electric car.

[0027] In one or more embodiments, the insulating barrier according to any of the above aspects has an average thickness in an uncompressed state ranging from about 2 mm to about 10 mm.

[0028] The insulating barriers described herein may offer one or more advantages over existing thermal runaway mitigation solutions. The insulating barriers described herein can minimize or eliminate cell thermal runaway propagation and assembly costs without significantly affecting the energy density of the battery module or battery pack. The insulating barriers of the present disclosure can provide favorable properties of compressibility, resilience, and compliance to accommodate continued cell expansion over the cell's lifetime, while retaining favorable thermal properties under normal operating conditions and under thermal runaway conditions. The insulating barriers described herein are durable, easy to handle, and provide favorable resistance to heat and fire propagation while minimizing the thickness and weight of the materials used, as well as favorable properties of compressibility, resilience, and compliance.

[0029] The disclosure is therefore described in general terms and reference is now made to the accompanying drawings, which are not necessarily drawn to scale. [Brief explanation of the drawings]

[0030] [Figure 1] FIG. 2 is an exploded view of an exemplary insulating barrier of the present disclosure. [Figure 2] FIG. 10 is a side view of an insulating layer fully surrounded by a support member. [Figure 3] FIG. 10 is a side view of an insulating layer surrounded by a U-shaped support member. [Figure 4] FIG. 1 is a side view of an insulating layer joined by two separate support members. [Figures 5A-5C] 5A-5C show a schematic diagram of three stages in the life of a battery cell. [Figure 6] 1 shows a schematic representation of the manufacturing process used to make the laminate encapsulation layer. [Figure 7] 10A and 10B schematically illustrate an encapsulation layer having an extension that forms a seal with the inner surface of the battery cell housing. [Figure 8] 1 shows a schematic representation of an insulating barrier with adhesive pads. [Figures 9A-9C]9A-9C show schematic diagrams of shear loads caused by battery cell expansion. [Figure 10] FIG. 10 shows a top view of a battery module having alignment guides for aligning insulating barriers with battery cells. [Figure 11] 10 illustrates an alternative embodiment of an insulating barrier consisting of an expansion material and a thermally conductive encapsulation layer. [Figure 12] 1 shows an enlarged view of a support member bonded to an insulating layer. [Figure 13] 1A and 1B show schematic diagrams of an expansion support member before and after a high temperature event. [Figure 14] 1 illustrates an embodiment of an insulating layer that includes a U-shaped support member that substantially surrounds the insulating layer. [Figure 15] 1 illustrates an embodiment of an insulating barrier having an insulating layer at least partially surrounded by a support member. [Figure 16] 10 illustrates an alternative embodiment of a support member having particle capture members incorporated into openings formed in the corners of the support member. [Figure 17] FIG. 1 illustrates a side view of an insulating barrier having an expanding support member bonded to an insulating layer and an encapsulation layer. [Figure 18] FIG. 1 shows a side view of an insulating barrier having an expanding support member wrapped around the edge of the encapsulation layer. [Figure 19] FIG. 1 shows a side view of an insulating barrier having an expanding support member wrapped around the edge of a U-shaped encapsulation layer. [Figure 20] FIG. 1 shows a side view of an insulating barrier having an expanding support member with a U-shaped encapsulation layer. [Figure 21] FIG. 1 shows a schematic diagram of a battery module / pack having an insulating layer with sealing tabs. [Figure 22] 1 shows a schematic diagram of a battery module / pack having an insulating layer with mating sealing tabs. [Figure 23] 1 shows a schematic diagram of a battery module / pack with sealing tabs placed over the expansion material. [Figure 24] 1 shows a schematic diagram of a battery module having a sealing tab coupled to a housing. DETAILED DESCRIPTION OF THE INVENTION

[0031] In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings which form a part hereof, and in which is shown, by way of illustration, specific embodiments in which the present disclosure may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present disclosure.

[0032] The present disclosure is directed to insulating barriers and systems including insulating barriers for managing thermal runaway issues in energy storage systems. Exemplary embodiments include an insulating barrier including at least one insulating layer, a support member surrounding at least a portion of the insulating layer, and an encapsulation layer at least partially surrounding the insulating layer. In some embodiments, the encapsulation layer contacts at least a portion of each of the support members.

[0033] The insulating layer can include any type of insulating layer typically used to separate battery cells or battery modules. Exemplary insulating layers include, but are not limited to, polymer-based thermal barriers (e.g., polypropylene, polyester, polyimide, and aromatic polyamide (aramid)), phase change materials, expandable materials, aerogel materials, mineral-based barriers (e.g., mica), and inorganic thermal barriers (e.g., fiberglass containing barriers).

[0034] In a preferred embodiment, the insulating layer comprises an aerogel. A description of aerogel insulating layers is set forth in U.S. Patent Application Publication No. 2021 / 0167438 and U.S. Provisional Patent Application No. 63 / 218,205, both of which are incorporated herein by reference.

[0035] The insulating layer of the present disclosure has a thermal conductivity of about 50 mW / mK or less, about 40 mW / mK or less, about 30 mW / mK or less, about 25 mW / mK or less, about 20 mW / mK or less, about 18 mW / mK or less, about 16 mW / mK or less, about 14 mW / mK or less, about 12 mW / mK or less, about 10 mW / mK or less, about 5 mW / mK or less, or a range between any two of these values, at 25°C when subjected to a load of up to about 5 MPa through the thickness dimension of the insulating layer.

[0036] Insulation layers can have several different physical properties that make incorporating the insulation layer into a battery module or battery pack difficult. For example, some insulation layers have a very low flexural modulus (e.g., less than 10 MPa), making it difficult to handle and position the material between battery cells. In addition, materials with a low flexural modulus can be difficult to manipulate, especially when using automated encapsulation processes. Other insulation layers can have a higher flexural modulus but can be brittle, making them prone to breakage during battery module or battery pack manufacturing.

[0037] The present disclosure helps alleviate these challenges by using a support member that surrounds at least a portion of the insulating layer. The support member is positioned around the periphery of the insulating layer and provides support to the insulating layer. Additionally, an encapsulation layer can be attached to the support member. When the support member is positioned along the periphery of the insulating layer, the attachment of the encapsulation layer to the support member at least partially encloses the insulating layer with the encapsulation layer.

[0038] An embodiment of an insulating barrier is shown in FIG. 1. The insulating barrier 100 includes an insulating layer 110. The insulating layer 110 is surrounded by a support member 120. In some embodiments, the support member 120 includes an opening 125 that is complementary in shape to the periphery of the insulating layer. The opening 125 can be sized to be approximately the same size as the insulating layer. During assembly, the insulating layer 110 can be placed in the opening 125 and held in place by the support member 120. For example, the support member 120 can have an opening that is the same dimensions (length x width) as the corresponding dimensions of the insulating layer, or slightly smaller than those dimensions. In such an embodiment, the insulating layer 110 fits within the opening 125 of the support member 120 and is held in place by a friction fit. Alternatively, or in addition, the insulating layer can be bonded to the support member by using an adhesive (e.g., glue or tape) that fastens the insulating layer to the support member. A side view of the encapsulating insulating layer 110 positioned within the opening of the support member 120 is shown in FIG. 2.

[0039] The encapsulation layer 130 is attached to the support member 120 and covers at least one side of the insulating layer 110 with encapsulating material. Preferably, the encapsulation layer 130 covers both sides of the insulating layer 110. In aspects of the present disclosure, the encapsulation layer 130 is comprised of two sheets of encapsulating material 130a and 130b. In some embodiments, the encapsulation layer(s) are attached to the support member and enclose at least a portion of the insulating layer. In some embodiments, when two sheets are used, the encapsulation sheet is attached to the support member and encloses the insulating material.

[0040] In an alternative embodiment, the encapsulation layer can be formed as a bag (see FIG. 6). A support member containing the insulating layer can be placed inside the bag-like encapsulation layer. The encapsulation layer is then attached to the support member, enclosing at least a portion of the insulating layer.

[0041] In some embodiments, the support member is formed as a single piece of material. For example, the support member can be formed from a single piece of material with an opening formed in the middle of the material. The opening in the single piece of material can be formed by cutting an opening in the material (e.g., using a laser cutter). Alternatively, the support member can be formed by an injection molding process, where the shape of the support member can be controlled by selecting the mold used to form the support member. In another embodiment, the support member can be made from two or more support pieces that are joined together to form the support member. For example, a rectangular support member can be formed from four separate support pieces that are joined together to form the support member. The support members can be glued or welded together.

[0042] While the embodiments of Figures 1 and 2 show the support member as a rectangular frame, it should be understood that the support member need not completely enclose the insulating layer to effectively enclose it. For example, Figure 3 shows an insulating barrier 300 having a support member 320 that is substantially U-shaped. Thus, the support member covers only three sides of the insulating layer 310. The U-shaped support member provides a surface that allows for partial or complete encapsulation of the insulating layer. The insulating layer can be placed into the U-shaped opening by a friction fit or by using an adhesive (glue or tape).

[0043] In another embodiment shown in Figure 4, the insulating barrier 400 includes two separate support members 420a and 420b disposed on the edges of the insulating layer 410. The two separate support members may be disposed on opposite edges of the insulating layer (as shown in Figure 4) or may be disposed in an L-shape along two adjacent sides of the insulating layer (not shown). The support members may be attached to the insulating layer by using adhesive (glue or tape).

[0044] In some embodiments, the support member is formed from a material different from the material used to form the insulating layer. In preferred embodiments, the support member has a flexural modulus greater than the flexural modulus of the insulating layer. For example, many different types of insulating layers are formed from materials with low flexural moduli. As used herein, the phrase "low flexural modulus" refers to a flexural modulus less than about 10 MPa. In preferred embodiments, the flexural modulus of the support member is greater than 100 MPa.

[0045] A variety of materials may be used to form the support member, including polymers and metals. Polymers are preferred as materials for forming the support member due to their ease of fabrication, light weight, dielectric properties, and heat and flame resistance. In some embodiments, the polymer selected to form the support member has a flexural modulus greater than about 100 MPa. Exemplary polymers that may be used to form the support member include, but are not limited to, polypropylene, polyester, polycarbonate, polyimide, and aromatic polyamide. Additives may be present in the polymer used to form the support member to improve flexural modulus, reduce thermal conductivity, reduce flammability, or modify any combination of these characteristics.

[0046] In certain embodiments, the support member has a thermal conductivity at 25°C through the thickness dimension of the insulating layer of about 50 mW / mK or less, about 40 mW / mK or less, about 30 mW / mK or less, about 25 mW / mK or less, about 20 mW / mK or less, about 18 mW / mK or less, about 16 mW / mK or less, about 14 mW / mK or less, about 12 mW / mK or less, about 10 mW / mK or less, about 5 mW / mK or less, or a range between any two of these values.

[0047] In certain embodiments, support members of the present disclosure may have a heat of combustion ("HOC") of about 750 cal / g or less, about 717 cal / g or less, about 700 cal / g or less, about 650 cal / g or less, about 600 cal / g or less, about 575 cal / g or less, about 550 cal / g or less, about 500 cal / g or less, about 450 cal / g or less, about 400 cal / g or less, about 350 cal / g or less, about 300 cal / g or less, about 250 cal / g or less, about 200 cal / g or less, about 150 cal / g or less, about 100 cal / g or less, about 50 cal / g or less, about 25 cal / g or less, about 10 cal / g or less, or a range between any two of these values. Within the context of the present disclosure, a first material having a heat of combustion less than the HOC of the second material would be considered an improvement of the first material over the second material. In certain embodiments of the present disclosure, the HOC of the insulating layer is improved by incorporating a fire-rated additive into the support member.

[0048] In certain embodiments, the support members of the present disclosure have an onset temperature of thermal decomposition of about 300°C or higher, about 320°C or higher, about 340°C or higher, about 360°C or higher, about 380°C or higher, about 400°C or higher, about 420°C or higher, about 440°C or higher, about 460°C or higher, about 480°C or higher, about 500°C or higher, about 515°C or higher, about 550°C or higher, about 600°C or higher, or a range between any two of these values. Within the context of the present disclosure, for example, a first composition having an onset temperature of thermal decomposition higher than the onset temperature of thermal decomposition of a second composition would be considered an improvement of the first composition over the second composition. It is contemplated herein that the addition of one or more fire-rated additives increases the onset temperature of thermal decomposition of a composition or material compared to a composition without any fire-rated additives.

[0049] In some embodiments, the support member may be formed from an expansion material. An expansion material is a material that expands when exposed to heat. In the context of a battery module, when a battery cell begins to fail, the temperature of the battery cell may rapidly increase, increasing the temperature inside the module. This temperature increase may cause heat-induced expansion of the expansion material used to form the support member, creating a seal between adjacent battery cells. This expansion of the support member may provide improved resistance to high-pressure gases and particulate matter released if the battery cells are forced open. Exemplary expansion materials are disclosed in U.S. Pat. No. 3,513,114 to Hahn et al., U.S. Pat. No. 5,487,946 to McGinniss et al., U.S. Pat. No. 5,591,791 to Deogon, U.S. Pat. No. 5,723,515 to Gottfried, U.S. Pat. No. 6,790,893 to Nguyen et al., PCT Patent Application Publication No. WO 94 / 17142 to Buckingham et al., PCT Patent Application Publication No. WO 98 / 04639 to Janci, and PCT Patent Application Publication No. WO 2020 / 077334 to Fleetwood et al., all of which are incorporated by reference in their entireties.

[0050] In some embodiments, the support member has a thickness less than that of the insulating layer. FIG. 5A shows a side view of the insulating layer 510 bonded to the support member 520. As can be seen, in the pre-assembly stage (no compression on the insulating layer), the support member 520 has a thickness that is less than that of the insulating layer 510. As shown, the insulating layer consequently protrudes from the support member. As shown in FIG. 5B, during installation, at the beginning of the battery cell life cycle, the insulating layer contacts the battery cell and compresses it slightly. In some cases, it has been discovered that if the support member has a thickness equal to or greater than the thickness of the insulating layer, the support member contacts the battery cell and prevents the insulating layer from contacting the battery cell. Using a support member that is thinner than the insulating layer can overcome this problem.

[0051] As shown in Figure 5C, at the end of the battery cell's life, the battery cell begins to expand. The configuration of support members positioned around the periphery of the insulating layer allows the battery cell to expand and, in the present disclosure, compress against the insulating layer, which is more compressible than the support members. Allowing the battery cell to expand as the battery cell deteriorates helps prevent catastrophic failure of the battery cell housing.

[0052] The encapsulating layer can be a single layer or multiple layers of material. The encapsulating layer can be in the form of a thin film, an envelope, or a bag. The encapsulating layer can be made of any material suitable for enclosing the insulating layer. The material used to form the encapsulating layer can be selected from polymers, elastomers, or combinations thereof. Examples of suitable polymers include polyethylene terephthalate (PET), polyethylene (PE), polyimide (PI), rubber, polypropylene, polyamide, and nylon, which have very low thermal conductivity (less than 1 W / m), which has the effect of reducing the planar thermal conductivity throughout the system. In one embodiment, the encapsulating layer comprises a polyethylene terephthalate polymer.

[0053] In another embodiment, the encapsulation layer is made of a multilayer material. For example, a multilayer material similar to that used to form a pouch battery cell case can be used. In one embodiment, the encapsulation layer includes a laminate including three layers: a first polymer layer, a second thermally conductive layer, and a third polymer layer, with the thermally conductive layer sandwiched between the first and third polymer layers. The first and third polymer layers are preferably formed from polymers with very low thermal conductivity (less than 1 W / m). Examples of polymers that can be used for the first and third polymer layers include, but are not limited to, polyethylene terephthalate (PET), polyethylene (PE), polypropylene, polyamide, and nylon. Examples of thermally conductive materials that can be used for the second layer include, but are not limited to, metals (e.g., copper, stainless steel, or aluminum), carbon fiber, graphite, and silicon carbide. When a metal thermally conductive layer is used, the metal can be in the form of a foil sandwiched between the polymer layers.

[0054] In another embodiment, the encapsulation layer comprises a laminate including three layers: a first polymer layer, a second flame-retardant layer, and a third polymer layer, with the flame-retardant layer sandwiched between the first and third polymer layers. As previously described, the first and third polymer layers are preferably formed from polymers with very low thermal conductivity (less than 1 W / m). Examples of flame-retardant materials that can be used in the second layer include, but are not limited to, metals (e.g., copper, stainless steel, or aluminum), mica, polybenzimidazole fibers (PBI fibers), coated nylon, melamine, modacrylic, and aromatic polyamides (aramids). When a metal thermally conductive layer is used, the metal can be in the form of a foil sandwiched between the polymer layers.

[0055] Metal is a preferred material for use in the laminate encapsulation layer. Metal provides both thermally conductive properties and flame retardancy to the encapsulation layer. By using a single material to provide both flame retardancy and thermal conductivity, the thickness of the encapsulation layer can be minimized.

[0056] The insulating layer can be encapsulated by an encapsulation layer, whether a single layer (polymer or metal) or a laminate layer is used, by attaching the encapsulation layer to at least a portion of the support member. The encapsulation layer can be attached by heat staking. The term "heat staking" as used herein refers to a process of connecting two separate pieces of polymeric material by fusing them with heat. In a heat staking process, one or both of the polymer pieces are heated above the glass transition temperature of the material used to form one or both of the polymer pieces. Heating the polymer pieces above the glass transition temperature causes the material of one or both pieces to soften and melt with the other piece. In one embodiment, the encapsulation layer is attached to at least a portion of the support member using a heat staking process.

[0057] In an alternative embodiment, the encapsulating layer is sealed to itself. In this alternative embodiment, the encapsulating layer extends beyond the support member and is placed in contact with itself. Again, a heat staking process can be used to fuse the encapsulating layer together, forming a seal between the two layers. In one embodiment, a single encapsulating sheet is used to encapsulate the insulating layer. In this embodiment, the encapsulating sheet covers one side of the insulating layer and is then folded over to cover the other side of the insulating layer. The edges of the encapsulating sheet are placed on top of each other and heat staked to enclose the insulating layer with the encapsulating layer. One, two, or three edges of the encapsulating sheet can be joined together to form the encapsulating layer.

[0058] In another embodiment, two separate encapsulating sheets can be used to encapsulate the insulating layer. A first sheet can be placed in contact with the support member and covering one side of the insulating layer. A second sheet can then be placed over the opposite side of the insulating layer and in contact with the opposite side of the support member. The first and second sheets can then be heat-staked to attach the sheets to at least a portion of the opposite side of the support member. In another embodiment, the first and second sheets are positioned on opposite sides of the insulating layer as described above. The first and second sheets extend beyond the support member, allowing the sheets to contact each other. The edges of the encapsulating sheets can be placed on top of each other and heat-staked to enclose the insulating layer in an encapsulating layer made up of two encapsulating sheets.

[0059] Figure 6 illustrates a system and method for producing a laminate encapsulation layer. In the embodiment shown in Figure 6, the laminate is made from two thin polymer films that serve as the outer surfaces of the laminate sheet. Metal foil is used as a thermally conductive / flame-retardant layer. Two separate polymer rolls of thin film are fed into a laminator along with two separate metal foil sheets. The lamination step combines and seals the sheets, sandwiching the metal foil between the two polymer sheets. The metal foil sheets are separated by a space that allows folds to be made in the laminate.

[0060] The laminate sheet is conveyed to a creasing device that creases the laminate sheet, allowing it to be folded into an envelope shape. After the laminate sheet is creased, it is stretched and cut to the appropriate size for encapsulating the insulating layer. After cutting, the laminate sheet is folded into an envelope shape, and the insulating layer and peripheral support member are placed into the envelope-shaped encapsulating layer. Flaps formed on the edges of the laminate sheet are folded over to seal the insulating layer and support member within the laminate sheet. In a final step, the laminate sheet is heated to melt and fuse the polymer layers together. Alternatively, the laminate sheet can be melted and fused together with the support member during the final heating step. A heat staking process can be used for the final sealing step. In the heat staking process, a metal staking device is heated to a temperature above the glass transition temperature of the polymer. The metal staking device is pressed against the laminate sheet and, upon cooling, melts and dissolves the laminate sheet at the contact point. In a preferred embodiment, the polymer is polyethylene terephthalate (PET) and the metal foil is stainless steel.

[0061] The encapsulant can reduce or eliminate the generation of dust or particulate material that sheds from the insulating layer. Additionally, the encapsulant can be formed from a material that allows for marking or writing of inscriptions on the insulating barrier, where marking of the insulating layer is not always possible.

[0062] The encapsulation layer may include at least one vent that allows air to flow in and out of the panel. The encapsulation member may include at least one filter that filters particulate matter. In an exemplary embodiment, the encapsulation layer includes a vent that allows air to flow in and out of the panel and a particulate filter over the vent that keeps particulate matter within the encapsulation member. In another embodiment, the encapsulation layer includes an edge seal that includes at least one vent and at least one particulate filter. In a further embodiment, the encapsulation layer includes an edge seal that includes at least one vent and at least one particulate filter, where the vent in the edge seal allows air to flow in and out of the encapsulation member edge and the filter captures and retains particulate matter in the airflow, preventing particulate matter from contaminating the air outside the encapsulation layer.

[0063] In another embodiment, the encapsulation layer may include an extension. The encapsulation layer may be composed of a metal foil, a laminate including a metal foil or a polymer with elastic properties, or the encapsulation layer may be composed of a polymer with elastic properties. Two sheets of the encapsulation layer may be placed on opposite sides of the insulating layer and in contact with the support member. FIG. 7 shows a side view of an insulating layer 710 covered on opposite sides by an encapsulation layer 720. The encapsulation layer partially, or preferably completely, encapsulates the insulating layer and is attached to a support member 730. When a metal foil layer is used as the encapsulation layer, the metal foil can be attached to the support member by crimping or welding.

[0064] In the embodiment shown in FIG. 7 , one or both of the encapsulation layers includes an extension 740 that extends beyond a portion of the support member toward an inner surface 750 (e.g., a sidewall or top) of the housing containing the battery cells. During assembly, the inner surface originates at position 755a. At this position, inner surface 755a contacts extension 740a. When the housing holding the battery cells or modules is assembled (e.g., by placing the top onto the housing), inner surface 755a moves to position 755b. During this assembly process, extension 740a bends to position 740b. In some embodiments, the extension can be creased before use, so that when the extension contacts the interior of the housing, it automatically bends to the correct position, allowing the extension to form a seal.

[0065] 7, contact of the extension at location 740b with the inner surface of the housing at location 755b forms a seal between the battery cells 760. Forming a seal between the insulating barrier and the inner surface of the housing can help thermally isolate the battery cells from adjacent battery cells. This is particularly useful for preventing a battery cell experiencing thermal runaway from causing a thermal runaway event in an adjacent battery cell.

[0066] In some embodiments, the insulating barrier has one or more adhesive pads bonded to the encapsulation layer. FIG. 8 shows a top and side view of an insulating barrier 800 having adhesive pads 840. An insulating layer 810 is encapsulated by an encapsulation layer 830. As previously described, a support member 820 is used to support the insulating layer and facilitate its encapsulation. In addition to the encapsulation layer, one or more adhesive pads 840 (e.g., one, two, three, four, or more adhesive pads) are attached to the outer surface of the encapsulation layer. As shown in FIG. 8, preferably, the adhesive pads are bonded to the encapsulation layer adjacent to the support member. FIG. 1 also shows an embodiment of an insulating barrier having adhesive pads 140.

[0067] FIG. 9A shows a top view of an insulating barrier placed between two battery cells. In FIG. 9B, an adhesive pad is positioned between the insulating barrier and the battery cell, providing a cushion between the insulating barrier and the battery cell. The adhesive pad can be a single-sided or double-sided adhesive pad. In embodiments where the adhesive pad is single-sided, an adhesive is used to adhere the adhesive pad to the encapsulation layer. The opposing non-adhesive portion of the adhesive pad rests against the adjacent battery cell, providing a cushion between the insulating barrier and the battery cell. In a preferred embodiment, the adhesive pad is formed from a double-sided adhesive. Similar to a single-sided adhesive pad, one side of a double-sided adhesive pad is attached to the encapsulation layer. The opposing side of the double-sided adhesive pad includes an adhesive surface that is used to adhere the adhesive pad to the battery cell. Adhering the insulating barrier to the battery cell (by an adhesive pad) can aid manufacturing by maintaining alignment of the insulating barrier with the battery when assembling a battery module (or battery pack). Without the adhesive, the insulating barrier may slip out of alignment with the battery cells, requiring the manufacturer to periodically realign the insulating barrier with the battery cells.

[0068] As shown in FIG. 9 , in a preferred embodiment, double-sided adhesive pads are placed on opposite sides of the insulating barrier. The use of opposing adhesive pads allows the insulating barrier to be bonded to both adjacent battery cells, ensuring that proper alignment between the battery cells and the insulating barrier is maintained throughout the manufacturing process. The use of adhesive can also help maintain the alignment of the battery cells with the insulating barrier during use. As previously explained, battery cells expand during the life of the energy storage system. Given the tight tolerances inside a packed battery module or battery pack, battery cell expansion can displace the insulating barrier from its aligned position. The presence of adhesive pads to bond the insulating barrier to the battery cells can help limit or prevent displacement of the insulating barrier relative to the battery cells during normal operation of the energy storage system.

[0069] Instead of or in addition to using adhesive to maintain the battery cells in alignment with the insulating barrier, an alignment system can be used to assist alignment. In the embodiment shown in FIG. 10 , one or more alignment guides 1040 are positioned inside the battery module (or battery pack) housing 1000. In one embodiment, the alignment guides can be rods extending from one end of the housing to the opposite end of the housing, substantially perpendicular to the longitudinal axes of the battery cells and insulating barrier. As shown in FIG. 2 , alignment elements 145 can be formed in the support members. In this specific embodiment, the alignment elements are openings formed in the support members. The openings have a diameter equal to or slightly larger than the diameter of the alignment guides. During assembly, the insulating barriers can be aligned with the battery cells by using the alignment elements (e.g., openings), and the insulating barriers can be moved into position along the alignment guides (e.g., rods). Other types of alignment systems can be used, including alignment systems that use protrusions / recesses as alignment guides / elements. Trays or channels can also be used in the alignment system.

[0070] FIG. 9 further illustrates the benefits of using a support frame with an insulating layer. FIG. 9C shows an insulating layer positioned between two battery cells. In FIG. 9C, a support member is not attached to the insulating layer. As the battery cells expand, the insulating layer is compressed. As shown in FIG. 9C, this creates shear strain in the insulating layer, displacing it and extending it away from the battery cells. In contrast, in FIG. 9B, the support member surrounds the sides of the insulating layer. As the battery cells begin to expand, the expansion of the insulating layer is contained by the support frame, preventing it from extending beyond the battery cells. This can be particularly useful when the battery cells are packed into a narrow enclosure, where displacement of the insulating layer could affect the integrity of the enclosure and the electronics associated with the sidewalls of the enclosure.

[0071] 11 shows an alternative embodiment of an insulating barrier comprised of an expandable material and a thermally conductive encapsulation layer. The insulating barrier 1100 includes an insulating layer 1110 encapsulated by an encapsulation layer 1130. As previously described, a support member 1120 is used to support and facilitate encapsulation of the insulating layer. In this embodiment, the support member 1120 includes three segments (1120a, 1120b, and 1120c) joined together to partially enclose the insulating layer.

[0072] FIG. 12 shows an enlarged view of a support member bonded to an insulating layer. As shown in FIG. 11, a support member 1120 at least partially surrounds the insulating layer 1110. An encapsulation layer 1130 is attached to the support member using a seal 1135. The seal can be created by placing the encapsulation layer against the support member and melting the encapsulation layer to form a bond. Alternatively, a sealing material (e.g., an adhesive or molten polymer) can be applied to the support member and the encapsulation layer pressed onto the sealing material. Sealing the encapsulation layer to the support member can minimize the amount of particulate matter from the insulating layer within the battery housing.

[0073] FIG. 13 shows a schematic diagram of the expanding support member 1120 before and after a high-temperature event (e.g., a thermal runaway event). During normal use (depicted on the left), the support member 1120 has a minimum thickness, and a gap exists between the support member and the wall 1140 of the battery cell / module housing. As used herein, a high-temperature event occurs when a temperature greater than 90° C., greater than 130° C., or greater than 180° C. is reached. When a high-temperature event occurs, battery cell components begin to degrade, creating a runaway condition that propagates to other battery cells. As shown in FIG. 13, when a high-temperature event occurs, the expanding support member expands to fill the gap between the insulating layer 1110 and the housing wall 1140. Filling the gap creates a thermal and physical barrier between the insulating layer and the housing wall, preventing heat and particulate matter from contacting adjacent battery cells.

[0074] 14 shows an embodiment of an insulating layer 1110 that includes a U-shaped support member 1120 that substantially surrounds the insulating layer 1110. In this embodiment, the underside of the insulating layer remains open and generally contacts the bottom of the housing.

[0075] Insulation layers, particularly those containing aerogel, tend to generate particulate matter (dust) that can be harmful to electrical storage systems, presenting manufacturing challenges. As explained above, particulate release can be mitigated by using an encapsulation layer. The encapsulation layer is typically sealed around the insulation layer, preventing particles and gases from entering or exiting the encapsulation layer. During compression of the encapsulation layer, the encapsulation layer may rupture, releasing particles and gases into the battery module. To mitigate this issue, a particle capture element can be added to the support member. Particles generated during compression of the insulator can be captured and at least partially retained within the particle capture element. As used herein, a particle capture element refers to a layer of material capable of trapping particles that impact the material. Examples of materials used for particle capture elements include, but are not limited to, foam (open or closed cell), woven materials, nonwoven materials (e.g., felt, batting, matted fabric), or mesh materials. Generally, particle capture elements are made of materials that allow gases to pass through the material while particles are retained within the particle capture element.

[0076] FIG. 15 shows an embodiment of an insulating barrier having an insulating layer 1110 at least partially surrounded by support members 1120. The insulating barrier further includes openings at one or more corners where there are no support members, allowing airflow out of the insulating layer during compression. The openings may be filled with particle capture members 1150 to inhibit or prevent particles (e.g., aerogel) from escaping the insulating barrier. In the embodiment shown in FIG. 15, the particle capture members 1150 may be larger than the support members and may partially overlap the support members. FIG. 16 shows an alternative embodiment of a support member having particle capture members embedded in openings formed in the corners of the support members. In FIG. 16, the particle capture members have substantially the same size as the support members.

[0077] 17 shows a side view of an insulating barrier having an expanding support member 1120 bonded to an insulating layer 1110 and an encapsulation layer 1130. The expanding support member can be T-shaped to better seal the gap between the insulating layer and the battery module housing. As shown in FIG. 12, the encapsulation layer 1130 can be adhered to the T-shaped expanding support member by melting a portion of the encapsulation layer or by using an adhesive.

[0078] FIG. 18 shows an alternative embodiment of an insulating barrier. In this embodiment, a T-shaped expanding support member 1120 is bonded to an insulating layer 1110 and an encapsulation layer 1130. This embodiment differs from the embodiment shown in FIG. 17 in that the expanding support member 1120 is wrapped around the edge of the encapsulation layer 1130. Wrapping the support member around the edge of the encapsulation member helps provide improved isolation of the battery cells when the expanding support member is triggered by a thermal runaway event.

[0079] 19 shows another embodiment of an insulating barrier. In this embodiment, the encapsulation layer 1130 is U-shaped, increasing the surface area of ​​the encapsulation layer with the heat exchange element 1170. The expansion support member 1120 can be wrapped around the edges of the encapsulation layer 1130. During use, heat generated by adjacent battery cells is transferred through the thermally conductive encapsulation layer 1130 to the heat exchange element 1170. The heat is then transferred away from the battery cells through the heat exchange element.

[0080] FIG. 20 shows an alternative embodiment of the insulating barrier. Similar to the insulating barrier of FIG. 19, the insulating barrier of FIG. 20 includes a large surface area to increase contact of the encapsulation layer 1130 with the heat exchange element 1170. The encapsulation layer consists of two L-shaped pieces. The L-shaped pieces are positioned on opposite sides of the insulating barrier 1110. During use, there may be a slight gap at the ends of the L-shaped encapsulation pieces. This gap allows the encapsulation layer some flexibility. As shown in FIG. 20, as the battery cell expands during use, the bottom arms of the L-shaped encapsulation pieces move toward each other and eventually come into contact with each other.

[0081] In one embodiment, an insulating barrier for use in an electrical energy storage system includes an insulating layer and a support member that surrounds at least a portion of the insulating layer. The insulating layer also includes an encapsulation layer that at least partially surrounds the insulating layer. One or more sealing tabs are coupled to the support member. The sealing tabs are made of a shape-memory material and are positioned such that when exposed to heat, the sealing tabs extend away from the support member. For example, during normal battery use, the sealing tabs are in a first position. In the first position, the sealing tabs are substantially stationary relative to the support member. When heated, the sealing tabs move to a second position. In the second position, the sealing tabs extend away from the support member that contacts the housing.

[0082] FIG. 21 shows a schematic diagram of a battery housing (e.g., a battery module housing or a battery pack housing). An insulating barrier 1200 is positioned between each of the battery cells (or battery modules) 1260. As described herein, the insulating barrier includes an insulating layer and an encapsulation layer. The insulating barrier 1200 also includes a sealing tab 1280 positioned between the insulating layer and the battery module / pack housing 1240. During normal use of the battery module / pack, the sealing tab remains in an "open" position, and as shown on the right side of the figure, the sealing tab is folded over the insulating barrier. When a thermal runaway event occurs, heat from the event reaches the sealing tab and induces a position change, as shown on the right side of the figure.

[0083] As shown in FIG. 21 , during a thermal runaway event, heat from a failed battery cell / module induces a change in the sealing tab. When hot air (e.g., from a failed battery cell or module) reaches the sealing tab, the heat causes the sealing tab to change shape and come into contact with a portion of the housing. The sealing tab in contact with the housing forms an additional barrier against heat and particles that can escape during a thermal runaway event. There may also be an additional tab 1265 to further protect the battery module from damage. The additional tab 1265 can be made from an expanding material. When heated, the additional tab 1265 expands and comes into contact with the housing 1240.

[0084] The sealing tab 1280 can be made from a shape memory alloy. A shape memory alloy is an alloy that, when heated, exhibits two distinct states. In the first state, the sealing tab is in a relaxed position relative to the insulating layer. When heated, the sealing tab moves to a second position, where the sealing tab contacts the housing. An exemplary shape memory alloy that can be used to form the sealing tab is a nickel-titanium alloy commonly known as Nitinol.

[0085] 22 shows an alternative embodiment of the battery housing. In this embodiment, two piece sealing tabs are spaced apart to protect the battery cells in the middle of the module. When activated by heat, the shape-memory sealing tabs block heat and mass transfer from both directions (e.g., blocking particles from a rupturing battery cell) due to their adjacent placement.

[0086] FIGS. 23 and 24 show alternative placements of the sealing tab 1265. In these embodiments, the sealing tab can be located on top of the housing and / or on the support member. In FIG. 23, the sealing tab is placed over the expansion material and bends toward the module housing. Placing the sealing tab in this orientation provides additional heat and particulate blocking during a thermal runaway event. As shown in the figure, during a thermal runaway event, the sealing tab responds to heat by expanding and forming a seal between the battery cells. In FIG. 24, the sealing tab is bonded to the support member and the housing. The sealing tab attached to the housing expands downward, while the sealing tab on the support member expands upward. In devices with a single separation tab associated with a pair of adjacent battery cells, the separation tab can be used to block heat and mass transfer in one direction. Two sealing tabs can be placed next to each other to block heat and mass transfer from both directions.

[0087] As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the content clearly dictates otherwise. As used in this specification and the appended claims, the term "or" is generally used in its sense including "and / or" unless the context clearly dictates otherwise.

[0088] As used herein, "about" means "approximately" or "nearly," and in connection with a stated numerical value or range, refers to ±5% of the numerical value. In certain embodiments, the term "about" may include conventional rounding to the nearest significant digit of the numerical value. Additionally, the phrase "about 'x' to 'y'" includes "about 'x' to about 'y'."

[0089] Within the context of this disclosure, the terms "aerogel," "aerogel material," or "aerogel matrix" refer to a gel that includes an interconnected framework with a corresponding network of interconnected pores integrated within the framework, that confines a gas, such as air, as a dispersed interstitial medium, and that is characterized by the following physical and structural properties (as determined by nitrogen porosimetry testing) that are ascribed to aerogels: (a) an average pore size ranging from about 2 nm to about 100 nm; (b) a porosity of at least 80% or greater; and (c) a porosity of at least about 100 nm. 2 / g or more surface area.

[0090] Thus, the aerogel materials of the present disclosure include any aerogel or other open-cell material that meets the defining elements set forth in the preceding paragraph, including materials that can otherwise be classified as xerogels, cryogels, ambigels, microporous materials, etc.

[0091] Within the context of this disclosure, references to "thermal runaway" generally refer to a sudden, rapid increase in cell temperature and pressure due to various operating factors, which may further result in the propagation of excessive temperatures throughout the associated module. Potential causes of thermal runaway in such systems may include, for example, cell defects and / or short circuits (both internal and external), cell breakdown or rupture, such as overcharging or accidental events, and excessive ambient temperatures (e.g., temperatures typically greater than 55°C). Under normal use, cells heat up as a result of their internal resistance. Under normal power / current loads and ambient operating conditions, the temperature within most Li-ion cells can be relatively easily controlled to remain within the 20°C to 55°C range. However, under stressful conditions such as high power draw at high cell / ambient temperatures, as well as individual cell defects, localized heating can suddenly increase. In particular, above a critical temperature, exothermic chemical reactions within the cells become activated. Furthermore, chemical heat generation typically leads to a rapid increase in temperature. As a result, the heat generated far exceeds the available heat dissipation. Thermal runaway can cause temperatures at the cell vent and inside to exceed 200°C.

[0092] Within the context of the present disclosure, the terms "flexible" and "flexibility" refer to the ability of a material or composition to bend or flex without macrostructural failure. The insulation layers of the present disclosure are capable of bending at least 5°, at least 25°, at least 45°, at least 65°, or at least 85° without macroscopic failure, and / or have a bend radius of less than 4 feet, less than 2 feet, less than 1 foot, less than 6 inches, less than 3 inches, less than 2 inches, less than 1 inch, or less than U inches without macroscopic failure. Similarly, the terms "highly flexible" or "high flexibility" refer to a material that is capable of bending at least 90° without macroscopic failure and / or has a bend radius of less than U inches. Additionally, the terms "classified flexibility" and "classified as flexible" refer to a material or composition that can be classified as flexible according to ASTM C1101 (ASTM International, West Conshohocken, PA).

[0093] The insulating layers of the present disclosure can be flexible, highly flexible, and / or graded flexible. The aerogel compositions of the present disclosure can also be drapeable. Within the context of the present disclosure, the terms "drapeable" and "drape-ability" refer to the ability of a material to bend or flex 90° or more without macroscopic failure and with a radius of curvature of about 4 inches or less. Insulating layers according to certain embodiments of the present disclosure are flexible such that the compositions are non-rigid, and the compositions can be applied and conformed to three-dimensional surfaces or objects, or preformed into various shapes and configurations for ease of installation or application.

[0094] Within the context of this disclosure, the terms "thermal conductivity" and "TC" refer to a measure of a material's or composition's ability to transfer heat between two surfaces on either side of the material's or composition's temperature difference between the two surfaces. Thermal conductivity is specifically measured as the heat energy transferred per unit time and per unit surface area divided by the temperature difference. It is usually recorded in SI units as mW / m*K (milliwatts per meter*Kelvin). The thermal conductivity of a material may be determined by the following test methods known in the art: Test methods include, but are not limited to, Test Method for Steady-State Thermal Transmission Properties by Means of the Heat Flow Meter Apparatus (ASTM C518, ASTM International, West Conshohocken, PA), Test Method for Steady-State Heat Flux Measurements and Thermal Transmission Properties by Means of the Guarded-Hot-Plate Apparatus (ASTM C177, ASTM International, West Conshohocken,PA), Test Method for Steady-State Heat Transfer Properties of Pipe Insulation(ASTM C335,ASTM International,West Conshohocken,PA), Thin Heater Thermal Conductivity Test(ASTM C1114,ASTM International,West Conshohocken,PA), Standard Test Method for Thermal Transmission Properties of Thermally Conductive Electrical Insulation Materials(ASTM D5470,ASTM International,West Conshohocken,PA), Determination of thermal resistance by means of guarded hot plate and heat flow meter methods (EN 12667, British Standards Institution, United Kingdom), or Determination of steady-state thermal resistance and related properties - Guarded hot plate apparatus (ISO 8203, International Organization for Standardization, Switzerland). While different methods may yield different results, within the context of this disclosure, unless expressly stated otherwise, it is understood that thermal conductivity measurements are taken in accordance with ASTM C518 standard (Test Method for Steady-State Thermal Transmission Properties by Means of the Heat Flow Meter Apparatus) at a temperature of about 37.5°C at ambient atmospheric pressure and under a compressive load of about 2 psi. Measurements reported per ASTM C518 generally correlate well with measurements made per EN 12667 with any relevant adjustment for compressive load.

[0095] Additionally, thermal conductivity measurements can be obtained at a temperature of about 10° C. at atmospheric pressure during compression. Thermal conductivity measurements at 10° C. are generally 0.5 to 0.7 mW / mK lower than corresponding thermal conductivity measurements at 37.5° C. In certain embodiments, insulating layers of the present disclosure have a thermal conductivity at 10° C. of about 40 mW / mK or less, about 30 mW / mK or less, about 25 mW / mK or less, about 20 mW / mK or less, about 18 mW / mK or less, about 16 mW / mK or less, about 14 mW / mK or less, about 12 mW / mK or less, about 10 mW / mK or less, about 5 mW / mK or less, or a range between any two of these values.

[0096] The term "flexural modulus" or "flexural modulus of elasticity" is a measure of a material's stiffness / resistance to bending when a force is applied perpendicular to the long edge of the sample in what is known as a three-point bend test. Flexural modulus indicates a material's ability to bend. Flexural modulus is represented by the slope of the initial linear portion of a stress-strain curve and is calculated by dividing the change in stress by the corresponding change in strain. The ratio of stress to strain is therefore a measure of flexural modulus. The international standard unit of flexural modulus is the pascal (Pa or N / m² or ml.kg.s²). Practical units used are the megapascal (MPa or N / mm²) or gigapascal (GPa or kN / mm²). In U.S. customary units, it is expressed as pounds (force) per square inch (psi). In certain embodiments, the insulating layer of the present disclosure has a flexural modulus of about 8 MPa or less, about 7 MPa or less, about 6 MPa or less, about 5 MPa or less, about 4 MPa or less, or about 3 MPa or less. Preferably, the insulating layer of the present disclosure, eg, aerogel, has a flexural modulus of about 2 MPa to about 8 MPa.

[0097] Within the context of this disclosure, the terms "heat of combustion," "HOC," and "ΔHC" refer to a measure of the amount of heat energy released upon combustion or exothermic decomposition of a material or composition. Heat of combustion is typically reported in units of calories of heat energy released per gram of aerogel material or composition (cal / g) or megajoules of heat energy released per kilogram of material or composition (MJ / kg). The heat of combustion of a material or composition can be determined by methods known in the art, including, but not limited to, Reaction to fire tests for products—Determination of the gross heat of combustion (calorific value) (EN ISO 1716, International Organization for Standardization, Switzerland; EN adopted). Within the context of this disclosure, heat of combustion measurements are obtained in accordance with the EN ISO 1716 standard (Reaction to fire tests for products—Determination of the gross heat of combustion (calorific value)) unless otherwise specified.

[0098] Within the context of this disclosure, all thermal analyses and related definitions refer to measurements made in air at ambient pressure, starting at 25°C and increasing at a rate of 20°C per minute up to 1000°C. Therefore, any changes in any of these parameters must be taken into account (or must be re-done under these conditions) when measuring and calculating the onset temperature of thermal decomposition, peak temperature of heat release, peak temperature of heat absorption, etc.

[0099] Within the context of this disclosure, the terms "onset temperature of thermal decomposition" and "TD" refer to the measured temperature of the lowest ambient temperature at which a rapid exothermic reaction from the decomposition of an organic material appears in a material or composition. Thermogravimetric analysis (TGA) can be used to measure the onset temperature of thermal decomposition of an organic material in a material or composition. The TGA curve of a material indicates the weight loss (% mass) of the material as it is exposed to an increase in ambient temperature, thus indicating thermal decomposition. The onset temperature of thermal decomposition of a material can be correlated to the intersection of the tangents of the TGA curve: a line tangent to the baseline of the TGA curve, and a line tangent to the TGA curve at the point of maximum slope during the rapid exothermic decomposition event for the decomposition of the organic material. Within the context of this disclosure, the measured onset temperature of thermal decomposition of an organic material is obtained using TGA analysis as provided in this paragraph, unless otherwise specified.

[0100] Differential scanning calorimetry (DSC) analysis can also be used to measure the onset temperature of thermal decomposition of a material. The DSC curve of a material indicates the thermal energy (mW / mg) released by the material when it is exposed to a gradual increase in ambient temperature. The onset temperature of thermal decomposition of a material can be correlated to the point on the DSC curve where ΔmW / mg (change in thermal energy output) increases maximally, and thus the DSC curve indicates the amount of heat generated by the aerogel material. Within the context of this disclosure, measurements of the onset temperature of thermal decomposition using DSC, TGA, or both are obtained using a temperature ramp rate of 20°C / min, as further defined in the preceding paragraph, unless otherwise expressly stated. DSC and TGA each provide similar values ​​for this onset temperature of thermal decomposition, and many times, test results are obtained from both DSC and TGA, with tests being run simultaneously.

[0101] Within the context of this disclosure, the terms "flame time" and "TFLAME" refer to a measurement of the flame duration of a material or composition under pyrolysis conditions, where "flame time duration" is the duration of a flame in any part of the visible portion of a test sample that lasts for 5 seconds or more. Flame time is typically recorded in seconds or minutes. The flame time of a material or composition may be determined by methods known in the art, including, but not limited to, Reaction to fire tests for building and transport products: Non-combustibility test (EN ISO 1182, International Organization for Standardization, Switzerland; EN adopted). Within the context of this disclosure, flame time measurements are obtained according to conditions equivalent to the EN ISO 1182 standard (Reaction to fire tests for building and transport products: Non-combustibility test), unless otherwise specified. In certain embodiments, the aerogel compositions of the present disclosure have a flame time of about 30 seconds or less, about 25 seconds or less, about 20 seconds or less, about 15 seconds or less, about 10 seconds or less, about 5 seconds or less, about 2 seconds or less, or a range between any two of these values. Within the context of this specification, for example, a first composition having a flame time that is shorter than the flame time of a second composition would be considered an improvement of the first composition over the second composition. It is contemplated herein that the flame time of a composition is reduced upon the addition of one or more fire-rated additives compared to a composition that does not contain any fire-rated additives.

[0102] Within the context of this disclosure, the terms "mass loss" and "ΔM" refer to a measurement of the amount of a material, composition, or composite that is lost or incinerated under pyrolytic conditions. Mass loss is typically reported in weight percent or wt%. The mass loss of a material, composition, or composite can be determined by methods known in the art, including, but not limited to, Reaction to fire tests for building and transport products: Non-combustibility test (EN ISO 1182, International Organization for Standardization, Switzerland; EN adopted). Within the context of this disclosure, mass loss measurements are obtained according to conditions equivalent to the EN ISO 1182 standard (Reaction to fire tests for building and transport products: Non-combustibility test), unless otherwise specified. In certain embodiments, the insulating layer or aerogel composition of the present disclosure can have a mass loss of about 50% or less, about 40% or less, about 30% or less, about 28% or less, about 26% or less, about 24% or less, about 22% or less, about 20% or less, about 18% or less, about 16% or less, or a range between any two of these values. Within the context of this specification, for example, a first composition having a mass loss that is less than the mass loss of a second composition would be considered an improvement of the first composition over the second composition. It is contemplated herein that the mass loss of a composition is reduced when one or more fire-rated additives are added compared to a composition without any fire-rated additives.

[0103] Within the context of this disclosure, the term "peak heat release temperature" refers to a measured temperature of the ambient heat at which the exothermic heat release from decomposition is greatest. TGA analysis, differential scanning calorimetry (DSC), or a combination thereof may be used to measure the peak heat release temperature of a material or composition. DSC and TGA will each provide similar values ​​for peak heat release temperature. Often, tests are run simultaneously, with results obtained from both DSC and TGA. In a typical DSC analysis, heat flow is plotted against temperature rise, and the peak heat release temperature is the temperature at which the highest peak in such a curve occurs. Within the context of this disclosure, measurements of the peak heat release temperature of a material or composition are obtained using TGA analysis as provided in this paragraph, unless otherwise specified.

[0104] In the context of endothermic materials, the term "peak heat absorption temperature" refers to the measured temperature of the ambient heat at which the endothermic heat absorption from decomposition is greatest. TGA analysis, differential scanning calorimetry (DSC), or a combination thereof may be used to measure the peak heat absorption temperature of a material or composition. In a typical DSC analysis, heat flow is plotted versus increasing temperature, and the peak heat absorption temperature is the temperature at which the lowest peak of such a curve occurs. Within the context of the present disclosure, the measured peak heat absorption temperature of a material or composition is obtained using TGA analysis as provided in this paragraph, unless otherwise specified.

[0105] Within the context of this disclosure, the terms "low flammability" and "lowly flammable" hereinafter refer to a material or composition that meets the following combination of properties: i) furnace temperature rise of 50°C or less, ii) flame time of 20 seconds or less, and iii) mass loss of 50 wt% or less. Within the context of this disclosure, the terms "non-flammable" and "non-flammable" hereinafter refer to a material or composition that meets the following combination of properties: i) furnace temperature rise of 40°C or less, ii) flame time of 2 seconds or less, and iii) mass loss of 30 wt% or less. As described herein, it is contemplated that the flammability of a composition (e.g., the combination of furnace temperature rise, flame time, and mass loss) is reduced upon inclusion of one or more fire-rated additives.

[0106] Within the context of this disclosure, the terms "low flammability" and "lowly flammable" refer to a low-flammability material or composition having a total heat of combustion (HOC) of 3 MJ / kg or less. Within the context of this disclosure, the terms "non-flammable" and "non-combustible" refer to a non-flammable material or composition having a heat of combustion (HOC) of 2 MJ / kg or less. As described herein, it is contemplated that the HOC of a composition will be reduced upon inclusion of one or more fire-rated additives.

[0107] Use of isolation barriers inside battery modules or battery packs Lithium-ion batteries (LIBs) are considered one of the most important energy storage technologies due to their high operating voltage, low memory effect, and high energy density compared to conventional batteries. However, safety concerns pose significant barriers to the large-scale use of LIBs. Under extreme conditions, exothermic reactions can result in heat release that can trigger subsequent dangerous reactions. The situation worsens when heat release from the cell under extreme conditions can activate chain reactions, resulting in sudden thermal runaway.

[0108] With the continuous improvement in the energy density of LIBs, enhancing their safety is becoming increasingly urgent with regard to the development of electric devices, such as electric vehicles. The mechanisms behind safety issues vary for different battery chemistries. This technology focuses on tailoring the insulating barrier and the corresponding configuration of the engineered barrier to obtain favorable thermal and mechanical properties. The insulating barrier of this technology ensures the stability of LIBs under normal operating modes (e.g., withstanding applied compressive stress) while providing effective heat dissipation measures under normal conditions as well as under thermal runaway conditions.

[0109] The insulating barriers disclosed herein are useful for isolating, insulating, and protecting battery cells or battery components of any configuration of battery, e.g., pouch cells, cylindrical cells, prismatic cells, as well as packs and modules incorporating or including any such cells. The insulating barriers disclosed herein are useful in rechargeable batteries, e.g., lithium ion batteries, solid-state batteries, and any other energy storage device or technology requiring isolation, insulation, and protection.

[0110] Passive devices such as cooling systems may be used in conjunction with the insulating barriers of the present disclosure inside the battery module or battery pack.

[0111] The isolation barrier according to various embodiments of the present disclosure of a battery pack includes a plurality of single battery cells or modules of battery cells to thermally isolate the single battery cells or modules of battery cells from one another. A battery module is made up of multiple battery cells arranged in a single housing. A battery pack is made up of multiple battery modules.

[0112] The battery modules and battery packs can be used to provide electrical energy to devices or vehicles. Devices that use the battery modules or battery packs include, but are not limited to, laptop computers, PDAs, mobile phones, tag scanners, audio devices, video devices, display panels, video cameras, digital cameras, desktop computers, military portable computers, military telephones, laser range finders, digital communication devices, intelligence gathering sensors, electronically integrated clothing, night vision equipment, power tools, calculators, radios, remote control devices, GPS devices, handheld and portable televisions, car starters, flashlights, sound devices, portable heating devices, portable vacuum cleaners, or portable medical tools. When used in vehicles, the battery packs can be used for all-electric vehicles or hybrid vehicles. Some of the embodiments of the invention related to the present invention are shown below. [Aspect 1] 1. An insulating barrier for use in an electrical energy storage system, comprising: at least one insulating layer; a support member surrounding at least a portion of the insulating layer; an encapsulation layer at least partially surrounding the insulating layer, the encapsulation layer contacting at least a portion of the support member. [Aspect 2] 2. The insulating barrier of claim 1, wherein the support member is made of a material different from a material used for the insulating layer. [Aspect 3] 3. The insulating barrier of any one of claims 1 to 2, wherein the insulating barrier comprises two support members positioned on opposite sides of the insulating layer. [Aspect 4] 3. The insulating barrier of any one of claims 1 to 2, wherein the insulating barrier comprises a U-shaped support member. [Aspect 5] 3. The insulating barrier of claim 1 or 2, wherein the insulating barrier includes a support member surrounding a periphery of the insulating barrier. [Aspect 6] 6. The insulating barrier of any one of aspects 1 to 5, wherein the support member is made of a polymer material. [Aspect 7] 7. The insulating barrier according to any one of aspects 1 to 6, wherein the support member has a flexural modulus greater than a flexural modulus of the insulating layer. [Aspect 8] 8. The insulating barrier according to any one of aspects 1 to 7, wherein the support member has a flexural modulus greater than 100 MPa. [Aspect 9]

[0023] Aspect 9. The insulating barrier of any one of aspects 1 to 8, wherein the support member comprises an expandable material. [Aspect 10] The insulating barrier of any one of aspects 1 to 9, wherein the support member includes one or more alignment elements coupled to alignment guides that align the insulating barriers and battery cells with each other. [Aspect 11] 11. The insulating barrier according to any one of aspects 1 to 10, wherein the support member has a thickness smaller than a thickness of the insulating layer. [Aspect 12] 12. The insulating barrier of any one of aspects 1-11, wherein the insulating layer has a thermal conductivity through a thickness dimension of the insulating layer of less than about 50 mW / m·K at 25°C and less than about 60 mW / m·K at 600°C. [Aspect 13] 13. The insulating barrier of any one of aspects 1 to 12, wherein the insulating layer comprises an aerogel. [Aspect 14] 14. The insulating barrier of any one of embodiments 1 to 13, wherein the encapsulation layer comprises a polymeric material. [Aspect 15] 14. The insulating barrier of any one of aspects 1 to 13, wherein the encapsulation layer comprises a polymeric material and a metal layer embedded in the polymeric material. [Aspect 16] 16. The insulating barrier of any one of aspects 1 to 15, wherein the encapsulation layer is attached to the support member. [Aspect 17] 17. The insulating barrier of any one of aspects 1-16, wherein the encapsulation layer surrounds the insulating layer and the support member, and the encapsulation layer itself is sealed to form an enclosure that at least partially surrounds the insulating layer. [Aspect 18]

[0032] Embodiment 18. The insulating barrier of any one of embodiments 1-17, further comprising one or more adhesive pads coupled to the encapsulation layer. [Aspect 19] 19. The insulating barrier of any one of aspects 1 to 18, wherein the encapsulation layer includes an extension that extends beyond a portion of the support member, and wherein, in use, the extension contacts an inner surface of an enclosure containing the insulating barrier. [Aspect 20] 1. An insulating barrier for use in an electrical energy storage system, comprising: at least one insulating layer; a support member surrounding at least a portion of the insulating layer, the support member comprising an expansion material; and an encapsulation layer at least partially surrounding the insulating layer, the encapsulation layer contacting at least a portion of the support member, the encapsulation layer comprising a thermally conductive material. [Aspect 21] 21. The insulating barrier of embodiment 20, wherein the insulating barrier includes two support members positioned on opposite sides of the insulating layer. [Aspect 22] 21. The insulating barrier of embodiment 20, wherein the insulating barrier comprises a U-shaped support member. [Aspect 23] 21. The insulating barrier of embodiment 20, wherein the support member surrounds the outer periphery of the insulating barrier. [Aspect 24] 24. The insulating barrier according to any one of aspects 20 to 23, wherein the support member has a flexural modulus greater than a flexural modulus of the insulating layer. [Aspect 25] 25. The insulating barrier according to any one of aspects 20 to 24, wherein the support member has a flexural modulus greater than 100 MPa. [Aspect 26] 26. The insulating barrier of any one of aspects 20 to 25, wherein the support member includes one or more alignment elements coupled to alignment guides that align the plurality of insulating barriers and battery cells with respect to one another. [Aspect 27] 27. The insulating barrier according to any one of aspects 20 to 26, wherein the support member has a thickness smaller than a thickness of the insulating layer. [Aspect 28] 28. The insulating barrier of any one of aspects 20-27, wherein the insulating layer has a thermal conductivity through a thickness dimension of the insulating layer of less than about 50 mW / m·K at 25°C and less than about 60 mW / m·K at 600°C. [Aspect 29] 29. The insulating barrier of any one of embodiments 20 to 28, wherein the insulating layer comprises an aerogel. [Aspect 30] 30. The insulating barrier of any one of aspects 20 to 29, wherein the encapsulation layer comprises a polymer material and a metal layer embedded in the polymer material. [Aspect 31] 31. The insulating barrier according to any one of aspects 20 to 30, wherein the encapsulation layer is attached to the support member. [Aspect 32] 32. The insulating barrier of any one of aspects 20 to 31, wherein the encapsulation layer surrounds the insulating layer and the support member, and the encapsulation layer is itself sealed to form an enclosure that at least partially surrounds the insulating layer. [Aspect 33]

[0041] Embodiment 33. The insulating barrier of any one of embodiments 20-32, further comprising one or more adhesive pads coupled to the encapsulation layer. [Aspect 34] 1. An insulating barrier for use in an electrical energy storage system, comprising: at least one insulating layer; a support member surrounding at least a portion of the insulating layer; an encapsulation layer at least partially surrounding the insulating layer; one or more sealing tabs coupled to the support member; the encapsulation layer contacts at least a portion of the support member, the encapsulation layer including a thermally conductive material; The insulating barrier, wherein the sealing tab is made from a shape memory material such that when exposed to heat, the sealing tab extends away from the support member. [Aspect 35] 35. The insulating barrier of claim 34, wherein the sealing tab is substantially stationary relative to the support member in a first position, the sealing tab extends away from the support member in a second position, and the sealing tab moves from the first position to the second position when exposed to heat. [Aspect 36] 35. The insulating barrier of embodiment 34, wherein the sealing tab is made from a shape memory nickel titanium alloy. [Aspect 37] 37. The insulating barrier according to any one of aspects 34 to 36, wherein the insulating barrier includes two support members positioned on opposite sides of the insulating layer. [Aspect 38] 37. The insulating barrier of any one of embodiments 34 to 36, wherein the insulating barrier comprises a U-shaped support member. [Aspect 39] 37. The insulating barrier according to any one of aspects 34 to 36, wherein the support member surrounds the outer periphery of the insulating barrier. [Aspect 40] 40. The insulating barrier according to any one of aspects 34 to 39, wherein the support member has a flexural modulus greater than a flexural modulus of the insulating layer. [Aspect 41]

[0072] Aspect 41. The insulating barrier of any one of aspects 34 to 40, wherein the support member comprises an expandable material. [Aspect 42] 42. The insulating barrier according to any one of aspects 34 to 41, wherein the support member has a flexural modulus greater than 100 MPa. [Aspect 43] 43. The insulating barrier of any one of aspects 34 to 42, wherein the support member includes one or more alignment elements coupled to alignment guides that align the plurality of insulating barriers and battery cells with respect to one another. [Aspect 44] 44. The insulating barrier according to any one of aspects 34 to 43, wherein the support member has a thickness smaller than a thickness of the insulating layer. [Aspect 45] 45. The insulating barrier of any one of embodiments 34-44, wherein the insulating layer has a thermal conductivity through a thickness dimension of the insulating layer of less than about 50 mW / m·K at 25°C and less than about 60 mW / m·K at 600°C. [Aspect 46] 46. ​​The insulating barrier of any one of embodiments 34 to 45, wherein the insulating layer comprises an aerogel. [Aspect 47] 47. The insulating barrier of any one of aspects 34 to 46, wherein the encapsulation layer comprises a polymer material and a metal layer embedded in the polymer material. [Aspect 48] 48. The insulating barrier of any one of aspects 34 to 47, wherein the encapsulation layer is attached to the support member. [Aspect 49] 49. The insulating barrier of any one of aspects 34 to 48, wherein the encapsulation layer surrounds the insulating layer and the support member, and the encapsulation layer itself is sealed to form an enclosure that at least partially surrounds the insulating layer. [Aspect 50]

[0082] Embodiment 50. The insulating barrier of any one of embodiments 34-49, further comprising one or more adhesive pads coupled to the encapsulation layer. [Aspect 51] A battery module, A plurality of battery cells; and one or more insulating barriers according to any one of aspects 1 to 50, wherein at least one insulating barrier is disposed between adjacent battery cells. [Aspect 52] A battery module as described in embodiment 51, wherein the battery cells are disposed in a housing, the one or more sealing tabs are coupled to the housing, the sealing tabs are made from a shape memory material, and when exposed to heat, the sealing tabs extend away from the housing toward the one or more insulating barriers. [Aspect 53] 53. A power system comprising one or more battery modules according to embodiment 51 or 52. [Aspect 54] A device or vehicle comprising the battery module of embodiment 51 or 52. [Aspect 55] 55. The device of embodiment 54, wherein the device is a laptop computer, a PDA, a mobile phone, a tag scanner, an audio device, a video device, a display panel, a video camera, a digital camera, a desktop computer, a military portable computer, a military telephone, a laser range finder, a digital communication device, a secret intelligence gathering sensor, an electronically integrated garment, a night vision device, a power tool, a calculator, a radio, a remote control device, a GPS device, a handheld and portable television, a car starter, a flashlight, an acoustic device, a portable heating device, a portable vacuum cleaner, or a portable medical tool. [Aspect 56] 55. The vehicle of claim 54, wherein the vehicle is an electric vehicle. [Aspect 57] 1. A method of encapsulating an insulating layer used between battery cells of an electrical energy storage system, comprising: Surrounding at least a portion of the insulating layer with a support member; forming an encapsulation layer over the insulating layer and at least a portion of the support members, the encapsulation layer contacting at least a portion of each of the support members; The method comprising: [Aspect 58] forming the encapsulation layer covering the insulating layer and at least a portion of the support member with the encapsulation layer; attaching at least a portion of the encapsulation layer to at least a portion of the support member; 58. The method of embodiment 57, comprising: [Aspect 59] 59. The method of embodiment 58, wherein the encapsulation layer is attached to at least a portion of the support member by heating the encapsulation layer while in contact with the support member. [Aspect 60] 60. The method of embodiment 59, wherein the encapsulation layer is held in contact with the support member by a heating element. [Aspect 61] forming the encapsulation layer covering the insulating layer and at least a portion of the support member with the encapsulation layer; connecting two or more separate portions of the encapsulation layer together to form a housing that encloses the insulating layer and at least a portion of the support member; 58. The method of embodiment 57, comprising: [Aspect 62] 58. The method of embodiment 57, wherein the two or more separate portions of the encapsulation layer are attached together by heating the two or more separate portions while they are in contact. [Aspect 63] 63. The method of any one of embodiments 57-62, wherein at least one metal layer is disposed between the two or more separate portions of the encapsulation layer. [Aspect 64] 64. The method of embodiment 63, wherein at least one metal layer is embedded between the two or more separate portions of the encapsulation layer. [Aspect 65] 65. The method of embodiment 63 or 64, further comprising forming a bend in the at least one metal layer to provide an extension extending from the insulating layer. [Aspect 66] 62. The method of embodiment 61, wherein the two or more separate portions are held together by pairs of elements on opposite sides of the two or more separate portions, and at least one of the elements is heated. [Aspect 67] Aspect 67. The method of any one of aspects 57 to 66, wherein at least a portion of the encapsulation layer is attached to the support member by an adhesive. [Aspect 68] 68. The method of any one of embodiments 57 to 67, wherein the encapsulation layer completely surrounds the insulating layer and the support member.

Claims

1. Isolation barriers used in electrical energy storage systems, including: at least one insulating layer having a thermal conductivity through its thickness dimension of less than about 50 mW / m K at 25°C and less than about 60 mW / m K at 600°C, measured according to ASTM C518 standard under a compressive load of about 2 psi at ambient atmospheric pressure; a support member surrounding at least a portion of the outer periphery of the insulating layer, the support member having a bending modulus of elasticity greater than that of the insulating layer; an encapsulation layer at least partially surrounding the insulating layer, the encapsulation layer being in the form of a film, envelope, or bag and contacting at least a portion of the support member; One or more adhesive pads coupled to the encapsulation layer.

2. The insulation barrier of claim 1 , wherein the support member is made of a material different from a material used for the insulation layer.

3. The insulating barrier of claim 1 , wherein the insulating barrier includes two support members positioned on opposite sides of the insulating layer.

4. The insulating barrier of claim 1 , wherein the insulating barrier comprises a U-shaped support member.

5. The insulating barrier of claim 1 , wherein the support member is made of a polymeric material.

6. 10. The insulating barrier of claim 1, wherein the support member has a flexural modulus greater than 100 MPa as determined using a three-point bend test.

7. The insulating barrier of claim 1 , wherein the support member comprises an expansion material.

8. The insulation barrier of claim 1 , wherein the support member includes one or more alignment elements coupled to alignment guides that align the plurality of insulation barriers and battery cells with one another.

9. The insulating barrier of claim 1 , wherein the support member has a thickness that is less than a thickness of the insulating layer.

10. The insulating barrier of claim 1 , wherein the insulating layer comprises an aerogel.

11. The insulating barrier of claim 1 , wherein the encapsulation layer comprises a polymeric material.

12. The insulating barrier of claim 1 , wherein the encapsulation layer comprises a polymeric material and a metal layer embedded in the polymeric material.

13. The insulating barrier of claim 1 , wherein the encapsulation layer is attached to the support member.

14. 10. The insulation barrier of claim 1, wherein the encapsulation layer surrounds the insulating layer and the support member, and the encapsulation layer itself is sealed to form an enclosure at least partially enclosing the insulating layer.

15. 10. The insulation barrier of claim 1, wherein the encapsulation layer includes an extension that extends beyond a portion of the support member, and in use, the extension contacts an inner surface of an enclosure containing the insulation barrier.

16. A battery module, A plurality of battery cells; and one or more insulating barriers according to any one of claims 1 to 15, wherein at least one insulating barrier is disposed between adjacent battery cells.

17. 17. The battery module of claim 16, wherein the battery cells are disposed in a housing, the one or more sealing tabs are coupled to the housing, the sealing tabs are made from a shape-memory material, and when exposed to heat, the sealing tabs extend away from the housing toward the one or more insulating barriers.

18. 17. A power system comprising one or more battery modules according to claim 16.

19. A device or vehicle comprising the battery module of claim 16.

20. 20. The device of claim 19, wherein the device is a laptop computer, a PDA, a mobile phone, a tag scanner, an audio device, a video device, a display panel, a video camera, a digital camera, a desktop computer, a military portable computer, a military telephone, a laser range finder, a digital communication device, a secret intelligence gathering sensor, an electronically integrated article of clothing, a night vision device, a power tool, a calculator, a radio, a remote control device, a GPS device, a handheld and portable television, a car starter, a flashlight, a sound device, a portable heating device, a portable vacuum cleaner, or a portable medical tool.

21. 20. The vehicle of claim 19, wherein the vehicle is an electric vehicle.

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