Battery with multiple thermal zones and method

Abstract

A battery system and related methods are disclosed. In one embodiment, the battery system includes a stack of battery cells including two or more distinct thermal zones. An embodiment is shown with two or more distinct thermal regulating members positioned between the battery cells in the stack of lithium-ion battery cells at the dividing point between the thermal zones.

Description

[Technical Field]

[0001] Priority claims This patent application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 426,639, filed November 18, 2022, entitled "BATTERY SYSTEM WITH MULTIPLE THERMAL ISOLATION ZONES AND METHOD," and U.S. Provisional Patent Application No. 63 / 538,694, filed September 15, 2023, entitled "BATTERY SYSTEM WITH MULTIPLE THERMAL ISOLATION ZONES AND METHOD," each of which is incorporated by reference herein in its entirety.

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

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

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

[0005] [Figure 1] 1 illustrates a battery system according to some embodiments. [Figure 2] 1 illustrates a battery module according to some embodiments. [Figure 3A] 1 illustrates another battery system according to some embodiments. [Figure 3B] 3B illustrates a cross section from the battery system of FIG. 3A according to some embodiments. [Figure 4A] 1 illustrates another battery system according to some embodiments. [Figure 4B] 4B illustrates a cross section from the battery system of FIG. 4A according to some embodiments. [Figure 4C] 4B illustrates another cross section from the battery system of FIG. 4A, according to some embodiments. [Figure 5A] 1 illustrates another battery system according to some embodiments. [Figure 5B] 5B illustrates a cross section from the battery system of FIG. 5A according to some embodiments. [Figure 6] 1 illustrates a flowchart of a method according to some aspects. [Figure 7] 1 illustrates another battery system according to some embodiments. [Figure 8] 1 illustrates another battery system according to some embodiments. [Figure 9] 1 illustrates another battery system according to some embodiments. [Figure 10] 1 illustrates another battery system according to some embodiments. [Figure 11] 1 illustrates another battery system according to some embodiments. [Figure 12] 1 illustrates another battery system according to some embodiments. [Figure 13]1 illustrates another battery system according to some embodiments. [Figure 14] 1 illustrates another battery system according to some embodiments. [Figure 15A] 1 illustrates a channel layer according to some embodiments. [Figure 15B] 1 illustrates another channel layer according to some embodiments. [Figure 15C] 1 illustrates another channel layer according to some embodiments. [Figure 16] 1 illustrates an electronic device according to some embodiments. [Figure 17] 1 illustrates an electric vehicle according to some embodiments. DETAILED DESCRIPTION OF THE INVENTION

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

[0007] The present disclosure is directed to a thermal conditioning member between stacks of battery cells in a battery system. The thermal conditioning member divides the battery system's housing into multiple thermal zones. Each thermal zone can have a different thermal conditioning member according to the heat distribution characteristics of the battery cells within the thermal zone. The thermal conditioning member includes an insulating material layer, a heat conductor plate, and an elastic layer. The thermal conditioning member is also referred to as a thermal barrier, a thermal conditioning member, a thermal conditioning element, a thermal conditioning material, a thermal conditioning layer, or a thermal conditioning barrier.

[0008] The insulating material layer separates the battery system housing into multiple thermal zones and limits, reduces, or prevents heat transfer between the thermal zones. In some embodiments, the insulating material layer comprises an aerogel. Accordingly, the insulating material layer is also referred to hereinafter as an aerogel layer.

[0009] The thermal conductor layer dissipates unwanted heat from the battery cell. The thermal conductor layer also provides mechanical support to the insulating material layer and may protect the insulating material from fire and / or particle impact during a thermal runaway event. The thermal conductor layer may partially or entirely cover the mounting area of ​​the battery cell and / or the insulating material layer.

[0010] The elastic layer accommodates the volume expansion and extraction of the battery cell during the charge and discharge process, thereby maintaining cell pressure and improving the electrochemical performance and cycle life of the battery cell.

[0011] The thermal regulating member may further include one or more other functional layers, such as a structural support layer, an adhesive layer, a heat absorption layer, other functional layers, or combinations thereof. Embodiments of the structural support layer include polymers, mica, ceramics, resins, rubbers, composites, other suitable materials, or combinations thereof.

[0012] Insulating material layer The insulating materials described in the following embodiments can be used as a single heat-resistant layer or in combination with other layers that provide additional functionality in a multi-layer configuration, such as mechanical strength, compressibility, heat dissipation / conduction, etc. The insulating layers described herein are responsible for ensuring containment and control of heat flow from heat-generating components in small spaces, providing safety for such products and preventing heat propagation and fire spread in the fields of electronics, industrial, and automotive technology.

[0013] In many aspects of the present disclosure, the insulating layer functions as a flame / fire deflector layer, either by itself or in combination with other materials that enhance its ability to contain and control heat flow. For example, the insulating layer itself may be heat, flame, and / or hot gas resistant and may further include entrained particulate materials that modify or enhance heat containment and control.

[0014] One embodiment of a highly effective insulating layer comprises aerogels, which are characterized by their structure: low density, open cell structure, and large surface area (often over 900 m²). 2This paper describes a class of materials based on their thermal insulating properties (e.g., pore sizes of 1000 kJ / g or greater) and sub-nanometer scale pore sizes. The pores may be filled with a gas, such as air. Aerogels can be distinguished from other porous materials by their physical and structural properties. Aerogel materials are exemplary insulating materials, but the invention is not limited thereto. Other thermal insulating material layers may also be used in embodiments of the present disclosure.

[0015] Selected aspects of aerogel formation and properties are described. In some aspects, precursor materials are gelled to form a network of solvent-filled pores. The solvent is then extracted, leaving a porous matrix. A variety of different aerogel compositions are known, and they may be inorganic, organic, and inorganic / organic hybrids. Inorganic aerogels are generally based on metal alkoxides and include materials such as silica, zirconia, alumina, and other oxides. Organic aerogels include, but are not limited to, urethane aerogels, resorcinol formaldehyde aerogels, and polyimide aerogels.

[0016] Inorganic aerogels can generally be formed from metal oxide or metal alkoxide materials. The metal oxide or metal alkoxide materials can be based on the oxide or alkoxide of any metal capable of forming an oxide. Such metals include, but are not limited to, silicon, aluminum, titanium, zirconium, hafnium, yttrium, vanadium, cerium, and the like. Inorganic silica aerogels are traditionally made via the hydrolysis and condensation of silica-based alkoxides (e.g., tetraethoxysilane) or via the gelation of silicic acid or water glass. Other relevant inorganic precursor materials for silica-based aerogel synthesis include, but are not limited to, metal silicates such as sodium silicate or potassium silicate, alkoxysilanes, partially hydrolyzed alkoxysilanes, tetraethoxysilane (TEOS), partially hydrolyzed TEOS, condensation polymers of TEOS, tetramethoxysilane (TMOS), partially hydrolyzed TMOS, condensation polymers of TMOS, tetra-n-propoxysilane, partially hydrolyzed and / or condensation polymers of tetra-n-propoxysilane, polyethylsilicate, partially hydrolyzed polyethylsilicate, monomeric alkylalkoxysilanes, bis-trialkoxyalkyl or arylsilanes, polyhedral silsesquioxanes, or combinations thereof.

[0017] In certain embodiments of the present disclosure, pre-hydrolyzed TEOS, such as Silbond H-5 (SBH5, Silbond Corp), which is hydrolyzed to a water / silica ratio of about 1.9 to 2, may be used as commercially available or may be further hydrolyzed before incorporation into the gelation process. Partially hydrolyzed TEOS or TMOS, such as polyethyl silicate (Silbond 40) or polymethyl silicate, may also be used commercially or may be further hydrolyzed before incorporation into the gelation process.

[0018] Inorganic aerogels can also include gel precursors containing at least one hydrophobic group, such as alkyl metal alkoxides, cycloalkyl metal alkoxides, and aryl metal alkoxides, which can impart or improve certain properties to the gel, such as stability and hydrophobicity. Inorganic silica aerogels, specifically, can include hydrophobic precursors such as alkyl silanes or aryl silanes. The hydrophobic gel precursor may be used as the primary precursor material to form the framework of the gel material. However, hydrophobic gel precursors are more commonly used as co-precursors in combination with simple metal alkoxides to form amalgam aerogels. Hydrophobic inorganic precursor materials for silica-based aerogel synthesis include, but are not limited to, trimethylmethoxysilane (TMS), dimethyldimethoxysilane (DMS), methyltrimethoxysilane (MTMS), trimethylethoxysilane, dimethyldiethoxysilane (DMDS), methyltriethoxysilane (MTES), ethyltriethoxysilane (ETES), diethyldiethoxysilane, dimethyldiethoxysilane (DMDES), ethyltriethoxysilane, propyltrimethoxysilane, propyltriethoxysilane, phenyltrimethoxysilane, phenyltriethoxysilane (PhTES), hexamethyldisilazane, and hexaethyldisilazane. Any derivatives of any of the above precursors may also be used, particularly certain polymers of other chemical groups may be added to or crosslinked with one or more of the above precursors.

[0019] Organic aerogels are generally formed from carbon-based polymer precursors. Such polymeric materials include, but are not limited to, resorcinol formaldehyde (RF), polyimides, polyacrylates, polymethyl methacrylates, acrylate oligomers, polyoxyalkylenes, polyurethanes, polyphenols, polybutadiene, trialkoxysilyl-terminated polydimethylsiloxanes, polystyrenes, polyacrylonitriles, polyfurfural, melamine-formaldehyde, cresol formaldehyde, phenol-furfural, polyethers, polyols, polyisocyanates, polyhydroxybenzenes, polyvinyl alcohol dialdehyde, polycyanurates, polyacrylamides, various epoxies, agar, agarose, chitosan, and combinations thereof. In one embodiment, organic RF aerogels are typically prepared from the sol-gel polymerization of resorcinol or melamine with formaldehyde under alkaline conditions.

[0020] Organic / inorganic hybrid aerogels are primarily composed of organically modified silica ("ormosil") aerogels. These ormosil materials contain organic components covalently bonded to the silica network. Ormosils are typically formed by the hydrolysis and condensation of an organically modified silane, R-Si(OX)3, with a conventional alkoxide precursor, Y(OX)4. In these formulas, X can represent, for example, CH3, CH5, CH7, or CH9; Y can represent, for example, Si, Ti, Zr, or Al; and R can be any organic fragment, such as methyl, ethyl, propyl, butyl, isopropyl, methacrylate, acrylate, vinyl, or epoxide. Additionally, the organic components in ormosil aerogels can be dispersed throughout the silica network or chemically bonded to it.

[0021] Aerogels can be formed from flexible gel precursors. Various flexible layers, including flexible fiber-reinforced aerogels, can be easily combined and molded to obtain a preform that, when mechanically compressed along one or more axes, provides an object with high compressive strength along any of those axes.

[0022] One method of aerogel formation involves batch casting. Batch casting involves catalyzing an entire volume of sol to simultaneously induce gelation throughout that volume. Gel formation techniques involve adjusting the pH and / or temperature of a dilute metal oxide sol to a point where gelation occurs. Materials suitable for forming inorganic aerogels include oxides of most metals capable of forming oxides, such as silicon, aluminum, titanium, zirconium, hafnium, yttrium, and vanadium. Particularly preferred are gels formed primarily from alcoholic solutions of hydrolyzed silicate esters (alcogels) due to their ready availability and low cost. Organic aerogels can also be made from melamine formaldehyde, resorcinol formaldehyde, and the like.

[0023] The aerogel may be organic, inorganic, or a mixture thereof. In some embodiments, the aerogel comprises a silica-based aerogel. One or more layers within the thermal barrier may include a reinforcing material. The reinforcing material may be any material that provides resilience, compliance, or structural stability to the aerogel material. Embodiments of the reinforcing material include, but are not limited to, open-cell macroporous framework reinforcement materials, closed-cell macroporous framework reinforcement materials, open-cell membranes, honeycomb reinforcement materials, polymeric reinforcement materials, and fibrous reinforcement materials such as, for example, staple fibers, woven materials, nonwoven materials, needled nonwovens, battings, webs, mats, and felts.

[0024] The reinforcing material can be selected from organic polymer-based fibers, inorganic fibers, carbon-based fibers, or combinations thereof. The inorganic fibers can be selected from glass fibers, rock fibers, metal fibers, boron fibers, ceramic fibers, basalt fibers, or combinations thereof. In some embodiments, the reinforcing material can include a reinforcement comprising multiple layers of materials.

[0025] Fiber reinforcement materials include polyester, polyolefin terephthalate, poly(ethylene) naphthalate, polycarbonate (e.g., rayon, nylon), cotton (e.g., Lycra manufactured by DuPont), carbon (e.g., graphite), polyacrylonitrile (PAN), oxidized PAN, pre-oxidized PAN, uncarbonized heat-treated PAN (e.g., manufactured by SGL Carbon), glass or glass fiber-based materials (e.g., S-glass, 901-glass, 902-glass, 475-glass, E-glass, etc.), silica-based fibers such as quartz (e.g., Quartz manufactured by Saint-Gobain), Q-felt (Johns Other fibers include polyamide fibers such as Manville (manufactured by Saffil), Durablanket (manufactured by Unifrax), Duraback (manufactured by Carborundum), Kevlar, Nomex, Sontera (all manufactured by DuPont), and Conex (manufactured by Taijin), polyolefins such as Tyvek (manufactured by DuPont), Dyneema (manufactured by DSM), and Spectra (manufactured by Honeywell), other polypropylene fibers such as Typar and Xavan (both manufactured by DuPont), fluoropolymers such as PTFE, which have trade names such as Teflon (manufactured by DuPont), Goretex (manufactured by WLGORE), and Nicalon (manufactured by COI). The range of materials may include, but are not limited to, silicon carbide fibers such as those manufactured by Epson Ceramics, ceramic fibers such as Nextel (manufactured by 3M), acrylic polymers, wool, silk, hemp, leather, suede fibers, PBO-Zylon fibers (manufactured by Tyobo), liquid crystal materials such as Vectan (manufactured by Hoechst), Cambrelle fibers (manufactured by DuPont), polyurethanes, polyamides, wood fibers, boron, aluminum, iron, stainless steel fibers, and other thermoplastics such as PEEK, PES, PEI, PEK, PPS, etc.

[0026] Glass or glass fiber-based fiber reinforced materials may be manufactured using one or more techniques. In certain aspects, it is desirable to create them using a carding and cross-lapping or airlaid process. In exemplary aspects, carded and cross-lapping glass or glass fiber-based fiber reinforced materials offer certain advantages over airlaid materials. For example, carded and cross-lapping glass or glass fiber-based fiber reinforced materials can provide consistent material thickness for a given basis weight. In some embodiments, fiber reinforced materials may be manufactured using a wet-laid process. In certain additional aspects, it is desirable to further needle fiber reinforced materials, which requires entanglement of fibers in the z-direction to improve mechanical and other properties in the final aerogel composition.

[0027] Thermal Conductive Layer In addition to thermal insulation layers, thermally conductive layers in combination with thermal insulation layers are effective in directing unwanted heat to desired external locations, such as external heat dissipation fins, heat dissipation enclosures, or other external structures for dissipating unwanted heat to the ambient air. Thermally conductive layers are also referred to as thermal conductor layers, thermal conductor plates, or thermal conducting layers. In one embodiment, one or more thermally conductive layers help dissipate heat from localized heat loads within a battery system or pack. Examples of highly thermally conductive materials include carbon fiber, graphite, silicon carbide, metals including, but not limited to, copper, stainless steel, aluminum, etc., as well as combinations thereof.

[0028] To aid in heat distribution and removal, in at least one embodiment, the thermally conductive layer is coupled to a heat sink. There are various heat sink types and configurations, as well as different techniques for coupling the heat sink to the thermally conductive layer, and it is understood that the present disclosure is not limited to the use of any one type of heat sink / coupling technique. In one embodiment, at least one thermally conductive layer of the multilayer material disclosed herein may be in thermal communication with an element of a cooling system of a battery system or pack, such as a cold plate or cooling channel of the cooling system. In another embodiment, at least one thermally conductive layer of the multilayer material disclosed herein may be in thermal communication with other elements of a battery pack, battery module, or battery system that can function as a heat sink, such as a wall of the pack, module, or system, or with other elements of the multilayer material disposed between battery cells. Thermal communication between the thermally conductive layer of the multilayer material and a heat sink element in a battery system can allow excess heat to be removed from the cell(s) adjacent to the multilayer material to the heat sink, thereby reducing the impact, severity, or propagation of thermal events that may generate excess heat.

[0029] Elastic layer In addition to the thermal insulating layer and the thermally conductive layer, the thermal regulating member may further include one or more elastic layers to accommodate volume changes of the battery cells during change and discharge. The elastic layers also accommodate mechanical stresses imposed on the battery system during operation or abuse conditions. In one aspect, the elastic layers can absorb mechanical stresses and strains during operation of the battery pack, such as during operation of an electric vehicle using the battery system.

[0030] The elastic material layer may include, but is not limited to, foam, fiber, fabric, sponge, spring structure, rubber, polymer, etc. In one embodiment, the elastic material layer comprises an aerogel layer, such as a monolithic aerogel layer, an aerogel plate, an aerogel blanket, a fiber-reinforced aerogel blanket, a foam-reinforced aerogel blanket, other aerogel layers, and combinations thereof. In one embodiment, the elastic material layer may be polyurethane foam. In one embodiment, the elastic layer can be compressed to return to 5%-95%, 10%-90%, 30%-90%, 40%-85%, 60%-80%, or any of the percentage ranges described herein, of its original thickness.

[0031] Figure 1 shows one embodiment of a battery system 100. The system 100 includes one or more battery modules 102. In the embodiment of Figure 1, each module includes a carrier frame and two batteries. A heat sink 104 is shown located on the side of the system 100 and in thermal communication with the battery modules 102.

[0032] FIG. 2 illustrates a cross section of a battery module 200 similar to the battery module 102 of FIG. 1. A first battery 210 and a second battery 212 are shown. The carrier frame 202 includes a first cavity 204 and a second opposing cavity 206. The first battery 210 and the second battery 212 are shown at least partially located within the first cavity 204 and the second cavity 206. In one embodiment, the batteries 210, 212 can be selected from different cell formats, such as prismatic, cylindrical, pouch, other cell formats, or combinations thereof. The battery cells 102 can be selected from different cell chemistries, such as lithium-ion, sodium-ion, other alkali-ion, nickel-manganese-cobalt, lithium-ion phosphate, anodeless, semi-solid, solid-state, other battery chemistries, or combinations thereof. Lithium-ion pouch cells are frequently used in electric vehicle battery systems. A central separator 208 is shown positioned between a pair of opposing cavities 204, 206.

[0033] FIG. 3A illustrates an embodiment of a battery system 300. The system 300 includes a stack 301 of battery cells 302. In one embodiment, the battery cells 302 include lithium-ion cells, although the invention is not so limited. A heat sink 320 is included in the system 300 of FIG. 3A and is located on the side of the stack of battery cells 302. The stack of battery cells 302 includes two or more distinct thermal zones. Each thermal zone includes at least one battery cell module similar to the battery cell module 102 of FIG. 1 or the battery cell module 200 of FIG. 2. In some embodiments, at least one thermal zone includes a battery cell 302A sandwiched between battery cells 302B and 302C. In one embodiment, the battery cells 302A, 302B, and 302C each have a different battery chemistry. In one embodiment, the battery cell 302A is an LFP battery cell, while the battery cells 302B and 302C are anode-free batteries.

[0034] The different thermal zones are separated by thermal regulating members, which prevent breathable gases, particles, and heat from transferring to adjacent thermal zones in the event of thermal runaway. In the embodiment of FIG. 3A, a first thermal zone 310 is located adjacent to a side of the stack 301. A second thermal zone 312 is located closer to the center of the stack 301. While two zones 310, 312 are shown, the invention is not so limited. Multiple zones are possible within the scope of the invention.

[0035] During operation, different locations of battery cells 302 within the stack 301 may dictate different thermal management needs. For example, battery cells at the edges of the stack 301 do not have other battery cells on either side. This may result in less heat to remove or regulate from the edge cells. Also, battery cells in more central locations within the stack 301 may retain more heat due to the proximity of more battery cells on either side of a given centrally located battery cell 302. Other factors, such as structures adjacent to the battery system 300 that cause local insulating or cooling effects, may determine where the zones 310, 312, etc. are divided.

[0036] A battery pack or battery module may have two or more thermal zones. The two or more thermal zones may have different temperatures during charging and discharging of the battery cells. One or more of the thermal zones may have a conductive plate. For example, the thermal zone with the highest temperature may have a conductive plate (e.g., 410 and 412 from FIG. 4C ) to facilitate heat conduction to the heat sink 320. Thermal zones that are more susceptible to thermal runaway also include a thermal conductive plate. The thermal zone with the thermal conductive plate may be located in the center of the battery module or anywhere else within the battery module.

[0037] Several different thermal regulating members are shown in FIG. 3A. The several different thermal regulating members are configured to provide different heat transfer characteristics to different adjacent thermal zones. A resilient material member 304 is shown on the exterior surface of stack 301. A first thermal regulating member 306 is shown between first thermal zone 310 and second thermal zone 312. A second thermal regulating member 308 is shown between second thermal zone 312 and third thermal zone 314. While three thermal zones 310, 312, 314 and two thermal regulating members 306, 308 are shown, the invention is not so limited. Those skilled in the art with the benefit of this disclosure will recognize that fewer than three thermal zones or more than three thermal zones and respective thermal regulating members are also possible.

[0038] In one embodiment, the different thermal regulating elements comprise different materials. In one embodiment, the different thermal regulating elements comprise different geometries or configurations having the same material. In one embodiment, the different thermal regulating elements comprise different layers within the battery system 300. In one embodiment, the different thermal regulating elements comprise one type of layer (e.g., layers 316 and 318) in a first location of the battery system 300 and a different type of thermal regulating element (e.g., layers 306 and 308) in a second location of the battery system 300. For example, the first location may comprise a thermally conductive layer (e.g., a metal layer) that provides high thermal conductivity, while the second location may comprise an insulating layer such as an aerogel layer. The different layers may be positioned toward different adjacent thermal zones that best suit the layer's provided properties.

[0039] In one aspect, the insulating layers seal individual thermal zones to prevent or reduce the transfer of heat or vent gases to adjacent thermal zones. In one aspect, the thermal regulating members (e.g., 306 and 308) have a large surface area the same as or similar to the cross-section of the interior of the battery module or pack to block heat, gases, and particles due to thermal runaway. In one aspect, the thermally conductive layers (e.g., layers 316 and 318) have a surface the same as or similar to the battery cells, which may be smaller than the cross-section of the interior of the battery module or pack.

[0040] In one embodiment, a layer of elastic material is included in one or more of the thermal zones. For example, layers 316 and 318 may be elastic material layers instead of the thermally conductive layers of FIG. 3A. During operation, thermal and electrochemical expansion may cause the battery cells 302 in the stack 301 to expand and contract. Including one or more elastic material layers in different thermal regulating members provides a mechanism to accommodate the expansion and contraction. Embodiments of elastic material layers include, but are not limited to, foam, polymer, expanded polymer layer, polyurethane foam, metal mesh layer, rubber, wool, cotton, other elastic material layers, or combinations thereof.

[0041] One thermal regulation material includes a thermally conductive material. For example, layers 316 and 318 can be a thermally conductive material such as copper, aluminum, steel, carbon fiber, graphene, graphite, silicon carbide, other thermally conductive materials, and combinations thereof. Metallic materials are typically good thermal conductors but add weight to the battery system.

[0042] Another characteristic that can be considered in selecting different thermal regulating members is their ability to provide thermal insulation. Some materials may decompose or melt under the heat of thermal runaway within a battery cell. Selecting different thermal regulating members at different locations adjacent to different thermal zones can more effectively manage the temperature requirements in areas of the stack 301 that are more prone to thermal runaway (e.g., thermal zone 312). For example, a combination of both thermal insulating and thermally conductive layers can be used in these zones that are more prone to thermal runaway. At the same time, areas of the stack 301 that are less likely to experience thermal runaway (e.g., thermal zones 310 or 314) can be protected with lighter or less expensive thermal regulating members. For example, thermally conductive plates may not be required in these zones that are less prone to thermal runaway.

[0043] 3A and 3B further include one or more vents 322. A thermal runaway event may result in the generation of combustion gases. The example system 300, including one or more vents 322, can dissipate the combustion gases in the event of a thermal runaway event. In one aspect, each thermal zone 310, 312, 314 may include a vent 322. In one aspect, the vent 322 is included only in thermal zones with a high risk of thermal runaway, such as thermal zone 312.

[0044] Figure 3B is a cross-sectional view taken along line AA' in Figure 3A. In Figure 3B, the vent 322 is shown adjacent to the side of the battery cell 302 that is spaced from the electrode tab 324. Other embodiments include the vent 322 adjacent to the tab 324, as shown in the following embodiment. In one embodiment, the area adjacent to the tab 324 is more susceptible to overheating, and locating the vent 322 adjacent to the tab 324 is advantageous.

[0045] FIG. 4A illustrates an embodiment of a battery system 400. The system 400 includes a stack 401 of battery cells 402. In one embodiment, the battery cells 402 include lithium-ion battery cells, although the invention is not so limited. A heat sink 420 is included in the system 400 of FIG. 4A and is located on the side of the stack of battery cells 402. Similar to the embodiment of FIGS. 3A and 3B, the system 400 includes several different thermal regulating members. A resilient material layer 404 is shown on the outer surface of the stack 401. A first thermal regulating member 406 is shown between the battery cells 402 in the stack 401, and a second thermal regulating member 408 is shown closer to the center of the stack 401 of battery cells 402.

[0046] The first thermal regulating member 406 includes two layers 405 and 407. In one embodiment, the first layer 405 includes a thermally insulating layer, and the second layer 407 includes a thermally conductive layer. As mentioned above, the thermally insulating layer 405 may be positioned to face a thermal zone (e.g., 450) where insulation is more favorable than conduction, and the thermally conductive layer 407 may be positioned toward a thermal zone where heat conduction to the heat sink 420 is more favorable.

[0047] 4A illustrates a second layer 407 (thermally conductive layer) located immediately adjacent to the first layer 405, but the invention is not so limited. In one embodiment, layer 405 is a thermally insulating layer that defines a central thermal zone 450 having a higher need for heat dissipation than side zones 452. One or more thermally conductive layers (407, 408) are included in central zone 450 where they are more needed. Other thermal zones, such as zones 452 and 454, include fewer or no thermally conductive layers.

[0048] 4B shows a cross section of a selected battery cell 402 from FIG. 4A taken along line BB'. An electrode tab 422 is shown at the edge of the battery cell 402. A hot zone 428 is shown adjacent to the tab 422. In many battery cells 402, the tab area is particularly susceptible to higher temperatures during operation. As mentioned above, in one embodiment, a vent 424 is located directly adjacent to the tab 422 to anticipate possible thermal runaway from the hot zone 428.

[0049] FIG. 4C shows a cross-sectional view of a thermal regulating member along line CC′ in one embodiment. The thermal regulating member includes a first thermal conductor plate 410 that directly interfaces with only a partial area of ​​an adjacent battery cell. In FIG. 4C, the thermal conductor plate 410 is aligned with one of the high-temperature zones 428 from FIG. 4B. The embodiment of FIG. 4C further includes a second thermal conductor plate 412 that corresponds to the other high-temperature zone 428 adjacent to tab 422 from FIG. 4B. Also shown is a thermal insulation layer 405 that is coupled to the conductor plates 410, 412 and separates the thermal zones within the module. In one embodiment, the thermal insulation layer 405 is larger than the battery cell 402 and fills the interior cross-section of the battery module housing 403.

[0050] The configuration shown in FIG. 4C can provide thermal conduction where needed, such as in the hot zones of the battery cell 402, while reducing the overall weight of the battery cell system 400 by reducing the amount of conductor plates, which are typically made from heavier materials such as metal. The thermal conductor plates 410 and 412 conduct heat from the hot zone 428 to the heat sink 420, thus preventing the hot zone 428 from triggering thermal runaway. The optional inclusion of a thermal insulation layer provides additional safety by insulating adjacent battery cells 402 within the stack 401. While the locations of the conductor plates 410 and 412 are shown next to the tab 422, the invention is not so limited. The conductor plates that directly interface with only some areas of the adjacent battery cells can include a single conductor plate or three or more portions of a conductor plate. The locations can include any areas of the battery cells that generate high heat and benefit from preferential conduction to the heat sink 420.

[0051] 5A and 5B illustrate an embodiment of a battery system 500. The system 500 includes a stack 501 of battery cells 502. In one embodiment, the battery cells 502 include lithium-ion battery cells, although the invention is not so limited. A heat sink 520 is included in the system 500 of FIG. 5A and is located on the side of the stack of battery cells 502. As with the other embodiments described above, the system 500 includes several different thermal regulating members. A first thermal regulating member 504 is shown on the outer surface of the stack 501. A second thermal regulating member 506 is shown between the battery cells 502 in the stack 501, and a third thermal regulating member 508 is shown closer to the center of the stack 501 or battery cells 502. Tabs 524, similar to those described in other embodiments, are shown on the edges of a given battery cell 502.

[0052] In the embodiment of Figures 5A and 5B, the elastic material member 504 lines the interior of the battery module housing 503. Figure 5B is a cross-sectional view of Figure 5A taken along line DD', which intersects one of the thermal zones. In one embodiment, the first thermal regulating member 504 lines the interior of the battery pack or module. One advantage of this configuration includes an improved ability to contain a thermal runaway condition to the system 500 without spreading to adjacent locations, such as the passenger area within an electric vehicle. By utilizing a different thermal regulating member, heat can be managed and directed to the heat sink 520 during normal operation. In the event of a thermal runaway event, the first thermal regulating member 504 contains or delays any fire or dangerous heat within the thermal zones of the battery system 500.

[0053] 6 shows a flow chart of an exemplary method of operation for an electronic device utilizing the described battery system. At operation 602, current is supplied to the electronic device from a stack of lithium-ion battery cells. At operation 604, temperature is regulated at different rates within different portions of the stack of lithium-ion battery cells as a result of different configurations of thermal conductor plates within the stack of lithium-ion battery cells. At operation 606, selected battery cells within the stack of lithium-ion battery cells are thermally insulated with one or more thermal insulation layers.

[0054] FIG. 7 shows another battery system 700 according to some embodiments of the present disclosure. The battery system 700 includes several battery cells 702. One or more intermediate structures 704 are included between the battery cells 702. In one embodiment, the intermediate structure 704 includes a thermal barrier. In one embodiment, the intermediate structure 704 includes a conductor plate. In one embodiment, the conductor plate conducts heat away from the battery cells 702 to a cooling plate 706. In one embodiment, the intermediate structure 704 includes an elastic layer. The battery system 700 of FIG. 7 may optionally include a housing 710 and a lid 712 for housing the battery cells 702 and other battery system 700 components.

[0055] FIG. 8 shows another battery system 800 according to some embodiments of the present disclosure. The battery system 800 includes several battery cells 802. One or more intermediate structures 804 are optionally included between the battery cells 802. In one embodiment, the intermediate structures 804 include a thermal barrier. In one embodiment, the intermediate structures 804 include a conductor plate. In one embodiment, the conductor plate conducts heat away from the battery cells 802 to a cooling plate 806. The battery system 800 of FIG. 8 may optionally include a housing 810 and a lid 812 for housing the battery cells 802 and other battery system 800 components.

[0056] The battery system 800 of FIG. 8 further includes one or more extended thermal barriers 824. Each of the extended thermal barriers 824 has a larger footprint than each of the battery cells 802. In one embodiment, the extended thermal barrier 824 includes aerogel. In one embodiment, the extended thermal barrier 824 is a single layer. In one embodiment, the extended thermal barrier 824 includes multiple layers laminated together. One advantage of incorporating the extended thermal barrier 824 into the battery system 800 includes dividing the housing 810 into multiple thermal zones, such as the thermal zone 811 shown by the dashed box. In some thermal runaway events, flames, gases, and ejecta are vented into a headspace 828 of the thermal zone between the battery cells 802. The headspace 828 is the space between the tops of the battery cells 802, the end plates 820, and the extended portions of the thermal barrier 824. The inclusion of the extended thermal barrier 824 provides better containment of flames, gases, and ejecta to the headspace 828 between the battery cells 802 .

[0057] In some configurations, the battery system 800 of FIG. 8 further includes an end plate 820 including one or more slots 822 positioned to accommodate an extended thermal barrier 824. When assembled, the one or more slots 822 hold the distal end of the extended thermal barrier 824 in place, enhancing the structural strength of the thermal zone and containing flames, gases, and ejecta to the headspace 828 of the thermal zone between the battery cells 802. Several material choices are useful for the end plate 820. Materials may include heat-resistant, flame-resistant, and particle-resistant materials, including, but not limited to, mica, metals, polymers, aerogels, and dielectric materials. The end plate 820 may be a single continuous material, such as a stamped metal, may include multiple laminated layers, or may include composite materials, such as fiber-reinforced materials.

[0058] FIG. 9 shows another battery system 900 according to some embodiments of the present disclosure. The battery system 900 includes several battery cells 902. One or more intermediate structures 904 are optionally included between the battery cells 902. In one embodiment, the intermediate structures 904 include a thermal barrier. In one embodiment, the intermediate structures 904 include a conductor plate. In one embodiment, the conductor plate conducts heat away from the battery cells 902 to a cooling plate 906. The battery system 900 of FIG. 9 may optionally include a housing 910 and a lid 912 for housing the battery cells 902 and other battery system 900 components.

[0059] The battery system 900 of FIG. 9 further includes one or more extended thermal barriers 924. In one embodiment, the extended thermal barrier 924 includes an aerogel. In one embodiment, the extended thermal barrier 924 is a single layer. In one embodiment, the extended thermal barrier 924 includes multiple layers stacked together. The battery system 900 of FIG. 9 further includes an end plate 920 including one or more slots 922 positioned to accommodate the extended thermal barrier 924. When assembled, the one or more slots 922 hold the distal ends of the extended thermal barrier 924 in place and provide additional structural support for containing flames, gases, and ejecta in the spaces between the battery cells 902. As with the above embodiments, the material of the end plate 920 can include a metal, a polymer, a mineral such as mica, an aerogel, or other dielectric material.

[0060] 9, some housing slots 914 in the housing 910 are configured to further engage side-extending portions of the extended thermal barrier 924. This configuration provides additional structural support to the extended thermal barrier 924 and further surrounds the side portions of the battery cells 802. The extended thermal barrier 924 divides the housing 910 into multiple thermal zones.

[0061] FIG. 10 shows another battery system 1000 according to some embodiments of the present disclosure. The battery system 1000 includes several battery cells 1002. One or more intermediate structures may optionally be included between the battery cells 1002. In one embodiment, the intermediate structure includes a thermal barrier. In one embodiment, the intermediate structure includes a conductor plate. In one embodiment, the conductor plate conducts heat away from the battery cells 1002 to a cooling plate. The battery system 1000 of FIG. 10 may optionally include a housing 1010 and a lid 1012 for housing the battery cells 1002 and other battery system 1000 components.

[0062] The battery system 1000 of FIG. 10 further includes one or more extended thermal barriers 1024. In one embodiment, the extended thermal barrier 1024 includes an aerogel. In one embodiment, the extended thermal barrier 1024 is a single layer. In one embodiment, the extended thermal barrier 1024 includes multiple layers laminated together. The battery system 1000 of FIG. 10 further includes an end plate 1020 including one or more slots 1022 positioned to accommodate the extended thermal barrier 1024. When assembled, the one or more slots 1022 hold the distal end of the extended thermal barrier 1024 in place and provide additional structural support for containing flames, gases, and ejecta in the spaces between the battery cells 1002. As with the above embodiments, the material of the end plate 1020 can include an aerogel, a metal, a polymer, a mineral such as mica, or other dielectric material.

[0063] 10 further includes a second end plate 1030 with one or more slots 1032 positioned to accommodate the extended thermal barrier 1024. In this manner, both the top and bottom extensions of the extended thermal barrier 1024 engage with and are supported by the end plate 1020 and the second end plate 1030.

[0064] 10 , some housing slots 1014 in the housing 1010 are configured to further engage side-extending portions of the extended thermal barrier 1024. This configuration provides additional structural support to the extended thermal barrier 1024 and further encloses the side portions of the battery cells 1002.

[0065] 10, several battery cells 1002 include pouch battery cells that each include an electrode tab 1003. The embodiment of FIG. 10 further includes electrode slots 1016 within housing 1010 to accommodate electrode tabs 1003.

[0066] Figure 11 shows the battery system 1000 of Figure 10 at an additional level of assembly. The electrode tabs 1003 are shown in electrode slots 1016 in the housing 1010. In an end-use device such as an electric vehicle, additional structure such as a bus bar (not shown) would be coupled to the portion of the electrode tabs 1003 that extends beyond the sides of the housing 1010. An extended thermal barrier 1024 is shown defining a headspace 1028 between the battery cells 1002.

[0067] 12 shows another battery system 1200 according to some embodiments of the present disclosure. The battery system 1200 includes several battery cells 1202. One or more intermediate structures 1204 are optionally included between the battery cells 1202. In one embodiment, the intermediate structures 1204 include a thermal barrier. In one embodiment, the intermediate structures 1204 include a conductor plate. In one embodiment, the conductor plate conducts heat away from the battery cells 1202 to a cooling plate 1206.

[0068] The battery system 1200 of FIG. 12 further includes one or more extended thermal barriers 1224. In one embodiment, the extended thermal barrier 1224 comprises an aerogel. In one embodiment, the extended thermal barrier 1224 is a single layer. In one embodiment, the extended thermal barrier 1224 comprises multiple layers laminated together. The battery system 1200 of FIG. 12 further includes an end plate 1220 including one or more slots 1222 positioned to accommodate the extended thermal barrier 1224. When assembled, the one or more slots 1222 hold the distal end of the extended thermal barrier 1224 in place and provide additional structural support for containment of flames, gases, and ejecta in the spaces between the battery cells 1202.

[0069] In the embodiment of FIG. 12 , the extended thermal barrier 1224 is shown as flexible. A potential bent state 1225 is shown with dashed lines. One advantage of a flexible extended thermal barrier 1224 includes the ability to more easily engage with the slots 1222 in the end plate 1020. In practice, it can be difficult to account for manufacturing tolerances when positioning the slots 1222 and extended thermal barrier 1224 within the battery system 1200. The ability of the extended thermal barrier 1224 to bend reduces or eliminates the need for precise alignment between the slots 1222 and the extended thermal barrier 1224. Any given extended thermal barrier 1224 can bend a discrete amount to align with a corresponding slot 1222. The flexibility of the extended thermal barrier 1224 also prevents or mitigates mechanical damage that may occur during operation of the battery system 1200, such as from expansion and contraction of the cells during charge / discharge cycles, expansion of the cells over the life of the battery system, or movement of the cells within the system, for example, while operating an electric vehicle using the battery system 1200.

[0070] 13 shows another battery system 1300 according to some embodiments of the present disclosure. The battery system 1300 includes several battery cells 1302. One or more intermediate structures 1304 are optionally included between the battery cells 1302. In one embodiment, the intermediate structure 1304 includes a thermal barrier. In one embodiment, the intermediate structure 1304 includes a conductor plate. In one embodiment, the conductor plate conducts heat away from the battery cells 1302 to a cooling plate 1306. In one embodiment, the intermediate structure 1304 includes an elastic layer.

[0071] The battery system 1300 of Figure 13 further includes one or more extended thermal barriers 1350. In one embodiment, the extended thermal barrier 1350 comprises an aerogel. The battery system 1300 of Figure 13 further includes an end plate 1320 including one or more slots 1322 positioned to accommodate the extended thermal barrier 1350. When assembled, the one or more slots 1322 hold the distal end of the extended thermal barrier 1350 in place and provide additional structural support for containment of flames, gases, and ejecta in the spaces between the battery cells 1302.

[0072] The one or more extended thermal barriers 1350 of FIG. 13 are laminated structures. A thermal insulator layer 1352 is included along with at least one rigid layer 1354. In one embodiment, the thermal insulator layer 1352 is positioned between a pair of rigid layers 1354, providing rigid protection from both sides of the extended thermal barrier 1350. In one embodiment, the thermal insulator layer 1352 includes an aerogel. In one embodiment, the rigid layer 1354 includes mica, polymer, ceramic, resin, rubber, composite material, other suitable material, metal, copper, stainless steel, aluminum, carbon fiber, graphene, graphite, silicon carbide, other rigid material, or combinations thereof. In practice, flames, gases, and ejecta can be abrasive. The thermal insulator layer 1352 can contain heat well but may not be very effective at resisting erosion and particle impact from abrasive ejecta. The addition of the rigid layer 1354 may increase resistance to erosion and particle impact, while the thermal insulator layer 1352 increases resistance to heat transfer. As noted above, one embodiment of the rigid layer 1354 includes mica. The mica may be continuous or may include mica particles suspended in a silicone matrix to form a mica composite. Other materials suitable for resisting erosion and particle impact include, but are not limited to, metals, dielectric materials, rigid polymers, and the like.

[0073] FIG. 14 shows another battery system 1400 according to some embodiments of the present disclosure. The battery system 1400 includes several battery cells 1402. One or more intermediate structures 1404 are optionally included between the battery cells 1402. In one embodiment, the intermediate structure 1404 includes a thermal barrier. In one embodiment, the intermediate structure 1404 includes a conductor plate. In one embodiment, the intermediate structure 1404 includes an elastic layer. The battery system 1400 of FIG. 14 may optionally include a housing 1410 for housing the battery cells 1002 and other battery system 1000 components.

[0074] The battery system 1400 of FIG. 14 further includes one or more extended thermal barriers 1450. In one embodiment, the extended thermal barrier 1450 comprises aerogel. The battery system 1400 of FIG. 14 further includes an end plate 1420 including one or more slots 1422 positioned to correspond to the extended thermal barrier 1450. When assembled, the one or more slots 1422 hold the distal end of the extended thermal barrier 1450 in place and provide additional structural support for containing flames, gases, and ejecta in the spaces 1428 between the battery cells 1402. The embodiment of FIG. 14 further includes a second end plate 1430 including one or more slots 1432. In one embodiment, the second end plate 1430 comprises a dielectric material. In one embodiment, the second end plate 1430 comprises a metal and functions as a cooling plate.

[0075] Similar to the embodiment of FIG. 13, the one or more extended thermal barriers 1450 of FIG. 14 are laminated structures. A thermal insulation layer 1452 is included along with at least one rigid layer 1454. In one embodiment, the thermal insulation layer 1452 is positioned between a pair of rigid layers 1454, providing rigid protection from both sides of the extended thermal barrier 1450. In one embodiment, the thermal insulation layer 1452 comprises aerogel. In one embodiment, the rigid layer 1454 comprises mica. Similar to the embodiment of FIG. 13, the addition of the rigid layer 1454 may increase resistance to erosion and particle impact, while the thermal insulation layer 1452 increases resistance to heat transfer.

[0076] The one or more extended thermal barriers 1450 in FIG. 14 further include an adhesive 1456 to hold the rigid layer 1454 to the thermal insulator layer 1452. In one embodiment, the adhesive 1456 occupies only a portion of the interface between the rigid layer 1454 and the thermal insulator layer 1452. FIG. 14 further illustrates the absence of an unoccupied interface 1458, such as a void, or simply the absence of the adhesive 1456. The unoccupied interface 1458 allows the top of the extended thermal barrier 1450 to better flex from side to side. This allows the extended thermal barrier 1450 to more easily mate with the corresponding slots 1422. The flexibility of the extended thermal barrier 1450 also prevents or mitigates mechanical damage that may occur during operation of the battery system 1400, such as from expansion and contraction of cells during charge / discharge cycles, expansion of cells over the life of the battery system, or movement of cells within the system, for example, while operating an electric vehicle using the battery system 1400.

[0077] The battery system 1400 of FIG. 14 further includes one or more slots 1422 that are wider than the extended thermal barrier 1450. This also allows the extended thermal barrier 1450 to more easily mate with the corresponding slot 1422. FIG. 14 further includes a sealant 1423 within the slot 1422, which seals out flames, gases, ejecta, etc., while still providing a looser tolerance for aligning the extended thermal barrier 1450 with the slot 1422. In one aspect, the sealant 1423 includes an intumescent material that can expand and further seal the slot 1422 and adjacent spaces. The intumescent material prevents heat, flames, and ejecta from migrating to adjacent thermal zones during a thermal runaway.

[0078] 15A-15C illustrate select embodiments of end plates that can be used in the battery system embodiments described above. FIG. 15A illustrates an end plate assembly 1500 that includes a plate 1502 having several channels 1504. The channels 1504 include a trapezoidal cross-sectional shape. In one embodiment, the trapezoidal cross-sectional shape aids in directing an extended thermal barrier into the channels 1504 during assembly.

[0079] FIG. 15B illustrates another embodiment of an end plate assembly 1520 including a plate 1522 having several channels 1524. In the embodiment of FIG. 15B, the multiple channels 1524 are included in several channel regions 1526. Each channel region 1526 is positioned within the battery system to correspond to an extended thermal barrier. Each of the channels 1524 has a triangular cross-sectional shape for ease of manufacturing. Some portions of the end plate assembly 1500 are channel-free. By including multiple channels 1524 in each channel region 1526, a corresponding extended thermal barrier can be snapped into any channel 1524 within the channel region 1526. This provides multiple options for each extended thermal barrier and reduces the manufacturing tolerances required when positioning components such as the extended thermal barriers and channels.

[0080] FIG. 15C shows another embodiment of an end plate assembly 1540 including a plate 1542 having several channels 1544. The end plate assembly 1540 has a sinusoidal cross-sectional shape. In one embodiment, the sinusoidal channels are dispersed throughout the end plate assembly 1540. The channels 1544 are formed on a pitch 1546. In one embodiment, more channels 1544 are included than corresponding extended thermal barriers. This configuration also reduces the manufacturing tolerances required when positioning components such as extended thermal barriers and channels. In one embodiment, the pitch 1546 is selected so that any given extended thermal barrier is flexible enough to successfully engage the channels 1544. Thus, the exact location of the channels 1544 is not critical, yet each extended thermal barrier can engage a channel 1544 to provide additional support to the extended thermal barrier as described above.

[0081] Battery systems such as those described above are used in several electronic devices. Figure 16 shows an embodiment of an electronic device 1600 including a battery system 1610. The battery system 1610 is coupled to functional electronics 1620 by circuitry 1612. In the embodiment shown, the battery system 1610 and circuitry 1612 are contained within a housing 1602. A charging port 1614 is shown coupled to the battery system 1610 to facilitate recharging the battery system 1610 when needed.

[0082] In one embodiment, functional electronics 1620 includes devices such as semiconductor devices with transistors and memory circuits, including, but not limited to, telephones, computers, display screens, navigation systems, etc.

[0083] FIG. 17 illustrates another electronic system utilizing a battery system including a multi-layer thermal barrier as described above. An electric vehicle 1700 is illustrated in FIG. 17. The electric vehicle 1700 includes a chassis 1702 and wheels 1722. In the illustrated embodiment, each wheel 1722 is coupled to a drive motor 1720. A battery system 1710 is shown coupled to the drive motor 1720 by circuitry 1706. A charge port 1704 is shown coupled to the battery module 1710 to facilitate recharging the battery module 1710 when needed.

[0084] Embodiments of electric vehicle 1700 include, but are not limited to, consumer vehicles such as cars and trucks. Commercial vehicles such as tractors and semi-trucks are also within the scope of the present invention. While a four-wheeled vehicle is shown, the present invention is not so limited. Embodiments include, but are not limited to, two-wheeled vehicles such as motorcycles and scooters.

[0085] In order to more fully describe the methods and apparatus disclosed herein, a non-limiting list of aspects is provided herein.

[0086] Aspect 1. A battery system comprising: a stack of lithium ion battery cells including two or more distinct thermal zones; and two or more distinct thermal regulating members positioned between battery cells in the stack of lithium ion battery cells at dividing locations between the thermal zones, the distinct thermal regulating members configured to provide different heat transfer characteristics to adjacent distinct thermal zones.

[0087] Aspect 2. The battery system of aspect 1, wherein a first of the different thermal regulating members is configured to cool a central battery cell of the stack of lithium ion battery cells faster than an end battery cell.

[0088] Embodiment 3. The battery system of embodiment 1, wherein opposite sides of a given thermal regulating member provide different heat transfer characteristics.

[0089] Aspect 4. The battery system of aspect 1, wherein at least one of the different thermal regulating components comprises an aerogel thermal insulation layer.

[0090] Aspect 5. The battery system of aspect 1, wherein at least one of the different thermal regulating members comprises an elastic layer.

[0091] Embodiment 6. The battery system of embodiment 1, further comprising one or more vents from the thermal zone.

[0092] Aspect 7. The battery system of aspect 1, wherein the stack of lithium ion battery cells comprises a stack of lithium ion pouch battery cells.

[0093] Aspect 8. A battery system comprising: a stack of lithium ion battery cells comprising two or more different thermal zones; and a thermal regulation member located between battery cells in the stack of lithium ion battery cells, the thermal regulation member comprising a thermal conductor plate that directly interfaces with only a portion of an area of ​​an adjacent lithium ion battery cell, and a thermal insulation layer.

[0094] Aspect 9. The battery system of aspect 8, wherein the thermal conductor plates include a pair of conductor plates overlying only the tab regions of the lithium ion battery cells.

[0095] Aspect 10. The battery system of aspect 8, wherein the thermal insulation layer comprises an aerogel layer.

[0096] Embodiment 11. The battery system of embodiment 8, further comprising a heat sink coupled to a side of the stack of lithium ion battery cells.

[0097] Aspect 12. The battery system of aspect 8, further comprising a vent coupled to a zone defined by the thermal regulating member.

[0098] Aspect 13. A method of operating a battery system, the method comprising: supplying current to an electronic device from a stack of lithium ion battery cells; regulating temperatures in different portions of the stack of lithium ion battery cells at different rates as a result of a plurality of different configurations of thermally conductive plates in the stack of lithium ion battery cells; and thermally insulating selected battery cells in the stack of lithium ion battery cells with one or more thermal insulation layers.

[0099] Aspect 14. The method of aspect 13, wherein regulating the temperature includes conducting heat from a tab portion of one or more lithium ion battery cells using a conductor plate including a gap on top of a central region of the stack of lithium ion battery cells.

[0100] Aspect 15. The method of aspect 13, wherein regulating the temperature includes conducting heat faster from central battery cells of the stack of lithium ion battery cells than from end battery cells.

[0101] Aspect 16. A battery system comprising: a battery housing; a stack of battery cells within the battery housing; one or more extended thermal barriers between selected battery cells within the stack of battery cells; and an end plate including one or more channels, wherein the one or more extended thermal barriers are positioned within the one or more channels.

[0102] Aspect 17. The battery system of aspect 16, wherein the one or more channels are grouped into channel regions adjacent to extended portions of the one or more extended thermal barriers.

[0103] Aspect 18. The battery system of aspect 16, wherein the end plate comprises a trapezoidal cross-sectional shape.

[0104] Aspect 19. The battery system of aspect 16, wherein the one or more extended thermal barriers include a thermally insulating layer and a rigid layer, both of which are located within the one or more channels.

[0105] Aspect 20. A battery system as described in aspect 16, wherein the battery housing includes one or more housing slots, and the extended portions of the one or more extended thermal barriers are positioned within the one or more housing slots.

[0106] The above description is intended to be illustrative, not limiting. For example, the above examples (or one or more aspects thereof) may be used in combination with each other. Other aspects may be employed, such as by one of ordinary skill in the art who reviews the above description. The Abstract is provided to enable the reader to quickly grasp the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be construed as intending that any unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter lies in less than all features of a particular disclosed embodiment. Accordingly, the following claims are incorporated into the Detailed Description herein, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or variations. The scope of the invention should be determined with reference to the appended claims, along with the full range of equivalents to which such claims are entitled.

[0107] While the inventive subject matter has been generally described with reference to particular embodiments, various modifications and changes can be made to these embodiments without departing from the broader scope of the disclosed embodiments. Such embodiments of the inventive subject matter may be referred to herein, individually or collectively, by the term "invention" for convenience only, and this is not intended to intentionally limit the scope of this application to any single disclosure or inventive concept where multiple inventions are in fact disclosed.

[0108] The embodiments illustrated herein are described in sufficient detail to enable those skilled in the art to practice the teachings disclosed. Other embodiments may be utilized and derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of the present disclosure. Therefore, the detailed description is not to be construed in a limiting sense, and the scope of various embodiments is defined only by the appended claims, along with the full range of equivalents to which such claims are entitled.

[0109] As used herein, the term "or" may be interpreted in either an inclusive or exclusive sense. Furthermore, multiple instances may be provided for resources, operations, or structures described herein as a single instance. Moreover, boundaries between various resources, operations, systems, engines, and data stores are somewhat arbitrary, and particular operations are illustrated in the context of specific example configurations. Other allocations of functionality are contemplated and may be included within the scope of various aspects of the disclosure. In general, structures and functionality that are represented as separate resources in an aspect configuration may be implemented as a combined structure or resource. Similarly, structures and functionality that are represented as a single resource may be implemented as separate resources. These and other variations, modifications, additions, and improvements are within the scope of the aspects of the disclosure as expressed by the appended claims. Accordingly, the specification and drawings should be regarded in an illustrative and not a restrictive sense.

[0110] The foregoing description, for purposes of illustration, has been set forth with reference to specific embodiments. However, the foregoing illustrative description is not intended to be exhaustive or to limit possible embodiments to the precise forms disclosed. Many modifications and variations are possible in light of the above teachings. The embodiments were chosen and described to best explain the principles involved and their practical application, thereby enabling those skilled in the art to best utilize various embodiments, with their various modifications, as suited to the particular uses intended.

[0111] It is also understood that terms such as "first" and "second" may be used herein to describe various elements, but these elements should not be limited by these terms. These terms are used only to distinguish one element from another. For example, a first contact portion can be referred to as a second contact portion, and similarly, a second contact portion can be referred to as a first contact portion, without departing from the scope of the present embodiment. Although the first contact portion and the second contact portion are both contact portions, they are not the same contact portion.

[0112] The terms used in the description of the aspects herein are for the purpose of describing particular aspects only and are not intended to be limiting. As used in the description of this embodiment and the accompanying embodiments, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. The term "and / or," as used herein, is also understood to refer to and encompass any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms "comprise" and / or "comprising," as used herein, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0113] As used herein, the term "if" may be interpreted to mean "when" or "upon" or "in response to determining" or "in response to detecting," depending on the context. Similarly, the phrase "if it is determined" or "if [a stated condition or event] is detected" may be interpreted to mean "upon determining" or "in response to determining" or "upon detecting [the stated condition or event]" or "in response to detecting [the stated condition or event]," depending on the context.

Claims

1. 1. A battery system comprising: a stack of lithium-ion battery cells including two or more distinct thermal zones; two or more different thermal regulating members positioned between battery cells in the stack of lithium ion battery cells at dividing locations between the thermal zones; The battery system, wherein the different thermal regulating members are configured to provide different heat transfer characteristics to different adjacent thermal zones.

2. 2. The battery system of claim 1, wherein a first one of the different thermal regulating members is configured to cool a central battery cell of the stack of lithium ion battery cells faster than an end battery cell.

3. The battery system of claim 1 , wherein opposite sides of a given thermal regulating member provide different heat transfer characteristics.

4. 10. The battery system of claim 1, wherein at least one of the different thermal regulating components comprises an aerogel thermal insulation layer.

5. The battery system of claim 1 , wherein at least one of the different thermal regulating members comprises a resilient layer.

6. The battery system of claim 1 further comprising one or more vents from the thermal zone.

7. 10. The battery system of claim 1, wherein the stack of lithium-ion battery cells comprises a stack of lithium-ion pouch battery cells.

8. 1. A battery system comprising: a stack of lithium-ion battery cells including two or more distinct thermal zones; a thermal regulating member positioned between battery cells in the stack of lithium ion battery cells, a thermal conductor plate that directly interfaces with only a partial area of ​​an adjacent lithium-ion battery cell; and the thermal regulating member comprising a thermal insulating layer;

9. 9. The battery system of claim 8, wherein the thermal conductor plates include a pair of conductor plates overlying only the tab regions of the lithium ion battery cells.

10. The battery system of claim 8 , wherein the thermal insulation layer comprises an aerogel layer.

11. 10. The battery system of claim 8, further comprising a heat sink coupled to a side of the stack of lithium-ion battery cells.

12. The battery system of claim 8 , further comprising a vent coupled to a zone defined by the thermal regulating member.

13. 1. A method of operating a battery system, comprising: supplying current from the stack of lithium-ion battery cells to an electronic device; Regulating temperatures in different portions of the stack of lithium-ion battery cells at different rates as a result of different configurations of heat-conducting plates in the stack of lithium-ion battery cells; and thermally insulating selected battery cells in the stack of lithium-ion battery cells with one or more thermal insulation layers.

14. 14. The method of claim 13, wherein regulating the temperature comprises conducting heat from a tab portion of one or more lithium ion battery cells using a conductor plate including a gap on top of a central region of the stack of lithium ion battery cells.

15. 14. The method of claim 13, wherein regulating temperature includes conducting heat faster from middle cells of the stack of lithium ion battery cells than from end cells.

16. 1. A battery system comprising: A battery housing; a stack of battery cells within the battery enclosure; one or more extended thermal barriers between selected battery cells in the stack of battery cells; an end plate including one or more channels, wherein the one or more extended thermal barriers are located within the one or more channels.

17. 17. The battery system of claim 16, wherein the one or more channels are grouped into channel regions adjacent extended portions of the one or more extended thermal barriers.

18. The battery system of claim 16 , wherein the end plates include a trapezoidal cross-sectional shape.

19. 17. The battery system of claim 16, wherein the one or more extended thermal barriers include a thermally insulating layer and a rigid layer, both of which are located within the one or more channels.

20. 17. The battery system of claim 16, wherein the battery housing includes one or more housing slots, and wherein the extended portions of the one or more extended thermal barriers are located within the one or more housing slots.

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