Protection of electrical components in the battery system

Abstract

To manage the thermal runaway problem in energy storage systems. [Solution] A battery module comprising a plurality of battery cells, a housing and housing lid for housing the plurality of battery cells, and a laminated busbar including an insulating layer between the housing lid and the plurality of battery cells, wherein the insulating layer includes aerogel.

Description

Technical Field

[0001] Claims of Priority This application claims the benefit of priority of U.S. Provisional Patent Application No. 63 / 338,331, filed on May 4, 2022, the entire disclosure of which is incorporated herein by reference.

[0002] The present disclosure generally relates to materials, systems, and methods for protecting electrical connection components. In particular, the present disclosure relates to materials, systems, and methods for encapsulating electrical connection components (e.g., busbars) using aerogel materials. The present disclosure further relates to battery modules or battery packs having one or more battery cells including encapsulated electrical connection components, and systems including such battery modules or battery packs.

Background Art

[0003] Rechargeable batteries such as lithium-ion batteries have found wide applications in power-driven and energy storage systems. Lithium-ion batteries (LIBs) are widely used for power supply to portable electronic devices such as mobile phones, tablets, laptops, power tools, and other high-current devices such as electric vehicles because they have a high operating voltage, a low memory effect, and a high energy density compared to conventional batteries. However, LIBs are a safety concern because they are prone to catastrophic failures under "misuse conditions" such as when a rechargeable battery is overcharged (charged beyond the design voltage), over-discharged, or operated or exposed to high temperature and high pressure. As a result, LIBs are subject to narrow operating temperature ranges and charge / discharge rates as they may fail due to rapid self-heating or thermal runaway events when exposed to conditions outside their design windows.

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

[0005] Based on an understanding of the mechanisms that lead to battery thermal runaway, many methods are being studied with the aim of reducing safety issues through the rational design of battery components.

[0006] A typical battery system includes one or more battery modules, each containing multiple battery cells. Subsets of battery cells are electrically connected in parallel, and subsets are electrically connected in series by a series of current collectors (or busbars). For example, terminal current collectors, or busbars, indicate a potential difference that defines a DC bus. Switching components, fuse components, busbars carrying the highest voltage of the battery module, any other suitable power electronics, any other suitable components, or any combination thereof may be located on or near the battery module(s). Busbars are typically located on the sides of the battery system (e.g., front, rear, top, bottom, or any side) to make appropriate electrical connections between components. Busbars tend to extend over parts of the battery module and thus may be located over one or more battery cells (e.g., the ventilation ends of battery cells). If a battery cell experiences a thermal event, adjacent structures such as busbars may be damaged. Therefore, it may be desirable to provide protection from heat, gases, and / or granular material. [Brief explanation of the drawing]

[0007] [Figure 1] Figure 1 shows a top view of a battery system according to several exemplary embodiments. [Figure 2] Figure 2 shows busbars according to several exemplary embodiments. [Figure 3] Figure 3 shows cross-sectional views of busbars according to several exemplary embodiments. [Figure 4] Figure 4 shows isometric views of a battery system according to several exemplary embodiments. [Figure 5] Figure 5 shows busbar assemblies according to several exemplary embodiments. [Figure 6] Figure 6 shows cross-sectional views of busbar assemblies according to several exemplary embodiments. [Figure 7] Figure 7 shows another busbar assembly according to several exemplary embodiments. [Figure 8] Figure 8 shows another busbar assembly according to several exemplary embodiments. [Figure 9] Figure 9 shows a battery system according to several exemplary embodiments. [Figure 10] Figure 10 shows another battery system according to several exemplary embodiments. [Figure 11] Figure 11 shows another battery system according to several exemplary embodiments. [Figure 12] Figure 12 shows another battery system according to several exemplary embodiments. [Figure 13] Figure 13 shows another battery system according to several exemplary embodiments. [Figure 14] Figure 14 shows another battery system in several exemplary embodiments. [Figure 15] Figure 15 shows another battery system according to several exemplary embodiments. [Modes for carrying out the invention]

[0008] The following detailed description of preferred embodiments includes references to the accompanying drawings, which form part of the disclosure and are shown as examples of specific embodiments in which the disclosure may be put into practice. It should be understood that other embodiments may be used and structural modifications may be made without departing from the scope of the disclosure.

[0009] This disclosure aims to protect electrical connection systems in energy storage systems. Exemplary embodiments include the protection of busbars in an energy storage system using aerogel material.

[0010] Figure 1 shows a schematic diagram of a typical electrical energy storage system 100, which includes a housing 104, battery modules 108A, 108B, and 108C (collectively referred to as 108), and one or more busbars 112. As described above, the energy storage system 100 can store and release electricity for use in an electric vehicle or other electric system.

[0011] In the electrical energy storage system 100, the battery module 108 is located inside the housing 104. The battery module 108 may include a plurality of individual cells 116 that can be electrically connected. In one embodiment, the cells 116 include lithium-ion cells, but the disclosure is not limited thereto. One or more busbars 112 of the system 100 electrically connect one or more of the battery modules 108. In some embodiments, the busbars 112 may be elongated conductive connectors that connect terminals from different battery modules or battery cells.

[0012] Figure 2 shows a detail view of one embodiment of a busbar 200, which includes a conductor 204 and plugs 208A, 208B (collectively 208). The conductor 204 may be a conductive elongated structure configured to span one or more battery modules and / or battery cells to connect corresponding terminals. In the busbar 200 shown in Figure 2, the conductor 204 is a metal bar. Other embodiments of the busbar 200 may have a conductor 204 of a different configuration, among others, a metal wire, a conductive trace on a structural support, etc. Regardless of its configuration, the conductor 204 serves as the conductive portion of the busbar 200. In some embodiments, the conductor 204 of the busbar 200 may be made of a conductive metal such as copper, aluminum, or a metal alloy.

[0013] The busbar 200 also includes plugs 208A and 208B connected to conductor 204. Plugs 208A and 208B connect the busbar 200 to terminals (not shown in Figure 2) of a battery module or battery cell. In one embodiment, plugs 208A and 208B are configured to engage with corresponding features on a module or cell in an energy storage system. One embodiment of the corresponding features for engaging plugs 208A and 208B includes slots on the module or cell. Examples of suitable materials for the busbar 200 include conductive metallic materials such as copper, aluminum, iron, or alloys thereof.

[0014] Figure 3 shows a cross-sectional view of the conductor 204 of the busbar 200 shown in Figure 2. As shown, the conductor 204 includes a conductive core 304, an insulating layer 308, and a sealing layer 312. The insulating layer 308 and the sealing layer 312 together are called a protective barrier 314 and provide a form of electrical, thermal, and mechanical protection to the conductor 204, thereby improving the overall resilience and durability of the busbar 200 in response to corresponding electrical, thermal, and / or mechanical stresses / perturbations. The material of the conductive core 304 corresponds to that already described above in the context of the conductor 204 shown in Figure 2.

[0015] In some embodiments, such as the embodiment shown in FIGS. 2 and 3, the protective barrier 314 at least partially covers the conductive core 304. In some embodiments, the protective barrier 314 may cover some or all of any subset of the length, width, and / or surface of the conductive core 304.

[0016] In some embodiments, the protective barrier 314 includes at least one insulating layer 308 and at least one encapsulation layer 312. As shown in FIG. 3, at least one of the insulating layers 308 is disposed between the conductive core 304 and the (outermost) encapsulation layer 312. It should be understood that different configurations of the protective barrier 314 having a greater number of one or more insulating layers 308 and / or encapsulation layers 312 are possible without departing from the concepts described herein. Further, different arrangements of layers may also be used to manufacture other embodiments of the protective barrier 314 without departing from the concepts described herein. Although not explicitly shown, the encapsulation layer 314 may surround at least a portion of the plug 208 (shown in FIG. 2) and some or all of the conductive core 304.

[0017] In some embodiments, the protective barrier 314 may include an aerogel material as a component within the insulating layer 308 and the encapsulation layer 312 that at least partially surrounds the insulating layer.

[0018] The insulating layer 308 can include any type of insulating layer commonly used to separate battery cells or battery modules that provides thermal insulation, electrical insulation, or both. In some embodiments, the insulating layer(s) 308 can include a polymer-based thermal barrier (e.g., polypropylene, polyester, polyimide, and aromatic polyamide (aramid)), a phase change material, a thermally expandable material, an aerogel material, a mineral-based barrier (e.g., mica), and an inorganic thermal barrier (e.g., a fiberglass-containing barrier), or any one or more of combinations thereof. For example, an exemplary insulating layer can include a combination of a material such as an aerogel material or composition and another material such as a mineral-based material (e.g., mica), a phase change material, or a thermally expandable material. In such an example, the aerogel material may incorporate other materials within the aerogel composition or structure. Alternatively, the aerogel material may be disposed adjacent to a layer of another material, e.g., a layer of an aerogel composition adjacent to a layer of a mineral-based material (e.g., mica), a layer of a phase change material, or a layer of a thermally expandable material. In further embodiments, the aerogel material may be disposed between a layer of a mineral-based material (e.g., mica), a layer of a phase change material, or a layer of a thermally expandable material.

[0019] The insulating layer 308 can have a thermal conductivity 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 in the range between any two of these values when mechanical loads of 25 °C and up to about 5 MPa are individually applied at atmospheric pressure.

[0020] In some embodiments, the insulating layer 308 comprises an aerogel further containing a reinforcing material. In some embodiments, the reinforcing material is a fiber selected from organic polymer fibers, inorganic fibers, carbon fibers, or a combination thereof. In some embodiments, the fiber is in the form of discrete fibers, woven materials, dry nonwoven materials, wet nonwoven materials, needle nonwovens, padding, woven fabrics, mats, felts, and / or combinations thereof. In some embodiments, the inorganic fiber is selected from glass fibers, rock fibers, metal fibers, boron fibers, ceramic fibers, basalt fibers, or a combination thereof. In some embodiments, the reinforcing material is a foam selected from siloxanes, polyolefins, polyurethanes, phenols, melamines, cellulose acetates, oxidized polyacrylonitriles, and polystyrenes. In some embodiments, the reinforcing material is selected from polymer materials. Non-limiting examples of polymer materials include resins, rubber, acrylic (PMMA), acrylonitrile butadiene styrene (ABS), nylon (polyamide, PA), polycarbonate (PC), polyethylene (PE), polyoxymethylene (POM), polypropylene (PP), polystyrene (PS), thermoplastic elastomer (TPE), and thermoplastic polyurethane (TPU).

[0021] In one or more embodiments, the aerogel of the insulating layer 308 comprises a silica-based aerogel and / or an alumina silicate aerogel. In one or more embodiments, the aerogel of the insulating layer 308 comprises one or more additives, which are present at a level of at least about 5 to 40% of the weight of the aerogel, preferably at a level of at least about 5 to 20% of the weight of the aerogel, and more preferably at a level of at least about 10 to 20% of the weight of the aerogel. In some embodiments, one or more additives comprises a refractory class additive. In some embodiments, one or more additives comprises an opacifier selected from B4C, diatomaceous earth, manganese ferrite, MnO, NiO, SnO, Ag2O, Bi2O3, TiC, WC, carbon black, titanium oxide, iron titanium oxide, zirconium silicate, zirconium oxide, iron(I) oxide, iron(III) oxide, manganese dioxide, iron titanium oxide (ilmenite), chromium oxide, or mixtures thereof. In some embodiments, one or more additives include an opaler containing silicon carbide. In some embodiments, one or more additives include a combination of a refractory class additive and an opaler. In one or more embodiments, the aerogel has a density in the range of about 0.25 g / cc to about 1.0 g / cc. In some embodiments, the aerogel has a flexural modulus of about 2 MPa to about 8 MPa. In some embodiments, the aerogel has a compression set in the range of about 10% to about 25% at about 70°C. In some embodiments, the aerogel exhibits a compressive resistance, and the compressive resistance at 25% strain is between about 40 kPa and about 180 kPa. In one or more embodiments, the aerogel is in the form of a monolith, beads, particles, granules, powder, thin film, sheet, plate, curved plate, or a combination thereof.

[0022] In some embodiments, the sealing layer 312 of the protective barrier 314 may be made of a material capable of protecting the busbar from the external environment. For example, particulate matter and fluids (e.g., cooling fluid and battery electrolyte) may be present within the housing of the electrical energy storage system, and without the sealing layer 312, the electrical and / or thermal performance of the insulating layer 308 and / or conductive core 304 may degrade. Furthermore, it is preferable that the sealing layer is electrically insulating. This feature can help prevent short circuits in the electrical system through the busbar.

[0023] In some embodiments, the sealing layer 312 may be made from a polymer selected from a collection consisting of polyoxymethylene, acrylonitrile butadiene styrene, polyamideimide, polyamide, polycarbonate, polyester, polyetherimide, polystyrene, polysulfone, polyimide, and terephthalate.

[0024] The sealing layer 312 and the insulating layer 308 may be bonded to protect the busbar from damage resulting from elevated temperatures associated with thermal runaway of the battery cell; however, some embodiments of the sealing layer 312 and / or insulating layer 308 may not protect the conductive core 304 from physical impacts of particulate matter from a ruptured battery cell. To improve the sealing layer 312's ability to resist mechanical damage from impacts with particles, the sealing layer 312 may be composed of a cured polymer material. In some embodiments, the cured polymer material may include a polymer layer filled with a second phase known to add improved mechanical, thermal, and abrasion resistance. In one embodiment, the cured second phase is particles of a ceramic material (e.g., silica nano / microparticles, silicate / clay nano / microparticles). In other embodiments, the cured second phase is a barrier layer (not shown) incorporated into the polymer material. The barrier layer may be made of a rigid material that suppresses damage from particulate matter impacting the busbar at high speed. Examples of materials that may be used for the barrier layer include, but are not limited to, metal foil, mica, microporous silica, ceramic fibers, mineral wool, metals, carbon, conductive polymers, or combinations thereof.

[0025] In addition to the busbars, the combination of the insulating layer 308 and the sealing layer 312 can also be used to protect other components within the battery pack, such as electrical devices and wiring, cooling tubes, battery cells or pack terminals, temperature sensors, connectors, and / or other components that are susceptible to damage during thermal runaway.

[0026] Figure 4 shows an embodiment of the electrical energy storage system 400. In this embodiment, the electrical energy storage system 400 includes a plurality of battery cells 404. Each battery cell 404 has two terminals 408 (a positive terminal and a negative terminal). In this embodiment, the battery cells 404 are connected in series by a busbar 412 connecting the positive or negative terminals 408 of adjacent battery cells 404 to each other. Embodiments of the busbar 412 shown in Figure 4 may include any combination and / or subset of the features described above in the context of any features described in Figures 1, 2, and 3, or elsewhere in this specification.

[0027] In some embodiments, including the embodiment shown in Figure 4, the electrical energy storage system 400 may further include a busbar protection assembly 416. The busbar protection assembly 416 may be used to enclose one or more busbars. In some embodiments, one of which is shown in Figure 6, the busbar protection assembly 416 includes a housing 604 having an internal space 606 defined by the inner surface 609 of the housing 604. The busbar protection assembly 416 may also include an insulating layer 608.

[0028] The housing 604 of the busbar protection assembly 416 is configured and sized such that the housing 609 can be positioned on one or more busbars 412, as shown in Figures 4 and 5. When positioned on a busbar 412, the busbar 412 is substantially enclosed by the housing 604.

[0029] In embodiments, the insulating layer 608 may include an aerogel material. The insulating layer 608 may conform to some or all of the inner surface of the housing 609, as shown in Figure 6. For example, as shown in Figure 6, the insulating layer 608 is located between one or more busbars 412 and the inner surface 609 of the housing 604. In embodiments, the insulating layer 608 covers at least a portion of the inner surface 609 of the housing 604.

[0030] In some embodiments, the insulating layer 608 may be made from an elastic material, either alone or in combination with an aerogel material. The elastic insulating layer 608 can be compressed by the terminal 408 and by conforming the insulating layer to the shape of the terminal 408. Thus, in some embodiments, the insulating layer 608 has a thickness that, when the insulating layer 608 is compressed, allows the terminal 408 to fit into the internal space 606 of the housing 604. In alternative embodiments, the insulating layer 608 has a thickness that allows the battery cell terminal 408 to fit into the internal space 606 of the housing 604 without compressing the insulating layer 608.

[0031] A busbar protection assembly can be configured (having shape and size) to allow the assembly to cover a single busbar or multiple busbars. In some embodiments, the busbar protection assembly covers all busbars on the surface of a battery module or battery pack.

[0032] In some embodiments, the busbar protection assembly covers the entire surface of the battery module or battery pack on which the busbar is located (e.g., the top surface to which the busbar is mounted). When the busbar protection assembly covers the entire surface of the module / pack, it provides cushioning for the module / pack against potential mechanical shocks, in addition to heat, fire, and electrical insulation. In this embodiment, the busbar protection assembly is slightly larger than the surface of the battery module / pack being covered, such that the surface of the module / pack with the busbar extends into the busbar protection assembly so that the busbar protection assembly surrounds a portion of the battery module / pack. An aerogel lining provides additional cushioning for the module / pack.

[0033] In some embodiments, as shown in Figures 7 and 8, the busbars 700 and 800 may each have a laminated structure. In the embodiment of the busbar 700 shown in Figure 7, the laminated busbar 700 includes one or more insulating layers 704A, 704B and one or more conductive layers 708. The one or more insulating layers preferably include an aerogel material.

[0034] The conductive layer includes two or more contacts 712A, 712B (collectively 712) that extend outward from the laminated structure and function as connection areas for connecting busbars to terminals of adjacent battery cells or battery modules.

[0035] In the embodiment shown in Figure 7, the insulating layer is positioned as the outer layer of a laminated structure in which one or more conductive layers are sandwiched between insulating layers.

[0036] In the embodiment shown in Figure 8, the laminated busbar 800 includes the elements described above in the context that the laminated busbar 800 (insulating layers 804A, 804B, conductive layer 808) may also include a barrier layer 816. The barrier layer, as shown, is located beneath the laminated structure and protects the conductive layer from damage caused by particulate matter emitted from the battery cell. Although shown as being present only on the "bottom" surface of the laminated structure, it should be understood that the barrier layer may be present on the "top" surface of the laminated structure (opposite the battery cell or battery module) or on both sides of the laminated structure.

[0037] In the embodiment shown in Figure 9, the busbar system 900 includes one or more busbars 912 connecting the terminals of adjacent battery cells 902 or battery modules. A first insulating layer 904A is positioned over at least a portion of the battery cells 902 or battery modules. The first insulating layer 904A includes a plurality of openings. The openings in the first insulating layer are substantially aligned with the terminals 908 of the battery 902 such that the battery terminals 908 extend through the first insulating layer 904A and contact one or more busbars 912. In this embodiment, the first insulating layer 904A protects the busbars 912 from heat generated from thermal runaway events without the need to modify commercially available busbars.

[0038] To further protect the busbars, a second insulating layer 904B may be located on one or more busbars 912. The first insulating layer 904A may be connected to the second insulating layer 904B such that one or more busbars 912 are substantially surrounded by the first insulating layer 904A and the second insulating layer 904B. In embodiments, one or more busbars 912 are in contact with and compressed by the second insulating layer 904B such that the compressed second insulating layer 904B substantially surrounds one or more busbars 912.

[0039] In embodiments, the first insulating layer 904A and / or the second insulating layer 904B include one or more additional openings aligned with one or more vents present in the battery cell or battery module. The openings aligned with the vents are typically aligned above vents that are not directly below or near the busbars 912. For vents located below one or more busbars 912, it is preferable that the insulating layer has a portion that covers the vent so that the insulating layer is located between the vent and the busbars.

[0040] In the embodiment, the first insulating layer 904A includes a thermal conductive element connected to a cooling element. In the embodiment, the thermal conductive element is positioned between the first insulating layer 904A and the battery cell 902. In the embodiment, the thermal conductive element is positioned between the first insulating layer and the second insulating layer. In the embodiment, the thermal conductive element is in direct contact with the busbar.

[0041] In the embodiment shown in Figure 10, the U-shaped busbar 1012 is configured to electrically connect a battery cell 1002 or a battery module. The U-shaped busbar 1012 includes a first conductive U-shaped portion 1012A, a second conductive U-shaped portion 1012B, and two channels 1013 that receive electrode tabs 1008 from an adjacent battery cell 1002. During assembly, the second conductive U-shaped portion 1012B fits into the first conductive U-shaped portion 1012A to secure the electrode tabs 1008 within the two channels 1013. The thermal insulation material 1004 is in contact with the first U-shaped portion 1012A and / or the second U-shaped portion 1012B. The thermal insulation material helps protect the U-shaped busbar.

[0042] In this embodiment, the thermal insulation material 1004 is located on top of the U-shaped busbars 1012. The thermal insulation material may include a first insulating material 1004A positioned within the internal space defined by the first U-shaped busbar 1012A, and a second insulating material 1004B in contact with the outer surface of the second U-shaped busbar 1012B. The second insulating material 1004B extends downward to isolate adjacent battery cells or battery modules. In this embodiment, the first thermal insulation material 1004A includes a corrugated structure, which is located on multiple U-shaped busbars. The insulating material in this embodiment is made of the same material used to form the insulating layer as described herein.

[0043] An alternative embodiment is shown in Figure 11. In this embodiment, the insulating material 1104 located inside the busbar 1112 is extended outward from the busbar 1112 and serves as a separator between adjacent battery cells 1102.

[0044] In the embodiment shown in Figure 12, the battery module 1200 includes a housing 1202 and a housing lid 1204 for enclosing two or more battery cells 1210. The two or more battery cells 1210 are electronically connected by busbars 1212. The busbars are substantially surrounded by a first insulating layer 1206 and a second insulating layer 1208. The battery module further includes an upper cover 1220 adjacent to the second insulating layer 1208. The upper cover 1220 protects the housing lid 1204 from damage caused, for example, by particulate matter emitted from the battery cells 1210 during thermal runaway, thereby containing the thermal runaway within the housing 1202 and lid 1204. In a non-limiting embodiment, the upper cover 1220 is located between the second insulating layer 1208 and the housing lid 1204. In some embodiments, the upper cover 1220 includes one layer having a uniform composition. In some embodiments, the upper cover 1220 contains an aerogel composition.

[0045] In the embodiment shown in Figure 13, the battery module 1300 includes a housing 1302 and a housing lid 1304 for enclosing two or more battery cells 1310. The upper cover 1320 includes an insulating layer 1322, as described with respect to Figures 7-11, and a rigid layer 1324 having greater rigidity than the insulating layer 1322. In some embodiments, the insulating layer 1322 prevents heat transfer through the housing lid 1304. For example, the insulating layer 1322 prevents heat transfer to the housing lid 1304 and components that may be above the battery module 1300 (e.g., the chassis). In another embodiment, the insulating layer 1322 prevents heat loss from the battery module 1300 to a cold climate environment. In a non-limiting embodiment, the rigid layer 1324 is placed between the insulating layer 1322 and the battery cells 1310 to protect the insulating layer 1322 from particulate matter that may be emitted from the battery cells 1310 during thermal runaway.

[0046] In an alternative embodiment shown in Figure 14, the battery module 1400 includes a housing 1402 and a housing lid 1404 for enclosing two or more battery cells 1410. The upper cover 1420 includes two rigid layers 1422, 1426 and an insulating layer 1424 positioned between them. The additional rigid layer 1422 between the insulating layer 1424 and the housing lid 1404 provides better protection than a single rigid layer with respect to any particulate matter that may be discharged from the battery cells 1410 during thermal runaway. In some embodiments, the upper cover 1420 may include two or more insulating layers 1424 and rigid layers 1422, 1426. In some embodiments, the rigid layers 1422, 1426 may include the same material as the barrier layer shown in Figure 8.

[0047] In some embodiments, one or more hard layers 1422, 1426 may be selected from aerogel (e.g., monolithic aerogel plate), metal foil, mica, microporous silica, ceramic fibers, fiberglass, mineral wool, metal, carbon, conductive polymer, acrylate polymer, polycarbonate, polyester, styrene, vinyl PVC, cellulose acetate, nylon, phenols, or combinations thereof.

[0048] In the embodiment shown in Figure 15, the battery pack 1500 includes a plurality of battery modules 1510, similar to the module shown in Figure 12, except that the second insulating layer 1508 extends over one more battery module 1510. In an alternative embodiment (not shown), each battery module 1510 has a separate second insulating layer 1508. The battery pack 1500 may also include a busbar 1512 positioned between the first insulating layer 1506 and the second insulating layer 1508 for electrical connection of the battery modules 1510. The battery pack 1500 may also include a secondary busbar 1514 positioned between the first insulating layer 1506 and the second insulating layer 1508 for lateral electrical connection of the battery modules 1510. The embodiment in Figure 15 may also include an upper cover 1520, as described above in relation to the embodiments in Figures 12-14. The top cover 1520 may cover each individual battery module 1510 separately. Alternatively, the top cover 1520 may extend over one or more battery modules, as shown in Figure 15.

[0049] As described above, the embodiments of the first insulating layer, the second insulating layer, and the upper cover may include one or more aerogel composition layers. Other insulating materials other than aerogel are also within the scope of this disclosure.

[0050] Use of isolation barriers within battery modules or packs The insulated electrical connectors (e.g., busbars) disclosed herein are useful for electrically connecting battery cells or battery components of batteries of any configuration, such as pouch cells, cylindrical cells, and prism cells, and packs and modules that incorporate or include any such cells. The electrical connectors disclosed herein are useful in rechargeable batteries, such as lithium-ion batteries, solid-state batteries, and any other energy storage devices or technologies.

[0051] Passive devices, such as cooling systems, may be used in conjunction with the isolated connectors of this disclosure within a battery module or battery pack.

[0052] The isolated electrical connectors according to various embodiments of this disclosure may be used in a battery pack comprising multiple battery modules, or in a battery module having multiple battery cells. A battery module consists of multiple battery cells arranged in a single housing. A battery pack consists of multiple battery modules.

[0053] Battery modules and battery packs may 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 devices, video devices, display panels, video cameras, digital cameras, desktop computers, military portable computers, military telephones, laser rangefinders, digital communication devices, information gathering sensors, electronically integrated apparel, night vision devices, power tools, calculators, radios, remote control devices, GPS devices, handheld and portable televisions, automotive starters, flashlights, acoustic devices, portable heating devices, portable vacuum cleaners, or portable medical devices. When used in vehicles, battery packs may be used in all-electric vehicles or hybrid vehicles.

[0054] To better illustrate the methods and apparatus disclosed herein, a non-limiting list of embodiments is provided herein.

[0055] Embodiment 1 is a busbar configured to electrically connect a battery cell or battery module, comprising a protective barrier that at least partially seals the busbar, wherein the busbar comprises an elongated conductive portion and plugs on opposite ends of the elongated conductive portion, and the protective barrier comprises at least one insulating layer and optionally an sealing layer that at least partially surrounds the insulating layer, the insulating layer being located between the busbar and the optional sealing layer.

[0056] Example 2 includes the busbar of Example 1, wherein the protective barrier completely surrounds the elongated conductive portion.

[0057] Example 3 includes one of the busbars from Examples 1-2, wherein the protective barrier surrounds at least a portion of the plug.

[0058] Example 4 includes one of the busbars from Examples 1 to 3, wherein an insulating layer covers one side of the elongated conductive portion, and a sealing layer completely surrounds the elongated conductive portion.

[0059] Example 5 includes one of the busbars from Examples 1 to 4, wherein the insulating layer has a thermal conductivity through the thickness dimension of the insulating layer of less than approximately 50 mW / m·K at 25°C and less than approximately 60 mW / m·K at 600°C.

[0060] Example 6 includes one of the busbars from Examples 1 to 5, wherein the insulating layer contains an aerogel material.

[0061] Example 7 includes one of the busbars from Examples 1 to 6, wherein the insulating layer further comprises a thermally expanding material.

[0062] Example 8 includes one of the busbars from Examples 1 to 7, wherein the insulating layer includes a reinforcing material.

[0063] Example 9 includes a busbar from any one of Examples 1 to 8, wherein the reinforcing material is a fiber selected from organic polymer fibers, inorganic fibers, carbon fibers, or a combination thereof.

[0064] Example 10 includes one of the busbars from Examples 1 to 9, wherein the fibers are in the form of discrete fibers, woven materials, dry nonwoven materials, wet nonwoven materials, needle nonwovens, padding, woven fabrics, mats, felts, and / or combinations thereof.

[0065] Example 11 includes one of the busbars from Examples 1 to 10, wherein the inorganic fibers are selected from glass fibers, rock fibers, metal fibers, boron fibers, ceramic fibers, basalt fibers, or a combination thereof.

[0066] Example 12 includes a busbar from any one of Examples 1 to 11, wherein the reinforcing material is a foam selected from siloxane, polyolefin, polyurethane, phenols, melamine, cellulose acetate, and polystyrene.

[0067] Example 13 includes a encapsulation layer comprising one of the busbars from Examples 1 to 12, which contains a polymer material.

[0068] Example 14 includes a busbar from any one of Examples 1 to 13, wherein the sealing layer includes a polymer material and a barrier layer incorporated into the polymer material.

[0069] Example 15 includes a barrier layer comprising one of the busbars from Examples 1 to 14, which contains a metal foil.

[0070] Example 16 includes a busbar from any one of Examples 1 to 15, wherein the barrier layer contains mica.

[0071] Example 17 includes a busbar from any one of Examples 1 to 16, wherein the barrier layer comprises microporous silica, ceramic fibers, mineral wool, metal, carbon, conductive polymer, aerogel powder, or a combination thereof.

[0072] Example 18 is a busbar protection assembly configured to at least partially enclose one or more busbars, the busbar protection assembly comprising: a housing having an internal space defined by the inner surface of the housing, the housing having a shape and size such that the housing can be positioned over one or more busbars, and the one or more busbars being substantially enclosed by the housing during use; and an insulating layer located inside the housing, the insulating layer being located between the one or more busbars and the inner surface of the housing.

[0073] Example 19 includes the busbar of Example 18, wherein the insulating layer covers at least a portion of the inner surface of the housing.

[0074] Example 20 includes one of the busbars from Examples 18 to 19, wherein the insulating layer has a thickness that allows the battery cell terminals to fit into the internal space of the housing without compressing the insulating layer.

[0075] Example 21 includes one of the busbars from Examples 18 to 20, wherein the insulating layer has a thickness that, when the insulating layer is compressed, allows the battery cell terminals to fit into the internal space of the housing.

[0076] Example 22 includes one busbar from any of Examples 18-21, in which the busbar protection assembly covers a single busbar.

[0077] Example 23 includes one busbar from any of Examples 18-22, in which the busbar protection assembly covers multiple busbars.

[0078] Example 24 includes one busbar from any of Examples 18-23, wherein the busbar protection assembly covers all busbars on the surface of the battery module or battery pack.

[0079] Example 25 includes one of the busbars from Examples 18 to 24, wherein the busbar protection assembly covers the entire surface of the battery module or battery pack, and the covered surface includes one or more busbars.

[0080] Example 26 includes a busbar from any one of Examples 18-25, wherein the insulating layer provides a buffer between the housing and the battery cell terminals or battery module terminals that extend into the housing during use.

[0081] Example 27 includes one of the busbars from Examples 18 to 26, wherein the insulating layer has a thermal conductivity through the thickness dimension of the insulating layer of less than approximately 50 mW / m·K at 25°C and less than approximately 60 mW / m·K at 600°C.

[0082] Example 28 includes one of the busbars from Examples 18 to 27, wherein the insulating layer comprises an aerogel material.

[0083] Example 29 includes one of the busbars from Examples 18 to 28, wherein the insulating layer further comprises a thermally expanding material.

[0084] Example 30 includes a encapsulation layer comprising one of the busbars from Examples 18 to 29, wherein the encapsulation layer contains a polymer material.

[0085] Example 31 includes a busbar from any one of Examples 18 to 30, wherein the sealing layer includes a polymer material and a barrier layer incorporated into the polymer material.

[0086] Example 32 includes a barrier layer comprising one of the busbars from Examples 18 to 31, which contains a metal foil.

[0087] Example 33 includes a barrier layer comprising one of the busbars from Examples 18 to 32, wherein the barrier layer contains mica.

[0088] Example 34 includes one of the busbars from Examples 18 to 33, wherein the busbar has a laminated structure comprising one or more insulating layers and one or more conductive layers, and the conductive layers include two or more contacts for connecting battery cells or battery modules during use.

[0089] Example 35 includes a busbar from any one of Examples 18 to 34, wherein the insulating layer is positioned as the outer layer of the laminated structure, and one or more conductive layers are sandwiched between the insulating layers.

[0090] Example 36 includes a busbar from any one of Examples 18 to 35, wherein the laminated structure further includes a barrier layer connected to the insulating layer.

[0091] Example 37 includes a busbar from any one of Examples 18 to 36, wherein the laminated structure comprises, in order from one side of the laminated structure to the other, a barrier layer, a first insulating layer, a conductive layer, and a second insulating layer.

[0092] Example 38 includes one of the busbars from Examples 18 to 37, wherein the insulating layer has a thermal conductivity through the thickness dimension of the insulating layer of less than approximately 50 mW / m·K at 25°C and less than approximately 60 mW / m·K at 600°C.

[0093] Example 39 includes a busbar from any one of Examples 18 to 38, wherein the insulating layer comprises an aerogel material.

[0094] Example 40 includes one of the busbars from Examples 18 to 39, wherein the insulating layer further comprises a thermally expanding material.

[0095] Example 41 includes a encapsulation layer comprising one of the busbars from Examples 18 to 40, which contains a polymer material.

[0096] Example 42 includes a busbar from any one of Examples 18 to 41, wherein the sealing layer includes a polymer material and a barrier layer incorporated into the polymer material.

[0097] Example 43 includes a barrier layer comprising one of the busbars from Examples 18 to 42, which includes a metal foil.

[0098] Example 44 includes a barrier layer comprising one of the busbars from Examples 18 to 43, wherein the barrier layer contains mica.

[0099] Embodiment 45 is a busbar system for connecting a plurality of battery cells or battery modules, the busbar system comprising a first insulating layer located on at least a portion of the battery cells or battery modules, the first insulating layer comprising a plurality of openings and one or more busbars for electrically connecting one or more battery cells or battery modules, the openings of the first insulating layer being aligned with the terminals of the batteries such that the terminals of the batteries extend through the first insulating layer and contact one or more busbars.

[0100] Example 46 includes the busbar of Example 45, further comprising a second insulating layer located on one or more busbars.

[0101] Example 47 includes any one of the busbars from Examples 45 to 46, wherein the first insulating layer is connected to the second insulating layer such that one or more busbars are substantially surrounded by the first insulating layer and the second insulating layer.

[0102] Example 48 includes one of the busbars from Examples 45 to 47, wherein one or more busbars contact and compress the second insulating layer such that the compressed second insulating layer substantially surrounds one or more busbars.

[0103] Example 49 includes any one of the busbars from Examples 45 to 48, wherein the first insulating layer and / or the second insulating layer includes one or more additional openings aligned with one or more vents present in the battery cell or battery module.

[0104] Example 50 includes one of the busbars from Examples 45 to 49, wherein one or more vents are not located beneath one or more busbars.

[0105] Example 51 includes any one busbar from Examples 45 to 50, wherein at least some of the one or more vents are located beneath one or more busbars, and when the vents are located beneath one or more busbars, the first insulating layer is located between the one or more vents.

[0106] Example 52 includes a busbar from any one of Examples 45 to 51, wherein the first insulating layer includes a thermally conductive element connected to a cooling element.

[0107] Example 53 includes one of the busbars from Examples 45 to 52, wherein the first insulating layer and / or the second insulating layer comprises an aerogel material.

[0108] Embodiment 54 is a U-shaped busbar configured to electrically connect a battery cell or battery module, the busbar comprising: a first conductive U-shaped portion; a second conductive U-shaped portion; two channels for receiving electrode tabs from an adjacent battery cell, the second conductive U-shaped portion fitting into the first conductive U-shaped portion so as to secure the electrode tabs within the two channels; and a thermal insulation material in contact with the first U-shaped portion and / or the second U-shaped portion.

[0109] Example 55 includes the U-shaped busbar of Example 54, wherein the thermal insulation material is located on top of the U-shaped busbar.

[0110] Example 56 includes one of the U-shaped busbars from Examples 54 to 55, wherein the insulating material comprises a first insulating material placed within the internal space defined by the U-shaped busbar and a second insulating material in contact with the outer surface of the U-shaped busbar.

[0111] Example 57 includes one of the U-shaped busbars from Examples 54-56, wherein a second insulating material extends downward to isolate adjacent battery cells or battery modules.

[0112] Example 58 includes a U-shaped busbar from any one of Examples 54 to 57, wherein a second insulating material extends downward through an opening in the bottom surface of the first conductive U-shaped portion.

[0113] Example 59 includes one of the U-shaped busbars from Examples 54 to 58, wherein the first insulating material includes a corrugated structure, and the corrugated structure is located on a plurality of U-shaped busbars.

[0114] Example 60 includes a U-shaped busbar from any one of Examples 54-59, wherein the insulating material contains aerogel.

[0115] Example 61 includes a battery module comprising a plurality of battery cells, a housing and housing lid for housing the plurality of battery cells, and an insulating layer between the housing lid and the plurality of battery cells.

[0116] Example 62 includes the battery module of Example 61, wherein the insulating layer comprises aerogel.

[0117] Example 63 includes one of the battery modules from Examples 61 to 62, further comprising a barrier layer between the multiple battery cells and the housing lid.

[0118] Example 64 includes one of the battery modules from Examples 61 to 63, wherein the barrier layer is located between the insulating layer and the housing lid.

[0119] Example 65 includes one of the battery modules from Examples 61 to 64, wherein the barrier layer is selected from materials chosen from metal foil, mica, microporous silica, ceramic fibers, mineral wool, metal, carbon, conductive polymer, or a combination thereof.

[0120] Example 66 includes a battery module of any one of Examples 61 to 65, further comprising one or more busbars or busbar systems according to any one of claims 1 to 60.

[0121] Example 67 includes one of the battery modules from Examples 61-66, wherein the top cover is configured to withstand damage from particulate matter ejected from the battery cells.

[0122] Example 68 includes one of the battery modules from Examples 61 to 67, wherein the upper cover includes a hard layer and an insulating layer.

[0123] Example 69 includes one of the battery modules from Examples 61 to 68, wherein the top cover contains metal foil or mica.

[0124] Example 70 is a power system comprising one or more battery modules as described in Example 61.

[0125] Example 71 is a device or vehicle that includes a battery module according to Example 70.

[0126] Example 72 includes the device of Example 71, 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, electronically integrated apparel, night vision equipment, power tools, calculator, wireless, remote control equipment, GPS device, handheld and portable television, car starter, flashlight, sound device, portable heating device, portable vacuum cleaner, or portable medical device.

[0127] Example 73 includes the device of Example 71, wherein the vehicle is an electric vehicle.

[0128] The above description is intended to be illustrative, not restrictive. For example, the embodiments described above (or one or more of their embodiments) may be used in combination with one another. Other embodiments may be used by those skilled in the art who have considered the above description. The abstract is provided to enable the reader to quickly grasp the essence of the technical disclosure. It is submitted with the understanding that it is not to be used to interpret or limit the claims or their meaning. Also, in the embodiments for carrying out the above invention, various features may be grouped together to streamline the disclosure. This should not be interpreted as meaning that any disclosed features not claimed are essential to any claim. Rather, the subject matter of the invention may lie in fewer features than all the features of a particular disclosed embodiment. Therefore, the following claims are incorporated herein into embodiments for carrying out the invention, and each claim stands alone as a separate embodiment, and such embodiments may be combined with one another in various combinations or substitutions. The scope of the invention should be determined in relation to the attached claims, along with the entire scope of the equivalent to which such claims are granted.

[0129] While the subject matter of the invention is outlined in relation to specific exemplary embodiments, various modifications and changes can be made to these embodiments without departing from the broader scope of embodiments of the present disclosure. Such embodiments of the subject matter of the invention may be referred to herein by the term “invention” for convenience only, without any intention to spontaneously limit the scope of this application to any single disclosure or inventive concept when more than one is actually disclosed, either individually or collectively.

[0130] The embodiments described herein are described in sufficient detail to enable those skilled in the art to practice the disclosed teachings. Other embodiments may be used and derived therefrom so that structural and logical substitutions and modifications may be made without departing from the scope of this disclosure. The forms for carrying out the invention should therefore not be taken in a limiting sense, and the scope of the various embodiments is defined only by the appended claims, along with the entire scope of equivalents to which such claims are granted.

[0131] The term “or” as used herein may be interpreted either in an inclusive or exclusive sense. Furthermore, multiple instances of a resource, operation, or structure described herein may be provided as a single instance. In addition, the boundaries between various resources, operations, systems, engines, and data stores are somewhat arbitrary, and certain operations are shown in the context of specific exemplary configurations. Other assignments of functionality are conceivable and may fall within the scope of various embodiments of this disclosure. Generally, structures and functionalities presented as separate resources in exemplary configurations may be implemented as combined structures or resources. Similarly, structures and functionalities presented as single resources may be implemented as separate resources. These and other variations, modifications, additions, and improvements fall within the scope of embodiments of this disclosure represented by the appended claims. Accordingly, the specification and drawings should be considered illustrative rather than restrictive.

[0132] The above description is provided for illustrative purposes with respect to specific exemplary embodiments. However, the above exemplary description is not intended to be exhaustive or to limit possible exemplary embodiments to the exact form disclosed. Many modifications and variations are possible in light of the above teaching. The exemplary embodiments have been selected and described to best illustrate the principles and their practical applications, thereby enabling those skilled in the art to best utilize various exemplary embodiments with various modifications suitable for the specific use intended.

[0133] While terms such as "first," "second," etc., may be used herein to describe various elements, it should be understood that these elements should not be limited by these terms. These terms are used solely to distinguish one element from another. For example, without departing from the scope of this exemplary embodiment, the first contact may be called the second contact, and similarly, the second contact may be called the first contact. Both the first and second contacts are contacts, but they are not identical contacts.

[0134] The technical terms used in the description of exemplary embodiments herein are for the purpose of describing specific exemplary embodiments only and are not intended to limit them. The singular forms “a,” “an,” and “the” used in the description of exemplary embodiments and appended examples are intended to include the plural forms as well, unless the context specifically indicates otherwise. It should also be understood that the terms “and / or” as used herein refer to and encompass one or more of the relevant enumeration items, and all possible combinations thereof. It should also be understood that the terms “comprises” and / or “comprising,” as used herein, indicate the existence of the described features, integers, steps, actions, elements, and / or components, but do not exclude the existence or addition of one or more other features, integers, steps, actions, elements, components, and / or sets thereof.

[0135] As used herein, the term “if” may be interpreted, depending on the context, to mean “when,” “upon,” “depending on the decision,” or “depending on the detection.” Similarly, the phrases “if it is decided” or “if [the stated condition or event] is detected” may be interpreted, depending on the context, to mean “when it is decided,” “depending on the decision,” or “when [the stated condition or event] is detected,” or “depending on [the stated condition or event] is detected.” Some embodiments of the present invention are shown below. [Embodiment 1] A busbar configured to electrically connect a battery cell or battery module, the busbar comprising a protective barrier that at least partially seals the busbar, wherein the busbar comprises an elongated conductive portion and plugs on opposing ends of the elongated conductive portion, and the protective barrier is At least one insulating layer, Optionally, a sealing layer that at least partially surrounds the insulating layer, The insulating layer is located between the busbar and the arbitrary sealing layer. The aforementioned bus bar. [Embodiment 2] The bus bar according to Embodiment 1, wherein the protective barrier completely surrounds the elongated conductive portion. [Embodiment 3] The bus bar according to embodiment 1 or 2, wherein the protective barrier surrounds at least a portion of the plug. [Embodiment 4] The busbar according to Embodiment 1, wherein the insulating layer covers one side of the elongated conductive portion, and the sealing layer completely surrounds the elongated conductive portion. [Embodiment 5] The busbar according to any one of Embodiments 1 to 4, wherein the insulating layer has a thermal conductivity through the thickness dimension of the insulating layer of less than approximately 50 mW / m·K at 25°C and less than approximately 60 mW / m·K at 600°C. [Embodiment 6] The bus bar according to any one of Embodiments 1 to 5, wherein the insulating layer comprises an aerogel material. [Embodiment 7] The busbar according to any one of Embodiments 1 to 6, wherein the insulating layer further comprises a thermally expandable material. [Embodiment 8] The bus bar according to any one of Embodiments 1 to 7, wherein the insulating layer includes a reinforcing material. [Embodiment 9] The bus bar according to Embodiment 1, further comprising a barrier layer, wherein the barrier layer comprises a metal foil. [Embodiment 10] A bus bar according to Embodiment 14, further comprising a barrier layer, wherein the barrier layer comprises mica. [Embodiment 11] The bus bar according to Embodiment 14, further comprising a barrier layer, wherein the barrier layer comprises microporous silica, ceramic fibers, mineral wool, metal, carbon, conductive polymer, aerogel powder, or a combination thereof. [Embodiment 12] A busbar protection assembly configured to at least partially enclose one or more busbars, wherein the busbar protection assembly is The housing having an internal space defined by the inner surface of the housing, wherein the housing has a shape and size such that the housing can be positioned on one or more busbars, and the one or more busbars are substantially enclosed by the housing during use, An insulating layer located inside the housing, wherein the insulating layer is located between the one or more busbars and the inner surface of the housing, The busbar protection assembly comprising the above. [Embodiment 13] The busbar protection assembly according to Embodiment 12, wherein the insulating layer comprises an aerogel material. [Embodiment 14] The busbar protection assembly according to Embodiment 12, wherein the insulating layer further comprises a thermally expandable material. [Embodiment 15] The busbar protection assembly according to Embodiment 12, further comprising a barrier layer, wherein the barrier layer comprises a metal foil. [Embodiment 16] The busbar protection assembly according to Embodiment 12, further comprising a barrier layer, wherein the barrier layer comprises mica. [Embodiment 17] A U-shaped busbar configured to electrically connect battery cells or battery modules, wherein the busbar is The first conductive U-shaped portion, A second conductive U-shaped portion, Two channels for receiving electrode tabs from an adjacent battery cell, wherein the second conductive U-shaped portion fits into the first conductive U-shaped portion so as to fix the electrode tabs within the two channels, A heat insulating material in contact with the first U-shaped portion and / or the second U-shaped portion, The bus bar comprising the above. [Embodiment 18] The busbar according to Embodiment 17, wherein the heat insulating material includes a first insulating material disposed within the internal space defined by the U-shaped busbar and a second insulating material in contact with the outer surface of the U-shaped busbar. [Embodiment 19] The busbar according to embodiment 18, wherein the second insulating material extends downward to isolate the adjacent battery cell or battery module. [Embodiment 20] It is a battery module, Multiple battery cells, A housing and housing lid for housing the plurality of battery cells, An insulating layer between the housing lid and the plurality of battery cells, The battery module comprising the above. [Embodiment 21] The battery module according to embodiment 20, wherein the insulating layer includes aerogel. [Embodiment 22] The battery module according to embodiment 20, further comprising a barrier layer between the plurality of battery cells and the housing lid. [Embodiment 23] The battery module according to embodiment 20, wherein the barrier layer is located between the insulating layer and the housing lid. [Embodiment 24] The battery module according to Embodiment 20, wherein the barrier layer is selected from a material selected from metal foil, mica, microporous silica, ceramic fibers, mineral wool, metal, carbon, conductive polymer, or a combination thereof.

Claims

1. It is a battery module, Multiple battery cells, A housing and housing lid for housing the plurality of battery cells, A laminated busbar including an insulating layer between the housing lid and the plurality of battery cells, Equipped with, The insulating layer includes an aerogel. The aforementioned battery module.

2. The battery module according to claim 1, further comprising a barrier layer between the plurality of battery cells and the housing lid.

3. The battery module according to claim 2, wherein the barrier layer is located between the insulating layer and the housing lid.

4. The battery module according to claim 2, wherein the barrier layer is selected from a material selected from metal foil, mica, microporous silica, ceramic fibers, mineral wool, metal, carbon, conductive polymer, or a combination thereof.

5. The battery module according to claim 1, wherein the insulating layer includes a plurality of openings, the plurality of battery cells include a plurality of terminals, and the plurality of terminals extend through the plurality of openings.

6. The battery module according to claim 1, wherein the insulating layer includes a plurality of openings, the plurality of battery cells include a plurality of ventilation holes, and the openings are aligned with the plurality of ventilation holes.

7. The battery module according to claim 1, wherein the plurality of battery cells include a plurality of vents, and the insulating layer is located between the plurality of vents and the busbar.

8. The battery module according to claim 7, wherein the insulating layer includes a plurality of openings aligned with the plurality of ventilation holes, and the plurality of ventilation holes are not aligned with the busbar.

9. The battery module according to claim 1, wherein the insulating layer is a first insulating layer, and the battery module further includes a second insulating layer between the housing lid and the plurality of battery cells.

10. The battery module according to claim 9, further comprising a stacked busbar, wherein the stacked busbar comprises a first insulating layer, a second insulating layer, and a conductive layer between the first insulating layer and the second insulating layer.

11. The battery module according to claim 10, wherein the plurality of battery cells include a plurality of terminals, and the conductive layer extends from the first insulating layer and the second insulating layer to connect the busbar and the plurality of terminals.

12. The battery module according to claim 10, wherein the conductive layer is in contact with the second insulating layer, and the second insulating layer is compressed, and the compressed second insulating layer surrounds the conductive layer.

13. The battery module according to claim 10, wherein the first insulating layer is connected to the second insulating layer, and the conductive layer is surrounded by the first insulating layer and the second insulating layer.

14. The battery module according to claim 2, wherein the barrier layer is located between the insulating layer and the plurality of battery cells.

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