Materials, systems, and methods for foil sealing of aerogels and aerogel composites

Abstract

Providing materials and systems for managing thermal runaway problems in energy storage systems. [Solution] An insulating barrier used in an electrical energy storage system, wherein the insulating barrier is At least one insulating layer, and The insulating barrier includes a sealing layer that at least partially surrounds the insulating layer, wherein the sealing layer comprises a laminate film comprising an outer polymer layer, a malleable layer comprising a malleable material, and an inner polymer layer, the inner polymer layer being in contact with the insulating layer, and the malleable layer being positioned between the outer polymer layer and the inner polymer layer.

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims the benefit and priority of U.S. Provisional Patent Application No. 63 / 304,258, filed on January 28, 2022, and entitled "Materials, Systems, and Methods for Foil Encapsulation of Aerogels and Aerogel Composites", and U.S. Provisional Patent Application No. 63 / 313,063, filed on February 23, 2022, and entitled "Materials, Systems, and Methods for Foil Encapsulation of Aerogels and Aerogel Composites". The contents of both provisional applications are hereby incorporated by reference in their entirety.

[0002] The present disclosure generally relates to materials, systems, and methods for encapsulating materials. In particular, the present disclosure relates to materials, systems, and methods for encapsulating thermal barriers used between battery cells or battery modules in an energy storage system. The present disclosure further relates to the encapsulation of aerogel thermal barriers. The present disclosure further relates to battery modules or battery packs including one or more battery cells containing an encapsulating thermal insulation material, and systems including such battery modules or battery packs.

Background Art

[0003] Rechargeable batteries, such as lithium-ion batteries, have found widespread applications in power drive and energy storage systems. Lithium-ion batteries (LIBs) are widely used to power portable electronic devices such as mobile phones, tablets, laptops, and power tools, as well as other high-current devices like electric vehicles, due to their higher operating voltage, lower memory effect, and higher energy density compared to conventional batteries. However, safety concerns exist because LIBs are prone to catastrophic failures under "misuse conditions," such as overcharging (charging beyond the design voltage), over-discharging, or operating at or being exposed to high temperatures and pressures. Consequently, their narrow operating temperature range and charge / discharge rate limit their use, as they can fail due to rapid self-heating or thermal runaway events when subjected to conditions outside their design range.

[0004] Thermal runaway can occur when the internal reaction rate increases to a point where more heat is being generated than can be removed, causing both the reaction rate and heat generation to increase further. During thermal runaway, the battery temperature rises rapidly as the high temperature triggers a chain reaction of exothermic reactions within the battery. Often, when thermal runaway occurs in one battery cell, the generated heat rapidly heats the cells immediately adjacent to the runaway cell. Each cell that joins the runaway reaction contains additional energy to continue the reaction, causing the thermal runaway to propagate within the battery pack, ultimately leading to a catastrophe involving ignition or explosion. Promoting heat dissipation and blocking heat transfer pathways can be effective measures to reduce the dangers caused by thermal runaway propagation.

[0005] Based on an understanding of the mechanisms leading to thermal runaway in batteries, many approaches have been studied with the aim of mitigating safety issues through the rational design of battery components. To prevent such cascading thermal runaway events, LIBs are generally designed to either keep the stored energy sufficiently low, or to isolate cells from potential thermal events in adjacent cells by using sufficient insulating material between them within the battery module or pack, or a combination of both. The former significantly limits the amount of energy that can potentially be stored in such a device. The latter limits the effective energy density by restricting how closely cells can be placed together.

[0006] Currently, there are many different methods used to maximize energy density while preventing a cascade of thermal runaway. One approach is to incorporate a sufficient amount of insulation between cells or cell clusters. While this approach is generally considered desirable from a safety standpoint, it determines the upper limit of the energy density that can be achieved, based on the required volume of insulation and the ability of the insulating material to absorb heat.

[0007] Another approach involves the use of phase-change materials. These materials undergo an endothermic phase change when they reach a certain temperature. The endothermic phase change cools a localized area by absorbing some of the heat generated. Generally, in the case of power storage devices, these phase-change materials rely on hydrocarbon materials such as waxes and fatty acids. While these systems are effective for cooling, they are flammable themselves, and therefore, once ignition occurs within the storage device, they are not useful in preventing thermal runaway.

[0008] The incorporation of intomessent materials is another measure to prevent a cascade of thermal runaway. These materials are designed to expand above a given temperature, forming a carbide layer, which is lightweight and provides thermal insulation when needed. While these materials can be effective in providing insulation, the expansion of the materials must be taken into account in the design of storage devices.

[0009] Aerogel materials are also used as thermal barriers. Aerogel thermal barriers offer many advantages over other thermal barriers. Some of these advantages include good resistance to heat and flame propagation while minimizing the thickness and weight of the material used. Aerogel thermal barriers also possess desirable properties of compressibility, compressive elasticity, and compliance. Some aerogel thermal barriers are lightweight and have low rigidity, which can make them difficult to install between battery cells, especially in mass production environments. Furthermore, aerogel thermal barriers tend to generate particulate matter (dust) that can adversely affect energy storage systems, causing manufacturing problems.

[0010] Many different materials are available, each possessing a wide range of properties, both desirable and undesirable, and it would be advantageous to seal in a thermal barrier to provide additional protection to both the battery cell and the thermal barrier, while also simplifying the manufacturing process. [Overview of the Initiative]

[0011] An objective of this disclosure is to eliminate or mitigate at least one drawback of the conventional methods and materials described above. The support members provided herein are designed to improve the sealing and handling of thermal barriers used in battery modules or battery packs.

[0012] In one aspect of the present disclosure, an insulating barrier used in an electrical energy storage system includes at least one insulating layer and a sealing layer that at least partially surrounds the insulating layer. The sealing layer includes a laminate film comprising an outer polymer layer, a malleable layer comprising a malleable material, and an inner polymer layer. The inner polymer layer is in contact with the insulating layer, and the malleable layer is positioned between the outer polymer layer and the inner polymer layer.

[0013] The outer polymer layer comprises a polymer resistant to dielectric heat transfer fluids in an electrical energy storage system. For example, the outer polymer layer comprises a polymer resistant to heat transfer fluids selected from the group consisting of hydrocarbon fluids, ester fluids, silicone fluids, fluoroether fluids, and combinations thereof. In one aspect of the present disclosure, the outer polymer layer is made from a polymer selected from the group consisting of polyoxymethylene, acrylonitrile butadiene styrene, polyamide-imide, polyamide, polycarbonate, polyester, polyetherimide, polystyrene, polysulfone, polyimide, and terephthalate.

[0014] The inner polymer layer contains a polymer that can be heat-welded to itself. For example, the inner polymer layer contains a polyolefin polymer. In some embodiments, the inner polymer is composed of a polymer different from the polymer of the outer polymer layer.

[0015] In some embodiments, the malleable layer includes a metal foil. In some embodiments, the malleable layer includes a malleable polymer.

[0016] In one aspect of the present disclosure, the sealing layer further includes an adhesive disposed between the outer polymer layer and the malleable layer, and / or between the inner polymer layer and the malleable layer.

[0017] In one aspect of this disclosure, the outer polymer layer has a thickness of about 10 μm to about 100 μm. In one aspect of this disclosure, the malleable layer has a thickness of about 10 μm to about 100 μm. In one aspect of this disclosure, the inner polymer layer has a thickness of about 10 μm to about 100 μm. In one aspect of this disclosure, the sealing layer has a total thickness of about 30 μm to about 300 μm.

[0018] In one aspect of the present disclosure, the insulating layer has a thermal conductivity in the thickness direction of the insulating layer of less than about 50 mW / mK at 25°C and less than about 60 mW / mK at 600°C. In one aspect of the present disclosure, the insulating layer comprises an aerogel.

[0019] In one aspect of the present disclosure, the sealing layer completely surrounds the insulating layer. In one aspect of the present disclosure, the sealing layer is composed of two laminate films heat-sealed to each other. In one aspect of the present disclosure, the sealing layer surrounds the insulating layer. The sealing layer is heat-sealed to itself to form a housing that at least partially surrounds the insulating layer.

[0020] One aspect of the present disclosure provides a method for sealing an insulating layer for use between battery cells in an electrical energy storage system, the method comprising surrounding at least a portion of the insulating layer with a laminate film comprising an outer polymer layer, a malleable layer comprising a malleable material, and an inner polymer layer (the inner polymer layer being in contact with the insulating layer, and the malleable layer being positioned between the outer polymer layer and the inner polymer layer), and heat-sealing the laminate film to form a sealing layer (the sealing layer at least partially surrounding the insulating layer).

[0021] In one aspect of the present disclosure, a method for sealing an insulating layer includes: covering at least a portion of the insulating layer with a first laminate film; covering at least a portion of the insulating layer with a second laminate film; and heat-sealing a portion of the first laminate film to the second laminate film to form a sealing layer.

[0022] In one aspect of the present disclosure, a method for sealing an insulating layer is provided, wherein a first recess is formed in a first laminate film, the shape and size of the first recess being complementary to the insulating layer; and a second recess is formed in a second laminate film, the shape and size of the second recess being complementary to the insulating layer. Forming the sealing layer includes: placing the insulating layer in the first recess of the first laminate film; placing the second laminate film on the first laminate film such that the second recess is substantially aligned with the first recess; and heat-sealing a portion of the first laminate film to a portion of the second laminate film.

[0023] In one aspect of the present disclosure, a method for sealing an insulating layer is provided, wherein a first recess is formed in a first laminate film, the shape and size of the first recess being complementary to the insulating layer; a second recess is formed in a second laminate film, the shape and size of the second recess being complementary to the first recess; forming the sealing layer includes: placing the insulating layer in the first recess of the first laminate film; placing the second laminate film on the first laminate film, substantially aligning the second recess with the first recess such that a portion of the second recess is located inside the first recess; and heat-sealing a portion of the first laminate film to a portion of the second laminate film.

[0024] In one aspect of the present disclosure, a method for sealing an insulating layer is provided, wherein a first recess is formed in a first laminate film, the shape and size of the first recess being complementary to the insulating layer; a second recess is formed in a second laminate film, the shape and size of the second recess being complementary to the first recess; forming the sealing layer includes: placing the insulating layer in the first recess of the first laminate film; placing the second laminate film on the first laminate film, substantially aligning the second recess with the first recess such that a portion of the second recess is located inside the first recess; and heat-sealing a portion of the first laminate film to a portion of the second laminate film.

[0025] In one aspect of the present disclosure, a method for sealing an insulating layer is provided, wherein a first recess is formed in a first laminate film, the shape and size of the first recess being complementary to the insulating layer; a second recess is formed in the laminate film, the shape and size of the second recess being complementary to the insulating layer. Forming the sealing layer at this stage includes: positioning the insulating layer in the first recess of the laminate film; folding the laminate film so that the second recess of the laminate film is substantially aligned with the first recess; and heat-sealing a portion of the laminate film to itself.

[0026] In one aspect of the present disclosure, the extended heat-sealed portion of the laminate film is folded against one or both sides of the insulating layer.

[0027] 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.

[0028] In another aspect, a device or vehicle is provided that includes a battery module or pack according to any one of the above aspects. In some embodiments, the device is a laptop computer, PDA, mobile phone, tag scanner, audio device, video device, display panel, video camera, digital camera, desktop computer, military portable computer, military phone, laser rangefinder, digital communication device, information collection sensor, electronics-integrated clothing, night vision device, power tool, calculator, radio, remote-controlled appliance, GPS device, handheld and portable television, automotive starter, flashlight, sound device, portable heating device, portable vacuum cleaner, or portable medical device. In some embodiments, the vehicle is an electric vehicle.

[0029] The insulating barriers described herein can provide one or more advantages over existing thermal runaway mitigation strategies. The insulating barriers described herein can minimize or eliminate the propagation of thermal runaway of the cells without significantly affecting the energy density and assembly cost of the battery module or pack. The insulating barriers of the present disclosure can have favorable thermal properties not only under normal operating conditions but also under thermal runaway conditions throughout the life of the cells, and can provide favorable properties in compressibility, compression recovery, and compliance to accommodate continued swelling of the cells. The insulating barriers described herein are durable, easy to handle, have favorable resistance to heat propagation and flame propagation while minimizing the thickness and weight of the materials used, and also have favorable properties in compressibility, compression recovery, and compliance.

[0030] Having explained this disclosure using general terminology, I will now refer to the attached drawings. The drawings are not necessarily drawn to a consistent scale. [Brief explanation of the drawing]

[0031] [Figure 1A] This is a cross-sectional view of the insulating layer sealed with a laminate film. [Figure 1B] This is a side view of the laminate film. [Figure 1C] This is a side view of a laminate film having two outer polymer layers. [Figure 2A] This is a schematic diagram of the process of forming a sealing layer around an insulating layer using two laminate film sheets. [Figure 2B] Figure 2A shows a schematic diagram of an insulating layer sealed with a sealing layer formed by the process shown. [Figure 2C] A schematic diagram of an alternative process using a single laminate film sheet to form a sealing layer around the insulating layer is shown. [Figure 3A] A schematic diagram shows the process of forming a sealing layer around an insulating layer using two laminate film sheets, both of which have recesses to receive the insulating layer. [Figure 3B] Figure 3A shows a top view of the insulating layer sealed with a sealing layer formed by the process shown. [Figure 3C] A schematic diagram shows an alternative process for forming a sealing layer around an insulating layer using a single laminate film sheet with two indentations. [Figure 4A] This is a schematic diagram of an alternative process that uses two recessed laminate film sheets to form a sealing layer around the insulating layer. [Figure 4B] Figure 4A shows a top view of the insulating layer sealed with a sealing layer formed by the process shown. [Figure 4C] A schematic diagram shows an alternative process for forming a sealing layer around an insulating layer using a single laminate film sheet with two indentations. [Figure 5A]A schematic diagram shows an alternative process using two laminate film sheets to form a sealing layer around the insulating layer, with one sheet having a recess and the other not. [Figure 5B] Figure 5A shows a top view of the insulating layer sealed with a sealing layer formed by the process shown. [Figure 5C] A schematic diagram shows an alternative process for forming a sealing layer around an insulating layer using a single laminate film sheet having a single recess in one section (the other section being unrecessed). [Figure 6A] A schematic diagram of the method for folding the sealing layer is shown. [Figure 6B] A schematic diagram of a method for folding a sealing body with notches at the corners is shown. [Figure 6C] A schematic diagram of a method for double-folding the edges of the sealing layer is shown. [Figure 7] A schematic diagram of the indentation formed in the laminate film is shown. [Figure 8A] This flowchart shows the assembly process for sealing an insulating barrier with a single laminate film. [Figure 8B] This flowchart shows the assembly process for sealing the insulating barrier with two laminate films. [Figure 9] A schematic diagram of a battery module having an insulating barrier between battery cells is shown.

[0032] While the present invention may be open to various modifications and alternative forms, specific embodiments will be shown, for example, in the drawings and described in detail herein. The scale of the drawings may not be accurate. However, it should be understood that the drawings and their detailed description are not intended to limit the invention to any specific form disclosed, as defined in the appended claims, but rather to encompass all modifications, equivalents, and alternatives that fall within the spirit and scope of the invention as defined in the appended claims. [Modes for carrying out the invention]

[0033] The following detailed description of preferred embodiments includes references to the accompanying drawings, which form part thereof, illustrating specific embodiments in which the disclosure may be carried out. It should be understood that other embodiments may be utilized and structural modifications may be made without departing from the scope of this disclosure.

[0034] This disclosure relates to an insulating barrier and a system including an insulating barrier for managing thermal runaway problems in an energy storage system. An exemplary embodiment includes an insulating barrier comprising at least one insulating layer and a sealing layer at least partially surrounding the insulating layer.

[0035] The insulating layer may include any type of insulating layer commonly used to isolate 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 polyamides (aramids)), phase-change materials, intomessent materials, aerogel materials, mineral-based barriers (e.g., mica), and inorganic thermal barriers (e.g., glass fiber-containing barriers).

[0036] In preferred embodiments, the insulating layer comprises an aerogel material. A description of the aerogel insulating layer is provided 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.

[0037] The insulating layer may have a thermal conductivity in the thickness direction of the insulating layer that is within the range of approximately 50 mW / mK or less, approximately 40 mW / mK or less, approximately 30 mW / mK or less, approximately 25 mW / mK or less, approximately 20 mW / mK or less, approximately 18 mW / mK or less, approximately 16 mW / mK or less, approximately 14 mW / mK or less, approximately 12 mW / mK or less, approximately 10 mW / mK or less, approximately 5 mW / mK or less, or any two of these values, at 25°C and a maximum load of approximately 5 MPa.

[0038] Insulating layers can have many different physical properties that make it difficult to incorporate them into battery modules or battery packs. For example, some insulating layers have a very low flexural modulus (e.g., less than 10 MPa), making the material difficult to handle and position between battery cells. Furthermore, materials with a low flexural modulus can be difficult to work with, especially when using automated sealing processes. Some insulating layers tend to generate particulate matter (dust) that can adversely affect energy storage systems, causing manufacturing problems.

[0039] This disclosure helps mitigate these problems by using a sealing layer comprising a laminate film. The sealing layer surrounds at least a portion of the insulating layer. In one embodiment, the laminate film comprises an outer polymer layer, a malleable layer comprising a malleable material, and an inner polymer layer. The inner polymer layer is in contact with the insulating layer. The malleable layer is positioned between the outer and inner polymer layers. The inner and outer polymer layers act as barriers to prevent damage to the insulating layer from the ambient atmosphere and fluids present in the energy storage system. While the malleable layer also provides protection to the insulating layer, it also provides the insulating layer with further support as a rigid yet malleable support for the insulating layer.

[0040] An embodiment of an insulating barrier including an insulating layer sealed by a sealing layer is shown in Figure 1A. The insulating barrier 100 includes an insulating layer 110. The insulating layer 110 is surrounded by a sealing layer 120. In one embodiment, the sealing layer is a laminate film including an outer polymer layer 122, a malleable layer 124, and an inner polymer layer 126. An enlarged side view of the laminate film is shown in Figure 1B. When used to seal an insulating layer, the inner polymer layer 126 is in contact with the insulating layer 110. The malleable layer 124 is positioned between the outer polymer layer 122 and the inner polymer layer 126.

[0041] In some electrical energy storage systems, a fluid transfer system is coupled to the electrical energy storage system. During use, the fluid transfer system passes a heat transfer fluid through the electrical energy storage system and collects the heat transfer fluid after it has passed through the electrical energy storage system. The fluid transfer system passes a dielectric liquid fluid or dielectric gas through the electrical energy storage system. In some embodiments, the fluid is heated or cooled so that it heats or cools components within the electrical energy storage system, respectively.

[0042] Examples of dielectric heat transfer fluids include, but are not limited to, hydrocarbon fluids, ester fluids, silicone fluids, and fluoroether fluids. Hydrocarbon fluids that can be used to cool components of an electrical energy storage system include, but are not limited to, aromatic hydrocarbons (e.g., diethylbenzene and dibenzyltoluene) and aliphatic hydrocarbons (e.g., paraffin oils, isoparaffin oils, and polyalphaolefins). Ester fluids that can be used to cool components of an electrical energy storage system include, but are not limited to, diester and polyol ester heat transfer fluids. Silicone fluids that can be used to cool components of an electrical energy storage system include, but are not limited to, dimethylpolysiloxane, methylphenylpolysiloxane, diphenylpolysiloxane, and halogenated polysiloxanes. Fluoroether fluids that can be used to cool components of an electrical energy storage device include, but are not limited to, perfluoropolyethers and hydrofluoroethers.

[0043] In one aspect of the present disclosure, the outer polymer layer comprises a polymer resistant to dielectric heat transfer fluids in an electrical energy storage system. In a particular aspect of the present disclosure, the outer polymer layer comprises a polymer resistant to one or more heat transfer fluids commonly used in electrical energy storage systems. For example, the outer layer comprises a polymer resistant to hydrocarbon fluids, ester fluids, silicone fluids, fluoroether fluids, or any combination thereof. Exemplary polymers that can be used in the outer polymer layer include, but are not limited to, polyoxymethylene, acrylonitrile butadiene styrene, polyamide-imide, polyamide, polycarbonate, polyester, polyetherimide, polystyrene, polysulfone, polyimide, terephthalate, or combinations thereof.

[0044] The outer polymer layer may also provide abrasion protection to the insulating layer. During use, external stresses may cause damage to the insulating layer. When the insulating layer is damaged, its insulating properties may be impaired. External stresses that may occur in an unprotected insulating layer include, but are not limited to, stresses caused by battery cell expansion, changes in ambient temperature, external impacts, external ruptures, and external damage to the insulating layer. In some aspects of this disclosure, the outer polymer layer is selected from a material that protects the insulating layer from external stresses. Exemplary polymers that can be used as the outer polymer layer include, but are not limited to, polyethylene terephthalate ("PET") and oriented nylon ("ONy").

[0045] Although a single outer polymer layer has been described above, it should be understood that the outer polymer layer may consist of two or more polymer layers. Figure 1C shows one embodiment of the present disclosure including an outer layer consisting of two different polymer layers 122a and 122b. When multiple outer polymer layers are used, the additional outer polymer layers may be formed from the same polymer or different polymers. In one embodiment of the present invention, the outer polymer layer consists of an ONy polymer layer having a PET polymer layer covering it.

[0046] As shown in Figure 1A, the inner polymer layer 126 is in contact with the insulating layer 110. The inner polymer layer 110 at least partially surrounds the insulating layer, protecting it from external chemical and mechanical damage. The insulating layer also acts as a barrier that retains particulate matter from the insulating layer contained within the sealing layer, preventing or inhibiting the dispersion of damaging particles within the electrical energy storage system.

[0047] As discussed herein, the sealing layer 120 may consist of two separate laminate films (e.g., an upper film 120a and a bottom film 120b) connected to each other to form a seal around the insulating layer 110. In an alternative embodiment, the sealing layer may be formed from a single laminate film that seals the insulating layer, which is folded and sealed in itself.

[0048] In one embodiment, the inner polymer layer 126 includes a material that can be heat-welded to itself. As shown in Figure 1A, after sealing the insulating layer 110, the sealing layer 120 expands away from the insulating layer. For example, an inner polymer layer positioned on the upper surface of the insulating layer can be heat-welded to an inner polymer layer positioned on the bottom surface of the insulating layer to form a seal around the insulating layer. The heat seal can be formed by applying a heated object to the upper and / or lower laminate film at a location outside the insulating layer. The heat from the heated object will raise the temperature of the polymer to a point where the polymers used in the upper and lower layers can melt. Exemplary polymers that can be used as inner layers of a laminate film are polyolefin polymers. Examples of polyolefin polymers that can be used as inner polymer layers include, but are not limited to, polyethylene and polypropylene.

[0049] The inner polymer layer may also provide the insulating layer with chemical resistance and / or heat resistance. During use, the temperature of the battery cells may rise due to the power demand of the battery module. Similarly, the temperature of the battery module may rise as the power demand of the battery pack increases. When the temperature of components separated by the insulating layer rises, stress may be placed on the insulating layer. Furthermore, leakage of chemicals from the battery cells may cause chemical damage to the insulating layer and impair its thermal properties. In some aspects of the present invention, the inner polymer layer is selected from materials that protect the insulating layer from chemical and thermal damage. Polyolefin polymers provide the insulating layer with excellent chemical resistance and heat resistance.

[0050] In one embodiment, the malleable layer 124 is positioned between the inner polymer layer 126 and the outer polymer layer 122. In some embodiments, the malleable layer is used to provide support and protection for an insulating barrier, such as an insulating layer containing a woven or nonwoven fiber-reinforced support. Such support-based insulating layers are lightweight and have low rigidity, which can make them difficult to install in electrical energy storage systems, particularly between battery cells. These problems are exacerbated in mass production environments. Placing the malleable layer within the encapsulation layer can allow it to function as a support that facilitates handling of the insulating barrier during manufacturing.

[0051] When used in a battery module, the malleable layer may also provide additional thermal and mechanical protection. In some aspects of this disclosure, the insulating barrier is positioned between battery cells within a battery module. During a thermal runaway event, a battery cell may explode and rupture, releasing hot particles and gases throughout the module. These releases can damage the casings of adjacent battery cells, potentially causing those adjacent cells to malfunction. An insulating barrier, including a malleable layer, can suppress or prevent particulate matter and gases from damaging adjacent battery cells. The malleable layer may also protect the insulating layer from moisture and air.

[0052] In one embodiment, the malleable layer comprises a malleable polymer or a malleable metal foil. Aluminum is the most common metal used in laminate sealing layers, but stainless steel and other malleable metal foils such as copper foil can also be used.

[0053] Using metal foil can also add heat transfer properties to the insulating barrier. When thermal runaway occurs in a battery cell, the cell becomes extremely hot. This heat can radiate to adjacent battery cells, increasing the likelihood that those cells will also enter a runaway state. Using metal foil can improve the thermal properties of the insulating barrier by providing a thermally conductive metal foil to the insulating layer. Heat generated by adjacent runaway battery cells can be transferred to the metal foil layer. The metal foil layer can be connected to a part of the case (e.g., a cooling plate) that allows heat to be transferred away from the battery cells through the metal foil.

[0054] As discussed herein, the encapsulation layer comprises a laminate structure including an outer polymer layer, an inner polymer layer, and a malleable layer positioned between the polymer layers. In some embodiments, the inner polymer layer is composed of a different polymer material than that of the outer polymer layer. For example, the inner polymer layer may be composed of a material that can be easily melted, while the outer polymer layer may be composed of a material that is resistant to the coolant used in electrical energy storage systems.

[0055] A laminate film used as a sealing layer may be constructed as a single film composed of multiple layers, as described herein. In one embodiment, a laminate film can be formed by placing a malleable layer between two polymer layers and melting the inner and outer polymer layers using heat and / or pressure. In another embodiment, an adhesive or tape can be used to hold the layers together. For example, an adhesive can be placed between the outer polymer layer and the malleable layer, and / or between the inner polymer layer and the malleable layer.

[0056] In one embodiment, the thickness of the sealing layer is approximately 30 μm to approximately 300 μm. The sealing layer may have a maximum thickness of approximately 30 μm, 40 μm, 50 μm, 60 μm, 70 μm, 80 μm, 90 μm, 100 μm, 120 μm, 150 μm, 200 μm, 250 μm, or 300 μm. If the sealing layer is a laminate film, the inner polymer layer may have a thickness of approximately 10 μm to approximately 100 μm; the malleable layer may have a thickness of approximately 10 μm to approximately 100 μm; and the outer polymer layer may have a thickness of approximately 10 μm to approximately 100 μm.

[0057] The insulating layers of the present disclosure, for example, insulating layers containing aerogel, can maintain or slightly increase their thermal conductivity (typically measured in mW / mK) under loads up to about 5 MPa. In certain embodiments, the insulating layers of the present disclosure have a thermal conductivity in the thickness direction of the insulating layer within the range 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 any two of these values, at 25°C and a load up to about 5 MPa. The thickness of the aerogel insulating layer can be reduced as a result of the load on the aerogel insulating layer. For example, the thickness of the aerogel insulating layer can be reduced to 50% or less, 40% or less, 30% or less, 25% or less, 20% or less, 15% or less, 10% or less, 5% or less, or any two of these values ​​under loads ranging from approximately 0.50 MPa to 5 MPa. The thermal resistance of the insulating layer containing aerogel may decrease as the thickness decreases, but the thermal conductivity can be maintained or even slightly increased.

[0058] In one embodiment, the sealing layer completely surrounds the insulating layer. Complete sealing of the insulating layer can be achieved by heat-welding two laminate films together. As used herein, the term “heat welding” refers to the process of joining two polymer material pieces by melting them with heat. In the heat welding 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. When the polymer pieces are heated above the glass transition temperature, the material of one or both pieces softens and melts with the other piece.

[0059] In one embodiment, a method for sealing an insulating layer includes, as described herein, surrounding at least a portion of the insulating layer with a laminate film and heat-sealing the laminate film to form a sealing layer, the sealing layer at least partially surrounding the insulating layer. Figure 2A shows one embodiment of a method for sealing an insulating layer. In this embodiment, two separate laminate films 220a and 220b each cover at least a portion of the insulating layer 210. For example, the first laminate film 220a may cover the upper surface of the insulating layer, and the second laminate film 220b may cover the lower surface of the insulating layer. Both the first and second laminate films are arranged so that their inner polymer layers are in contact with each other. The sealing layer can be formed by heat-sealing a portion of the first laminate film to the second laminate film. For example, a heating element with the overall shape of the insulating layer can be brought into contact with the first laminate film and pressed onto the first laminate film. The heated element melts the inner polymer layer of the first laminate film with the inner polymer layer of the second laminate film. Figure 2B shows a schematic diagram of a completely sealed insulating layer.

[0060] In another embodiment, as described herein, the insulating layer is sealed by surrounding at least a portion of the insulating layer with a laminate film and heat-sealing the laminate film to form a sealing layer that at least partially surrounds the insulating layer. Figure 2C shows one embodiment of a method for sealing the insulating layer. In this embodiment, a single laminate film 225 is folded over itself such that each section of the single laminate film covers at least a portion of the insulating layer 210. For example, a first section of the laminate film 225a may cover the upper surface of the insulating layer, and a second section 225b of the laminate film may cover the lower surface of the insulating layer. Both the first and second sections of the laminate film are arranged so that their inner polymer layers are in contact with each other. The sealing layer can be formed by heat-sealing a portion of the first laminate film to the second laminate film. For example, a heating element the shape of the entire insulating layer may be brought into contact with the first laminate film and pressed onto the first laminate film. The heated element melts the inner polymer layer of the first laminate film with the inner polymer layer of the second laminate film.

[0061] As shown in Figure 3A, a method for sealing the insulating layer 310 includes forming a first recess 325 in a first laminate film 320. The first recess 325 is formed by bending the laminate film into a shape complementary in shape and size to the insulating layer. If a malleable layer is present in the laminate film, it is possible to form the first recess and maintain the desired shape and size. A second recess 335 is formed in a second laminate film 330. Both the first and second laminate films are positioned such that the insulating layer is located within the recess. For example, in one embodiment, the insulating layer 310 is first positioned within the second recess 335. Then, the first laminate film 320 is positioned on top of the second laminate film such that the insulating layer is located within the first recess 325. The sealing layer can be completed by heat-sealing a portion of the first laminate film to the second laminate film. Figure 3B shows a top view of the completely sealed insulating layer.

[0062] In an alternative embodiment, the sealing layer is sealed by itself. In this alternative embodiment, a single sealing layer is folded over itself to be long enough to surround the insulating layer. Once folded, the sealing layer is heat-sealed to itself to seal the insulating layer. Figure 3C shows a schematic diagram of a method for sealing the insulating layer 310 with a sealing layer 350 comprising a single laminate film. A first recess 354 and a second recess 358 are formed in the laminate film 350. Both recesses have a size and shape that is complementary to the insulating layer in size and shape. In this embodiment, the sealing layer is formed by placing the insulating layer 310 in the first recess 354. The laminate film is folded over itself such that the second recess 358 is substantially aligned with the first recess 354. The sealing layer can be completed by heat-sealing a portion of the first laminate film to the second laminate film.

[0063] An alternative method for sealing the insulating layer is shown in Figure 4A. In this alternative embodiment, the method for sealing the insulating layer 410 includes forming a first recess 425 in the first laminate film 420. The first recess 425 is formed by bending the laminate film into a shape complementary in shape and size to the insulating layer. A second recess 435 is formed in the second laminate film 430. The second recess 435 has a shape and size complementary in shape and size to the first recess. Specifically, the second recess 435 has a shape and size that allows the recessed portion of the second laminate film to fit into the first recess. Both the first and second laminate films are arranged such that the insulating layer is located within the first recess 425 and on the second recess 435, as shown in Figure 4A. For example, in one embodiment, the insulating layer 410 is first placed in the first recess 425. Next, the second laminate film 430 is placed in contact with the first laminate film such that the insulating layer is located both in the first recess 425 and on the second recess 435. The sealing layer can be completed by heat-sealing a portion of the first laminate film to the second laminate film. Figure 4B shows a top view of the completely sealed insulating layer.

[0064] In another embodiment, a single laminate film is used to form a sealing insulating layer. Figure 4C shows an embodiment in which a single laminate film 450 is folded over itself such that each section of the single laminate film covers at least a portion of the insulating layer 410. In one embodiment, a first recess 465 is formed in a first section of the laminate film. The first recess 465 is formed by bending the laminate film into a shape that is complementary in shape and size to the insulating layer. A second recess 475 is formed in a second section of the laminate film. The second recess 475 has a shape and size that is complementary in shape and size to the first recess. Specifically, the second recess 475 has a shape and size that allows the recessed portion of the second laminate film to fit into the first recess. The first section and the second section of the laminate film are arranged such that the insulating layer is located within the first recess 465 and on the second recess 475, as shown in Figure 4C. For example, in one embodiment, the insulating layer 410 is initially placed within the first recess 465. The second section of the laminate film 450 is folded onto the first laminate film and placed in contact with it such that the insulating layer is located within the first recess 465 and in contact with the second recess 475. The sealing layer can be completed by heat-welding a portion of the first section of the laminate film to a portion of the second section of the laminate film to form a sealing insulating layer.

[0065] An alternative method for sealing the insulating layer is shown in Figure 5A. As shown in Figure 5A, the method for sealing the insulating layer 510 includes forming a first recess 525 in the first laminate film 520. The insulating layer 510 is placed within the first recess 525. Next, the second laminate film 530 is placed in contact with the first laminate film so that the insulating layer is covered by the second laminate film. The sealing layer can be completed by heat-sealing a portion of the first laminate film to the second laminate film. Figure 5B shows a top view of a fully sealed insulating layer.

[0066] Figure 5C shows an embodiment in which a single laminate film 550 is folded over itself such that each section of the single laminate film covers at least a portion of the insulating layer 510. As shown in Figure 5C, a first recess 565 is formed in the first section of the laminate film 550. The insulating layer 510 is placed within the first recess 565. Next, a second section 575 of the laminate film 550 is placed in contact with the first section of the laminate film such that the insulating layer is covered by the second section of the laminate film. The sealing layer can be completed by heat-sealing a portion of the first section of the laminate film to a portion of the second section of the laminate film.

[0067] For example, after a sealing layer is formed by heat-sealing laminate film(s), there may be several additional materials surrounding the insulating layer, typically the portions of the sealing layer that are heat-sealed to each other. As shown in Figure 6A, the insulating layer is sealed with the sealing layer 620. The heat-sealed portions 625 of the sealing layer extend outward from the insulating layer. This can be problematic in some energy storage systems where there is very little additional space, if any, to accommodate these extended portions. In this embodiment, the extended portions 625 may be folded back toward the insulating layer to reduce the size of the insulating barrier. In an alternative embodiment shown in Figure 6B, a notch 630 may be formed in the extended portion 625. The notch allows the extended portion to be folded more easily without bulging the material at the corner, where the material may double if each edge of the seal is folded toward the insulating layer. In some embodiments, a double fold may be used.

[0068] Figure 6C shows an embodiment in which the edge is folded twice. In Figure 6C, an insulating layer (not shown) is sealed with a sealing layer 620. A portion 625 of the heat-sealed sealing layer extends outward from the insulating layer. The first fold is a 180-degree fold, in which the edge material folds over itself. Furthermore, to reduce the extended edge, the edge material is folded a second time at 90 degrees, so that the edge material folds against the side of the pouch.

[0069] When a recess is used to form a pouch around an insulating barrier, the physical parameters of the recess can be optimized to improve sealing of the insulating layer. Figure 7 shows a schematic diagram of a recess 710 formed in a laminate film 700. Recess parameters that can be modified to improve sealing of the insulating layer include depth (D); length (L); and recess angle θ. C , and inner edge radius θ E This includes the material of the malleable layer and its thickness, and the coefficient can be optimized to take these into account.

[0070] Figure 8A shows a typical assembly process for sealing an insulating layer using a single laminate film. In a typical assembly process, both the laminate film and the insulating layer material are supplied as rolls and introduced into the assembly process. First, both the laminate film and the insulating layer material are unwound from the rolls for the process. The laminate film is cut to a predetermined length required for sealing, and the necessary indentations are formed in the laminate film for the process. The insulating layer (in this example, an aerogel insulating layer) is also cut to a predetermined length required for use as a thermal barrier between battery cells or modules. The cut materials are removed from the cutting machine and prepared for assembly. In this example, a single laminate sheet is used to seal the insulating layer by folding the laminate sheet on itself. The laminate film is prepared by forming a fold line or crease in the laminate film. Next, the insulating layer (aerogel) is placed in the appropriate portion of the laminate film, and the film is prepared for thermal sealing. Two sides of the laminate film are heat-sealed to each other to partially enclose the insulating layer, forming a bag-like housing with an open end. In some embodiments, the open end of the bag is heat-sealed to complete the enclosure of the insulating layer. In one alternative embodiment, the partially sealed insulating layer is placed in a vacuum chamber. When the chamber is evacuated, the open end of the sealed layer is sealed, completing the full enclosure of the insulating layer under vacuum. The process is completed by folding the heat-sealed ends of the sealed layer to the sides, if necessary.

[0071] Figure 8B shows a typical assembly process for sealing an insulating layer using two laminate films. As discussed above, both the laminate film and the insulating layer material are supplied as rolls and introduced into the assembly process. First, both the laminate film and the insulating layer material are unwound from the rolls for the process. The laminate film is cut into two separate pieces of predetermined length required for sealing, and the necessary indentations are formed in the laminate film for the process. The insulating layer (in this example, an aerogel insulating layer) is also cut to predetermined length required for use as a thermal barrier between battery cells or modules. The cut material is removed from the cutting machine and prepared for assembly. In this example, two laminate sheets are used to seal the insulating layer. The insulating layer (aerogel) is placed in the appropriate portion of the laminate film, and the film is prepared for thermal sealing. Two sides and one end of the laminate film are heat-sealed to each other to partially enclose the insulating layer, forming a bag-like housing with an open end. In some embodiments, the open end of the bag is simply heat-sealed to complete the sealing of the insulating layer. In one alternative embodiment, a partially sealed insulating layer is placed in a vacuum chamber. When the chamber is evacuated, the open end of the sealing layer is sealed, completing the full sealing of the insulating layer under vacuum. The process is completed by folding the heat-sealed end of the sealing layer to the side, if necessary.

[0072] A test protocol was developed to determine the effectiveness of the insulating barrier described herein. The test protocol tests the insulating barrier's ability to withstand high temperatures and the impact of heated particles. This simulates the rupture conditions that can occur during thermal runaway of a battery cell. In both tests, the insulating barrier is coupled to a metal support plate (e.g., a stainless steel plate). A thermal sensor is attached to the support plate to monitor its temperature during use.

[0073] To test the heat resistance of an insulating barrier, the insulating barrier is bonded to a support plate and subjected to a combustion test. A propane torch (Benzomatic) is used to generate a temperature of approximately 1000°C on the insulating barrier. During the test, the heat of the support plate can be monitored to determine the heat resistance of the insulating layer. After the combustion test is complete, damage to the insulating layer is observed. In an exemplary combustion test protocol, the insulating barrier is bonded to a support, and a propane torch is used to heat the insulating layer to 1000°C for 2 minutes. The insulating layer is then observed for damage.

[0074] The test protocol also includes a heated particle test. The same combustion test system is used in the heated particle test, but modified to include heated particles. In an exemplary experiment, an insulating barrier mounted on a support is heated to approximately 1000°C. A stream of particles inert to the operating temperature (approximately 1000°C) was directed towards the insulating barrier so that the particles were heated by the torch before they collided with the barrier. The heated particles were directed towards the insulating barrier for 10 seconds. After stopping the heated particles, the insulating barrier was heated to 1000°C for 2 minutes without the particles.

[0075] In both tests, the insulating barrier maintained its integrity and insulating properties. While the polymer layer burned under the test conditions, the malleable layer (stainless steel) and insulating layer (aerogel) only discolored. The sealing material can reduce or eliminate the generation of dust or particulate matter emitted from the insulating layer. Furthermore, the sealing layer can be formed from a material that allows for marking or printing on the insulating barrier. Marking the insulating layer is not always possible.

[0076] As used herein and in the appended claims, the singular forms "a," "an," and "the" refer to multiple subjects unless otherwise explicitly indicated in the content. As used herein and in the appended claims, the term "or" generally refers to "and / or" unless otherwise explicitly indicated in the context.

[0077] As used herein, “about” means approximately or nearly, and in the context of a number or range described, it means ±5% of the number. In one embodiment, the term “about” may include conventional rounding by significant figures of a number. Furthermore, the expression “about “x” to “y”” includes “about “x” to about “y””.

[0078] In the context of this disclosure, the terms “aerogel,” “aerogel material,” or “aerogel matrix” refer to a gel that includes a framework of interconnected structures, having a corresponding network of interconnected pores integrated within the framework, and containing a gas such as air as a dispersed interstitial medium, which is thought to be due to the aerogel, including (a) an average pore diameter in the range of about 2 nm to about 100 nm, (b) a porosity of at least 80%, and (c) about 100 nm. 2 It is characterized by physical and structural properties (determined by nitrogen porosimetry testing), specifically a surface area of ​​1 / g or more.

[0079] Accordingly, the aerogel materials of this disclosure include any aerogel or other open-cell material that satisfies the defining elements described in the preceding paragraph, and include materials that can be otherwise categorized as xerogels, cryogels, ambigels, microporous materials, etc.

[0080] In the context of this disclosure, the term “thermal runaway” generally refers to a sudden and rapid increase in cell temperature and pressure due to various operating factors, which can result in excessive temperature propagation throughout the entire module in question. Potential causes of thermal runaway in such systems may include, for example, cell failure and / or short circuits (both internal and external), overcharging, cell puncture or rupture in the event of an accident, and excessive ambient temperature (e.g., generally above 55°C). Under normal use, cells become hot as a result of their internal resistance. Under normal power / current load and ambient operating conditions, the temperature inside most Li-ion cells can be controlled relatively easily to remain within the range of 20°C to 55°C. However, not only stressful conditions such as high power consumption at high cell / ambient temperatures, but also failures in individual cells can cause a sharp increase in localized heat generation. In particular, above the critical temperature, exothermic chemical reactions within the cell are activated. Furthermore, chemical heat generation generally increases exponentially with temperature. As a result, heat generation becomes much greater than the available heat dissipation. Overheating could cause cells to eject, potentially exceeding 200°C internally.

[0081] In the context of this disclosure, the terms “flexible” and “flexible” refer to the ability of a material or composition to bend or flex without macrostructural failure. The insulating layers of this disclosure are capable of being bent at least 5°, at least 25°, at least 45°, at least 65°, or at least 85° without macroscopic failure; and / or having a bending 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 “highly flexible” refer to a material that can be bent to at least 90° and / or have a bending radius of less than U inches without macroscopic failure. Furthermore, the terms “classified flexible” and “classified as flexible” refer to a material or composition that can be classified as flexible according to ASTM Cl 101 (ASTM International, West Conshohocken, PA).

[0082] The insulating layers of the present disclosure may be flexible, highly flexible, and / or classified flexible. The aerogel compositions of the present disclosure may also be drapeable. In the context of the present disclosure, the terms “drapeable” and “drapeable” refer to the ability of a material to bend or flex at a radius of curvature of 90° or more with a radius of curvature of about 4 inches or less without macroscopic defects. The insulating layers according to certain embodiments of the present disclosure are flexible such that the composition is non-rigid and may be applied to, adapted to, or pre-formed into various shapes and configurations to simplify installation or application.

[0083] In the context of this disclosure, the terms “thermal conductivity” and “TC” refer to a measure of a material or composition’s ability to transfer heat between two surfaces of the material or composition, given a temperature difference between the two surfaces. Specifically, thermal conductivity is measured as the thermal energy transferred per unit time and per unit surface area divided by the temperature difference. It is generally expressed as mW / m². * K (atmosphere) *It is recorded in SI units as milliwatts per Kelvin. The thermal conductivity of the material is determined using the 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);Alternatively, it may be determined by test methods known in the art, including but not limited to the Determination of steady-state thermal resistance and related properties—Guarded hot plate apparatus (ISO 8203, International Organization for Standardization, Switzerland). In the context of this disclosure, unless expressly stated otherwise, it should be understood that, due to different methods that may yield different results, thermal conductivity measurements are obtained in accordance with the ASTM C518 standard (Test Method for Steady-State Thermal Transmission Properties by Means of the Heat Flow Meter Apparatus) at a temperature of approximately 37.5°C, at atmospheric pressure in the ambient environment, and under a compressive load of approximately 2 psi. Measurements reported in accordance with ASTM C518 generally correlate well with any measurements performed in accordance with EN 12667 with any relevant adjustments to the compressive load.

[0084] Furthermore, thermal conductivity measurements can also be obtained under compression at atmospheric pressure at a temperature of approximately 10°C. Thermal conductivity measurements at 10°C are generally 0.5 to 0.7 mW / mK lower than the corresponding thermal conductivity measurements at 37.5°C. In certain embodiments, the insulating layer of the present disclosure has a thermal conductivity at 10°C within the range of approximately 40 mW / mK or less, approximately 30 mW / mK or less, approximately 25 mW / mK or less, approximately 20 mW / mK or less, approximately 18 mW / mK or less, approximately 16 mW / mK or less, approximately 14 mW / mK or less, approximately 12 mW / mK or less, approximately 10 mW / mK or less, approximately 5 mW / mK or less, or between any two of these values.

[0085] Use of insulating barriers within battery modules or 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 are a major obstacle to the large-scale application of LIBs. Under misuse conditions, exothermic reactions can release heat, which can trigger subsequent unsafe reactions. The situation is further exacerbated as heat is released from cell misuse, activating a chain reaction that can lead to a catastrophic thermal runaway.

[0086] The continuous improvement in energy density of lithium-ion batteries (LIBs) and the resulting increase in their safety are becoming increasingly urgent for the development of electrical devices (e.g., electric vehicles). The underlying mechanisms of safety issues differ depending on the chemical properties of the various batteries. This technology focuses on adjusting the corresponding configurations of insulating barriers and their tuned barriers to obtain desirable thermal and mechanical properties. The insulating barriers of this technology provide effective thermal dissipation not only under normal conditions but also under thermal runaway conditions, while ensuring the stability of LIBs under normal operating modes (e.g., withstanding applied compressive stress).

[0087] The insulating barriers disclosed herein are useful for isolating, insulating, and protecting battery cells or battery components of any configuration of battery, such as pouch cells, cylindrical cells, and non-circular cells, as well as packs and modules that incorporate or include any such cells. The insulating barriers disclosed herein are useful for rechargeable batteries, such as lithium-ion batteries and solid-state batteries, as well as any other energy storage devices or technologies that require isolation, insulation, and protection.

[0088] Passive devices, such as cooling systems, may be used in conjunction with the insulating barriers of this disclosure within a battery module or battery pack.

[0089] The insulating barriers according to various embodiments of this disclosure thermally isolate the single battery cells or battery cell modules from each other in a battery pack comprising a plurality of single battery cells or battery cell modules. A battery module consists of a plurality of battery cells arranged in a single housing. A battery pack consists of a plurality of battery modules. Figure 9 shows an embodiment of a battery module 900 having a plurality of battery cells 950. The sealing insulating barrier 925 is positioned between the battery cells 950. The sealing insulating barrier can prevent or block damage to adjacent battery cells in the event that a battery cell is experiencing thermal runaway or any other catastrophic battery cell failure.

[0090] Battery modules and battery packs can be used to supply electrical energy to devices or vehicles. Devices that use battery modules or battery packs include, but are not limited to, laptop computers, PDAs, mobile phones, tag scanners, audio equipment, video equipment, display panels, video cameras, digital cameras, desktop computers, military portable computers, military telephones, laser rangefinders, digital communication equipment, information gathering sensors, electronics-integrated clothing, night vision devices, power tools, calculators, radios, remote-controlled appliances, GPS devices, handheld and portable televisions, automotive starters, flashlights, sound equipment, portable heaters, portable vacuum cleaners, or portable medical devices. When used in vehicles, battery packs can be used in all-electric vehicles or hybrid vehicles.

[0091] The manner of disclosure is described in the following numbered clauses.

[0092] 1. An insulating barrier used in an electrical energy storage system, wherein the insulating barrier is At least one insulating layer, and The insulating barrier includes a sealing layer that at least partially surrounds the insulating layer, wherein the sealing layer comprises a laminate film comprising an outer polymer layer, a malleable layer comprising a malleable material, and an inner polymer layer, the inner polymer layer being in contact with the insulating layer, and the malleable layer being positioned between the outer polymer layer and the inner polymer layer.

[0093] 2. The insulating barrier according to Clause 1, wherein the outer polymer layer comprises a polymer resistant to dielectric heat transfer fluids in the electrical energy storage system.

[0094] 3. The insulating barrier according to Clause 2, wherein the outer polymer layer comprises a polymer resistant to a heat transfer fluid selected from the group consisting of hydrocarbon fluids, ester fluids, silicone fluids, fluoroether fluids, and mixtures thereof.

[0095] 4. The insulating barrier according to any one of the preceding clauses, wherein the outer polymer layer is made from a polymer selected from the group consisting of polyoxymethylene, acrylonitrile butadiene styrene, polyamide-imide, polyamide, polycarbonate, polyester, polyetherimide, polystyrene, polysulfone, polyimide, and terephthalate.

[0096] 5. The insulating barrier according to any one of the preceding clauses, wherein the inner polymer layer is composed of a polymer that can be heat-welded to itself.

[0097] 6. The insulating barrier according to any one of the preceding clauses, wherein the inner polymer layer is composed of a polyolefin polymer.

[0098] 7. The insulating barrier according to any one of the preceding clauses, wherein the inner polymer layer is composed of a polymer different from the polymer of the outer polymer layer.

[0099] 8. An insulating barrier according to any one of the preceding clauses, wherein the outer polymer layer is made of polyethylene terephthalate ("PET") or stretched nylon ("ONy"), and the inner polymer layer is made of polypropylene ("PP").

[0100] 9. The insulating barrier according to any one of the preceding clauses, wherein the outer polymer layer comprises a first polymer film made of a first material and a second polymer film made of a second material, and the first material is different from the second material.

[0101] 10. The insulating barrier according to any one of the preceding clauses, wherein the malleable layer includes a metal foil.

[0102] 11. The insulating barrier according to any one of the clauses 1 to 10, wherein the malleable layer comprises a malleable polymer.

[0103] 12. The insulating barrier according to any one of the preceding clauses, wherein the sealing layer further includes an adhesive disposed between the outer polymer layer and the malleable layer and / or between the inner polymer layer and the malleable layer.

[0104] 13. The insulating barrier according to any one of the preceding clauses, wherein the outer polymer layer has a thickness of approximately 10 μm to approximately 100 μm.

[0105] 14. The malleable layer is an insulating barrier according to any one of the preceding clauses, having a thickness of approximately 10 μm to approximately 100 μm.

[0106] 15. The insulating barrier according to any one of the preceding clauses, wherein the inner polymer layer has a thickness of approximately 10 μm to approximately 100 μm.

[0107] 16. The insulating barrier according to any one of the preceding clauses, wherein the sealing layer has a total thickness of approximately 30 μm to approximately 300 μm.

[0108] 17. An insulating barrier according to any one of the preceding clauses, wherein the insulating layer has a thermal conductivity in the thickness direction of the insulating layer of less than about 50 mW / mK at 25°C and less than about 60 mW / mK at 600°C.

[0109] 18. The insulating barrier according to any one of the preceding clauses, wherein the insulating layer comprises an aerogel.

[0110] 19. An insulating barrier according to any one of the preceding clauses, wherein the sealing layer completely surrounds the insulating layer.

[0111] 20. The insulating barrier according to any one of the preceding clauses, wherein the sealing layer is composed of two laminate films heat-sealed to each other.

[0112] 21. The insulating barrier according to any one of the preceding clauses, wherein the sealing layer surrounds the insulating layer, and the sealing layer is heat-welded to itself to form a housing that at least partially surrounds the insulating layer.

[0113] twenty two. Multiple battery cells, and A battery module comprising one or more insulating barriers as described in any one of Clauses 1 to 21, wherein at least one insulating barrier is located between adjacent battery cells.

[0114] 23. A power system including one or more battery modules as described in Clause 22.

[0115] 24. A device or vehicle including a power system as described in Clause 23.

[0116] 25. The device described in Clause 24, which is a laptop computer, PDA, mobile phone, tag scanner, audio equipment, video equipment, display panel, video camera, digital camera, desktop computer, military portable computer, military telephone, laser rangefinder, digital communication equipment, information gathering sensor, electronics-integrated clothing, night vision equipment, power tools, calculator, radio, remote-controlled appliance, GPS device, handheld and portable television, automobile starter, flashlight, sound equipment, portable heater, portable vacuum cleaner, or portable medical device.

[0117] 26. The vehicle described in Article 24, wherein the vehicle is an electric vehicle.

[0118] 27. A method for sealing an insulating layer for use between battery cells in an electrical energy storage system, wherein the method is Surrounding at least a portion of the insulating layer with a laminate film comprising an outer polymer layer, a malleable layer containing a malleable material, and an inner polymer layer, wherein the inner polymer layer is in contact with the insulating layer, and the malleable layer is positioned between the outer polymer layer and the inner polymer layer, and The method comprising heat-sealing the laminate film to form a sealing layer, wherein the sealing layer at least partially surrounds the insulating layer.

[0119] 28. Forming the sealing layer Covering at least a portion of the insulating layer with a first laminate film, Covering at least a portion of the insulating layer with a second laminate film, A portion of the first laminate film is heat-sealed to the second laminate film to form the sealing layer. The method described in Article 27, including the method described in Article 27.

[0120] 29. A first recess is formed in the first laminate film, and the shape and size of the first recess are complementary to the insulating layer. A second recess is formed in the second laminate film, and the shape and size of the second recess are complementary to the insulating layer. Forming the aforementioned sealing layer The insulating layer is placed in the first recess of the first laminate film. Placing the second laminate film on the first laminate film such that the second recess is substantially aligned with the first recess, and A portion of the first laminate film is heat-sealed to a portion of the second laminate film. The method described in Article 28, including the method described in Article 28.

[0121] 30. A first recess is formed in the first laminate film, and the shape and size of the first recess are complementary to the insulating layer. A second recess is formed in the second laminate film, and the shape and size of the second recess are complementary to the first recess. Forming the aforementioned sealing layer The insulating layer is placed in the first recess of the first laminate film. Placing the second laminate film on the first laminate film such that a portion of the second recess is located inside the first recess, and substantially aligning the second recess with the first recess, and A portion of the first laminate film is heat-sealed to a portion of the second laminate film. The method described in Article 28, including the method described in Article 28.

[0122] 31. A first recess is formed in the first laminate film, and the shape and size of the first recess are complementary to the insulating layer. Forming the aforementioned sealing layer The insulating layer is placed in the first recess of the first laminate film. Placing the second laminate film on the first laminate film, and A portion of the first laminate film is heat-sealed to a portion of the second laminate film. The method described in Article 28, including the method described in Article 28.

[0123] 32. A first recess is formed in the laminate film, and the shape and size of the first recess are complementary to the insulating layer. A second recess is formed in the laminate film, and the shape and size of the second recess are complementary to the insulating layer. Forming the aforementioned sealing layer The insulating layer is placed in the first recess of the laminate film. Folding the laminate film such that the second recess of the laminate film is substantially aligned with the first recess, and A portion of the laminate film is heat-sealed to itself. The method described in Article 27, including the method described in Article 27.

[0124] 33. A first recess is formed in the laminate film, and the shape and size of the first recess are complementary to the insulating layer. Forming the aforementioned sealing layer The insulating layer is placed in the first recess of the laminate film. Folding the laminate film such that a portion of the laminate film substantially covers the insulating layer and separate portions of the laminate film, and A portion of the laminate film is heat-sealed to itself. The method described in Article 27, including the method described in Article 27.

[0125] 34. The method according to any one of the clauses 27 to 33, wherein the sealing layer completely surrounds the insulating layer.

[0126] 35. The method according to any one of the claims 27 to 34, wherein the heat-sealed portion of the laminate film is folded with respect to one or more sides of the insulating layer.

[0127] This patent incorporates certain U.S. patents, U.S. patent applications, and other materials (e.g., papers) by reference. However, the texts of such U.S. patents, U.S. patent applications, and other materials are incorporated by reference only to the extent that there is no conflict between such texts and other descriptions and drawings contained herein. Where such a conflict arises, any such conflicting texts that would be incorporated by such reference to the U.S. patents, U.S. patent applications, and other materials are not incorporated by reference in particular.

[0128] Further modifications and alternative embodiments of various aspects of the present invention will become apparent to those skilled in the art upon consideration of this description. Therefore, this description should be interpreted as illustrative only and is intended to teach those skilled in the art general methods of carrying out the invention. It should be understood that the forms of the invention shown and described herein should be interpreted as examples of embodiments. Elements and materials may be replaced with those illustrated and described herein, parts and processes may be reversed, and certain features of the invention may be used independently, all of which will become apparent to those skilled in the art after benefiting from this description of the invention. Modifications to the elements described herein may be made without departing from the spirit and scope of the invention, as described in the following claims.

[0129] As used herein and in the claims, “including” and “including” and their variations mean that a particular feature, step, or integer is included. The terms should not be construed as excluding the existence of other features, steps, or components.

[0130] While certain exemplary embodiments of the present invention are described, the scope of the appended claims is not intended to be limited to these embodiments only. The claims should be construed to encompass literally, purposefully, and / or equivalently.

Claims

1. An insulating barrier used in an electrical energy storage system, wherein the insulating barrier is At least one insulating layer, and The insulating barrier includes a sealing layer that at least partially surrounds the insulating layer, wherein the sealing layer comprises a laminate film comprising an outer polymer layer, a malleable layer comprising a malleable material, and an inner polymer layer, the inner polymer layer being in contact with the insulating layer, and the malleable layer being positioned between the outer polymer layer and the inner polymer layer.

2. The insulating barrier according to claim 1, wherein the outer polymer layer comprises a polymer resistant to dielectric heat transfer fluids in the electrical energy storage system.

3. The insulating barrier according to claim 2, wherein the outer polymer layer comprises a polymer resistant to a heat transfer fluid selected from the group consisting of hydrocarbon fluids, ester fluids, silicone fluids, fluoroether fluids, and mixtures thereof.

4. The insulating barrier according to any one of the prior claims, wherein the outer polymer layer is made from a polymer selected from the group consisting of polyoxymethylene, acrylonitrile butadiene styrene, polyamide-imide, polyamide, polycarbonate, polyester, polyetherimide, polystyrene, polysulfone, polyimide, and terephthalate.

5. The insulating barrier according to any one of the prior claims, wherein the inner polymer layer is made of a polymer that can be heat-welded to itself.

6. The insulating barrier according to any one of the prior claims, wherein the inner polymer layer is composed of a polyolefin polymer.

7. The insulating barrier according to any one of the prior claims, wherein the inner polymer layer is composed of a polymer different from the polymer of the outer polymer layer.

8. The insulating barrier according to any one of the prior claims, wherein the outer polymer layer is made of polyethylene terephthalate ("PET") or stretched nylon ("ONy"), and the inner polymer layer is made of polypropylene ("PP").

9. The insulating barrier according to any one of the prior claims, wherein the outer polymer layer is composed of a first polymer film made of a first material and a second polymer film made of a second material, and the first material is different from the second material.

10. The insulating barrier according to any one of the prior claims, wherein the malleable layer includes a metal foil.

11. The insulating barrier according to any one of claims 1 to 10, wherein the malleable layer comprises a malleable polymer.

12. The insulating barrier according to any one of the prior claims, wherein the sealing layer further includes an adhesive disposed between the outer polymer layer and the malleable layer, and / or between the inner polymer layer and the malleable layer.

13. The insulating barrier according to any one of the prior claims, wherein the outer polymer layer has a thickness of about 10 μm to about 100 μm.

14. The insulating barrier according to any one of the prior claims, wherein the malleable layer has a thickness of about 10 μm to about 100 μm.

15. The insulating barrier according to any one of the prior claims, wherein the inner polymer layer has a thickness of about 10 μm to about 100 μm.

16. The insulating barrier according to any one of the prior claims, wherein the sealing layer has a total thickness of about 30 μm to about 300 μm.

17. The insulating barrier according to any one of the prior claims, wherein the insulating layer has a thermal conductivity in the thickness direction 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.

18. The insulating barrier according to any one of the prior claims, wherein the insulating layer comprises an aerogel.

19. The insulating barrier according to any one of the prior claims, wherein the sealing layer completely surrounds the insulating layer.

20. The insulating barrier according to any one of the prior claims, wherein the sealing layer is composed of two laminate films heat-sealed to each other.

21. The insulating barrier according to any one of the prior claims, wherein the sealing layer surrounds the insulating layer, and the sealing layer is heat-welded to itself to form a housing that at least partially surrounds the insulating layer.

22. Multiple battery cells, and A battery module comprising one or more insulating barriers according to any one of claims 1 to 21, wherein at least one insulating barrier is positioned between adjacent battery cells.

23. A power system comprising one or more battery modules as described in claim 22.

24. A device or vehicle comprising the power system described in claim 23.

25. The device according to claim 24, wherein the device is a laptop computer, PDA, mobile phone, tag scanner, audio device, video device, display panel, video camera, digital camera, desktop computer, military portable computer, military telephone, laser rangefinder, digital communication device, information gathering sensor, electronics-integrated clothing, night vision device, power tool, calculator, radio, remote-controlled appliance, GPS device, handheld and portable television, automobile starter, flashlight, sound device, portable heater, portable vacuum cleaner, or portable medical device.

26. The vehicle according to claim 24, wherein the vehicle is an electric vehicle.

27. A method for sealing an insulating layer for use between battery cells in an electrical energy storage system, wherein the method is Surrounding at least a portion of the insulating layer with a laminate film comprising an outer polymer layer, a malleable layer containing a malleable material, and an inner polymer layer, wherein the inner polymer layer is in contact with the insulating layer, and the malleable layer is positioned between the outer polymer layer and the inner polymer layer, and The method comprising heat-sealing the laminate film to form a sealing layer, wherein the sealing layer at least partially surrounds the insulating layer.

28. Forming the aforementioned sealing layer Covering at least a portion of the insulating layer with a first laminate film, Covering at least a portion of the insulating layer with a second laminate film, A portion of the first laminate film is heat-sealed to the second laminate film to form the sealing layer. The method according to claim 27, including the method described in claim 27.

29. A first recess is formed in the first laminate film, and the shape and size of the first recess are complementary to the insulating layer. A second recess is formed in the second laminate film, and the shape and size of the second recess are complementary to the insulating layer. Forming the aforementioned sealing layer The insulating layer is placed in the first recess of the first laminate film. Placing the second laminate film on the first laminate film such that the second recess is substantially aligned with the first recess, and A portion of the first laminate film is heat-sealed to a portion of the second laminate film. The method according to claim 28, including the method described in claim 28.

30. A first recess is formed in the first laminate film, and the shape and size of the first recess are complementary to the insulating layer. A second recess is formed in the second laminate film, and the shape and size of the second recess are complementary to the first recess. Forming the aforementioned sealing layer The insulating layer is placed in the first recess of the first laminate film. Placing the second laminate film on the first laminate film such that a portion of the second recess is located inside the first recess, and aligning the second recess substantially with the first recess, and A portion of the first laminate film is heat-sealed to a portion of the second laminate film. The method according to claim 28, including the method described in claim 28.

31. A first recess is formed in the first laminate film, and the shape and size of the first recess are complementary to the insulating layer. Forming the aforementioned sealing layer The insulating layer is placed in the first recess of the first laminate film. Placing the second laminate film on the first laminate film, and A portion of the first laminate film is heat-sealed to a portion of the second laminate film. The method according to claim 28, including the method described in claim 28.

32. A first recess is formed in the laminate film, and the shape and size of the first recess are complementary to the insulating layer. A second recess is formed in the laminate film, and the shape and size of the second recess are complementary to the insulating layer. Forming the aforementioned sealing layer The insulating layer is placed in the first recess of the laminate film. Folding the laminate film such that the second recess of the laminate film is substantially aligned with the first recess, and A portion of the laminate film is heat-sealed to itself. The method according to claim 27, including the method described in claim 27.

33. A first recess is formed in the laminate film, and the shape and size of the first recess are complementary to the insulating layer. Forming the aforementioned sealing layer The insulating layer is placed in the first recess of the laminate film. Folding the laminate film such that a portion of the laminate film substantially covers the insulating layer and separate portions of the laminate film, and A portion of the laminate film is heat-sealed to itself. The method according to claim 27, including the method described in claim 27.

34. The method according to any one of claims 27 to 33, wherein the sealing layer completely surrounds the insulating layer.

35. The method according to any one of claims 27 to 34, wherein the heat-sealed portion of the laminate film is folded with respect to one or more sides of the insulating layer.

Images