Proportional heat barrier device

Abstract

The battery module (100) includes a plurality of battery cells (102). Each battery cell defines a heat transfer surface that defines the cross-sectional area. The battery module includes one or more thermal barriers (110) that divide the plurality of battery cells into cell subdivisions (112, 114), each of which has a cell subdivision energy storage capacity. The thermal barrier is formed from the volume of thermal insulating material. The surface energy density is equal to half the cell subdivision energy storage capacity divided by the cross-sectional area. The volume of thermal insulating material divided by half the cell subdivision energy storage capacity defines the ratio.

Description

[Technical Field]

[0001] Cross-references to related applications This application claims the benefit of U.S. Provisional Application No. 63 / 531,793, filed on 9 August 2023, which is incorporated herein by reference in its entirety.

[0002] This 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, this disclosure provides thermal barrier materials. This disclosure further relates to battery modules or packs having one or more battery cells containing thermal barrier materials, as well as systems containing such battery modules or packs. Generally described examples may include aerogel materials. [Background technology]

[0003] Lithium-ion batteries (LIBs) are used to power various electronic devices such as mobile phones, tablets, laptops, and power tools, as well as other high-current devices including electric vehicles, due to their higher operating voltage, lower memory effect, and higher energy density compared to conventional batteries. Some LIBs may be susceptible to certain failure modes under conditions exceeding normal operating conditions, such as when rechargeable batteries are overcharged (above the design voltage), over-discharged, operated at temperatures and pressures outside the design parameter space, or exposed to temperatures and pressures outside the design parameter space. [Overview of the project]

[0004] To prevent cascaded thermal runaway events, effective isolation and heat dissipation strategies are needed to address these and other technical challenges of LIBs. [Brief explanation of the drawing]

[0005] [Figure 1A] It is a semi-schematic perspective view showing a battery module according to some embodiments. [Figure 1B] It is a semi-schematic front view showing another battery module according to some embodiments. [Figure 2A] It is a schematic perspective view showing components of a battery module according to some embodiments. [Figure 2B] It is a cross-sectional view through a vertical plane of the thermal barrier shown in FIG. 2A with a thermal gradient superimposed on the cross-sectional view. [Figure 2C] It is a graph of battery module data according to some embodiments. [Figure 2D] It is a side view of the components of the battery module shown in FIG. 2A. [Figure 3] It is a semi-schematic exploded perspective view of another battery module according to some embodiments. [Figure 4] It is a semi-schematic partially exploded perspective view of another battery module according to some embodiments. [Figure 5] It is a semi-schematic partially exploded perspective view of another battery module according to some embodiments. [Figure 6] It is a semi-schematic partially exploded perspective view of another battery module according to some embodiments. [Figure 7A] It is a semi-schematic partially exploded perspective view of a battery pack according to some embodiments. [Figure 7B] It is a side view of the assembled battery pack shown in FIG. 7A with a part of the housing and the lid removed. [Figure 8] It is a semi-schematic partially exploded perspective view of another battery pack according to some embodiments. [Figure 9] It is a semi-schematic partially exploded perspective view of another battery pack according to some embodiments. [Figure 10] It is a semi-schematic top view of an electronic device according to some embodiments. [Figure 11] It shows a semi-schematic top view of an electric vehicle according to some embodiments. [Modes for carrying out the invention]

[0006] The following description and drawings fully illustrate specific embodiments to enable those skilled in the art to implement them. Other embodiments may incorporate structural, logical, electrical, process, and other modifications. Parts and features of some embodiments may be included in or replace parts and features of other embodiments. Embodiments described in the claims encompass all available equivalents of those claims.

[0007] This disclosure relates to an energy storage system comprising a plurality of battery cells and one or more thermal barriers positioned between them. The energy storage system is defined by the ratio of the thickness of the thermal barrier to the areal energy density of the battery cells. The energy storage system may also be defined by the ratio of the volume of the thermal barrier to the energy stored in the energy storage system. These ratios are designed to delay or prevent extreme thermal events such as overheating or thermal runaway.

[0008] The thermal barrier may include insulating materials, thermal conductive materials, elastic materials, etc., as described in the following examples, and may be used in a battery module to compartmentalize individual battery cells or groups of battery cells within a battery device. Multiple battery cells coupled together are referred to as a battery module in this disclosure. However, the devices and methods described may be used in any of several types of multiple-cell arrangements, which may be referred to as battery packs, battery systems, etc.

[0009] The insulating materials described below may be used as a single heat-resistant layer or in combination with other layers (e.g., conductive and / or elastic layers) that provide additional functionality to a multilayer configuration, such as mechanical strength, compressibility, or heat dissipation / conductivity. The heat-resistant layer may be resistant to damage from high temperatures and / or may resist the transfer of thermal energy through the heat-resistant layer by having a low heat transfer coefficient. The insulating layers described herein play a role in reliably containing and controlling heat flow from heat-generating components in small spaces and preventing or resisting flame propagation to such products in the electronic, industrial, and automotive fields.

[0010] In many aspects of this disclosure, the insulating layer functions as a heat / flame / fire deflection layer, either by itself or in combination with other materials that enhance its ability to contain and control heat flow. In one aspect, the insulating layer itself may further include an associated particulate material that is resistant to flames and / or hot gases and modifies or enhances heat containment and control.

[0011] One highly effective form of insulating layer includes aerogel. Aerogels have a structure that is low in density, open in cells, and large surface area (e.g., 900 m²). 2 Aerogels refer to a type of material based on pore size (greater than or equal to 1 / g) and sub-nanometer scale. The pores may be filled with gases 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 present invention is not limited thereto. Other thermal insulating material layers may also be used in aspects of this disclosure.

[0012] This document describes selected forms of aerogel formation and properties. In some embodiments, a precursor material is gelled to form a network of pores filled with a solvent. The solvent is then extracted, leaving a porous matrix. In one embodiment, the solvent is extracted by supercritical drying. During the supercritical drying process, the insulating material (e.g., aerogel) is placed under appropriate pressure and temperature to reach supercritical conditions for the solvent. Under supercritical conditions, the solvent can be extracted without damaging the porous matrix due to the reduction of surface tension and capillary stress.

[0013] Various different aerogel compositions are known, and they may be inorganic, organic, or inorganic / organic hybrids. Inorganic aerogels are generally metal alkoxide-based 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.

[0014] Inorganic aerogels can generally be formed from metal oxide or metal alkoxide materials. These materials may be based on oxides or alkoxides of any metal capable of forming oxides. Such metals include, but are not limited to, silicon, aluminum, titanium, zirconium, hafnium, yttrium, vanadium, and cerium. Inorganic silica aerogels are conventionally prepared via hydrolysis and condensation of silica-based alkoxides (e.g., tetraethoxysilane) or via 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, condensed polymers of TEOS, tetramethoxysilane (TMOS), partially hydrolyzed TMOS, condensed polymers of TMOS, tetra-n-propoxysilane, partially hydrolyzed and / or condensed polymers of tetra-n-propoxysilane, polyethyl silicates, partially hydrolyzed polyethyl silicates, monomeric alkylalkoxysilanes, bis-trialalkoxyalkyl or arylsilanes, polyhedral silsesquioxanes, or combinations thereof.

[0015] In certain aspects of this disclosure, pre-hydrolyzed TEOS such as Silbond H-5 (SBH5, Silbond Corp), which is hydrolyzed at a water / silica ratio of about 1.9 to 2, may be used as-is or may be further hydrolyzed before being incorporated into the gelation process. Partially hydrolyzed TEOS or TMOS, such as polyethyl silicate (Silbond 40) or polymethyl silicate, may also be used as-is or may be further hydrolyzed before being incorporated into the gelation process.

[0016] Inorganic aerogels may 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 specific properties to the gel, such as stability and hydrophobicity. Inorganic silica aerogels may specifically include hydrophobic precursors such as alkylsilanes or arylsilanes. Hydrophobic gel precursors 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 for the formation of amalgam aerogels. Examples of 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 derivative of any of the above precursors may be used, specifically by adding or crosslinking certain polymers of other chemical groups to one or more of the above precursors.

[0017] Organic aerogels are generally formed from carbon-based polymer precursors. Such polymer materials include, but are not limited to, resorcinol formaldehyde (RF), polyimide, polyacrylate, polymethyl methacrylate, acrylate oligomer, polyoxyalkylene, polyurethane, polyphenol, polybutadiene, trialkoxysilyl-terminated polydimethylsiloxane, polystyrene, polyacrylonitrile, polyfurfural, melamine-formaldehyde, cresol formaldehyde, phenol-furfural, polyether, polyol, polyisocyanate, polyhydroxybenzene, polyvinyl alcohol dialdehyde, polycyanurate, polyacrylamide, various epoxies, agar, agarose, chitosan, and combinations thereof. In one embodiment, organic RF aerogels are typically prepared from sol-gel polymerization of resorcinol or melamine with formaldehyde under alkaline conditions.

[0018] 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. Ormosil is generally 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, C2H5, C3H7, or C4H9; 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. Furthermore, the organic components in the ormosil aerogel may be dispersed throughout the silica network or chemically bonded to the silica network.

[0019] 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, gives an object with high compressive strength along any of those axes.

[0020] One method of aerogel formation involves batch casting. Batch casting involves catalyzing the entire volume of a single sol to simultaneously induce gelation throughout its entire volume. Gel formation techniques involve adjusting the pH and / or temperature of a diluted metal oxide sol to the point at which gelation occurs. Suitable materials for forming inorganic aerogels include oxides of most metals that can form oxides, such as silicon, aluminum, titanium, zirconium, hafnium, yttrium, and vanadium. Particularly preferred are gels (alcogels) formed mainly from alcoholic solutions of hydrolyzed silicates, as they are readily available and inexpensive. Organic aerogels can also be made from melamine formaldehyde, resorcinol formaldehyde, and the like.

[0021] In one embodiment, the aerogel material may be monolithic or continuous in its structure or as a whole layer. In another embodiment, the aerogel material may include a composite aerogel material having aerogel particles mixed with a binder or carrier. Other additives, including but not limited to surfactants that assist in the dispersion of aerogel particles within the binder or carrier, may be included in the composite aerogel material. The composite aerogel slurry may be applied to a support plate such as a mesh, felt, or web, and then dried to form a composite aerogel structure.

[0022] The aerogel may be organic, inorganic, or a mixture thereof. In some embodiments, the aerogel includes silica-based aerogels. One or more layers within the thermal barrier may contain a reinforcing material. The reinforcing material may be any material that imparts elasticity, adaptability, or structural stability to the aerogel material. The composite of aerosol and reinforcing material may contain 25–95% by weight of aerosol and 5–75% by weight of reinforcing material. Embodiments of the reinforcing material include, but are not limited to, open-cell macroporous framework reinforcing materials, closed-cell macroporous framework reinforcing materials, open-cell membranes, honeycomb reinforcing materials, polymer reinforcing materials, and fiber reinforcing materials such as short fibers, woven materials, nonwoven materials, needle nonwovens, battings, webs, mats, and felts.

[0023] The reinforcing material may be selected from, but is not limited to, organic polymer fibers, inorganic fibers, carbon fibers, or combinations thereof. Inorganic fibers may be selected from glass fibers, rock fibers, metal fibers, boron fibers, ceramic fibers, basalt fibers, pre-oxidized fibers, pre-oxidized polyacrylonitrile, foams, rubber, resins, polymers, or combinations thereof. In some embodiments, the fibers may be in the form of short fibers, woven materials, dry nonwoven materials, wet nonwoven materials, airlaid nonwovens, needle nonwovens, battings, webs, mats, felts, and / or combinations thereof. In some embodiments, the reinforcing material may include reinforcement comprising layers of multiple materials.

[0024] heat conduction layer In addition to the thermal insulation layer, the isolation material layer may further include a thermal conductive material layer. The thermal conductive material layer, combined with the thermal insulation layer, is effective in directing unwanted heat to a desired external location. Thermal communication between the thermal conductive layer and the heat sink element in the battery system allows for the removal of excess heat from one or more battery cells adjacent to the isolation material layer to the heat sink. Removing excess heat reduces the impact, severity, or propagation of thermal events that may cause excess heat. In addition to heat removal, the thermal conductive layer can diffuse or dissipate heat from areas of high heat concentration to wider areas of low heat concentration, thereby reducing the possibility of localized overheating and the resulting thermal runaway. In one embodiment, one or more thermal conductive layers help dissipate heat from localized thermal loads within a battery module or pack.

[0025] High thermal conductivity materials include, but are not limited to, metals and combinations thereof, such as carbon fiber, graphite, silicon carbide, copper, stainless steel, and aluminum.

[0026] To further distribute or remove undesirable heat, the thermal conduction layer is coupled to external heat dissipation fins, a heat dissipation housing, or other external structure that dissipates unwanted heat to the surrounding air. In at least one embodiment, the thermal conduction layer is coupled to a heat sink. There are various types and configurations of heat sinks, as well as different techniques for coupling heat sinks to thermal conduction layers, and it is understood that this disclosure is not limited to the use of any one type of heat sink / coupling technique. In one embodiment, at least one thermal conduction layer of the multilayer material disclosed herein may be in thermal communication with an element of a cooling system of a battery module or pack, such as a cooling plate or cooling channel of a cooling system. In another embodiment, at least one thermal conduction layer 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 pack, module, or system wall, or with other elements of the multilayer material placed between battery cells.

[0027] Elastic material layer In addition to the thermal insulation layer and the thermal conductivity layer, the separation material layer may further include one or more elastic material layers. In one embodiment, the elastic layer absorbs any volume expansion of one or more battery cells during normal operation. In one embodiment, the cells may expand during charging and contract during discharging. In one embodiment, the elastic layer may also absorb permanent volume expansion caused by aging, degradation and / or thermal runaway of any of the battery cells. The elastic material layers may include, but are not limited to, foams, fibers, cloths, sponges, spring structures, rubbers, polymers, resins, and the like.

[0028] Figure 1A shows an example of a battery module 100. Module 100 includes a stack of battery cells 102. In one example, the stack of battery cells 102 includes lithium-ion battery cells 102, but other cell types are within the scope of this disclosure. Several configurations of lithium-ion battery cells 102 are possible. In one example, the stack of lithium-ion battery cells 102 includes lithium-ion prismatic battery cells, lithium-ion pouch battery cells, or lithium-ion cylindrical battery cells, but the present invention is not limited to these. In one example, the stack of lithium-ion battery cells 102 includes lithium nickel manganese cobalt (NMC) oxide battery cells and / or lithium iron phosphorus (LFP) battery cells, but the present invention is not limited to these. Some battery cells 102 are grouped into several cell subdivisions 112, 114. As described above, it is desirable to stop or mitigate thermal runaway conditions that may occur in battery cells such as lithium-ion battery cells 102. The thermal barrier 110 is positioned between adjacent cell subdivisions 112 and 114 to stop or mitigate thermal runaway between them.

[0029] Each battery cell 102 in Figure 1A includes an electrical terminal 104. While an example of a battery cell 102 having terminals 104 on its upper surface is shown in Figure 1A, other configurations are also within the scope of the present invention, including but not limited to other examples shown in the following figures.

[0030] Figure 1B shows an arbitrary configuration of a battery module 150, including a heatsink 154 located on the side of the module 150 and in thermal communication with the battery cells 152. Figure 1B shows a cross-section of the battery module 150. One or more battery cells 152 are shown separated by one or more thermal barriers 160. In Figure 1B, only a selected group or subdivision of battery cells 152 are separated by thermal barriers 160, but the disclosure is not limited thereto. In other examples, all cells 152 are bounded by thermal barriers 160. The side, bottom, or top of the battery module 150 may also include thermal barriers 160. Examples of thermal barriers 110, 160 are shown in more detail in the following description of the figures.

[0031] Figure 2A shows a diagram of the first thermal barrier 214 separating the first cell subdivision 210 from the second cell subdivision 212. The second thermal barrier 214' is adjacent to the second cell subdivision 212 distal to the first thermal barrier 214. The first thermal barrier 214 and the second thermal barrier 214' each have dimensions including a height of 202, a width of 204, and a thickness of 206. The cross-sectional area is defined as the height 202 multiplied by the width 204. The volume of the first thermal barrier 214 and the second thermal barrier 214' is defined as the height 202 multiplied by the width 204 and the thickness 206.

[0032] The first thermal barrier 214 forms a first interface 215 with the first cell subdivision 210 and a second interface 217 with the second cell subdivision 212. Subdivisions 210 and 212 each have a height 202 and a width 204.

[0033] Figure 2B is a cross-sectional view of the thermal barrier 214 shown in Figure 2A, with the thermal gradient 219 superimposed on the cross-sectional view 2B, passing through the vertical plane. The temperature gradient 219, with an arrow indicating heat 221 visible, shows that heat flows from a high temperature to a low temperature. As used herein, heat into a system is considered to have a positive direction.

[0034] As used herein, the term "heat" means either thermal energy or the transfer of thermal energy, depending on the context. Furthermore, in some cases, the term "heat" may refer to "high temperature."

[0035] Fourier's Law can be expressed as q = (k / s)A dT, where q = heat transfer (watts (W), joules / second (J / s)), k = thermal conductivity of the material (watts / meter Kelvin, W / m°C), s = thickness of the material (m), and A = heat transfer area (m²). 2 ), dT = t1 - t2 = temperature gradient (difference) of the material (°C). U = k / s, heat transfer coefficient (W / (m). 2 K))

[0036] As Fourier's law demonstrates, the temperature drop across a thermal barrier over a given period depends on the rate of energy transfer and the heat transfer area. As disclosed herein, the heat transfer (q) from a cell subdivision is limited by the amount of energy stored in the cell subdivision. In other words, if all the energy stored in the cell subdivision is released over a given period, the system has the highest possible q. Furthermore, Fourier's law can be shown to be proportional to the heat transfer area.

[0037] In this disclosure, the term “surface energy density” means the energy within a cell subdivision (or body for other purposes) divided by the heat transfer area. In some embodiments, the temperature and heat transfer possibilities may be considered symmetrical on both sides of the cell subdivision. Thus, in some embodiments, the surface energy density may be calculated by dividing the energy stored in the cell subdivision by the total area on both sides of the cell subdivision. If heat is removed from the cell subdivision 210 using a cooling channel, the energy removed by the cooling channel is subtracted from the stored energy when calculating the surface energy density. This total energy potentially available for transfer (stored energy - removed energy) is divided by the area over which thermal energy can be transferred, i.e., the surface area of ​​the cell subdivision. For convenience, the calculations in this disclosure assume that errors introduced by assuming that thermal energy is available only for transfer through the two largest opposing surfaces of the prismatic battery cell are negligible. The surface area of ​​a cell subdivision (e.g., cell subdivision 212, which is equal to the area of ​​the second interface 217 (height 202 multiplied by width 204)) is added to the area of ​​the third interface 213 (also height 202 multiplied by width 204). In the example shown in Figure 2B, the area of ​​the second interface 217 is equal to the area of ​​the third interface 213, and therefore the surface area of ​​the cell subdivision (e.g., the second cell subdivision 212) can be described as twice the surface area of ​​the interface region. In the illustrated example, the second interface 217 and the third interface 213 represent the insulated heat transfer surfaces of the cell subdivisions.

[0038] Figure 2C shows a graph 250 relating the surface energy density of the cell defined above to the thickness of the thermal barrier 214. As used herein, the term "X-axis" refers to the horizontal axis of a two-dimensional graph. As used herein, the term "Y-axis" refers to the vertical axis of a two-dimensional graph. In Figure 2C, the X-axis 256 represents kWh / m 2 This shows the surface energy density of the cell. As disclosed herein, the surface energy density of a cell is defined as the amount of energy (E) stored in the cell subdivision divided by the surface area of ​​the thermal barrier in contact with the cell subdivision (e.g., twice the cross-sectional area, or the surface area (A)). 面(Twice the area of ​​). As shown in Figure 2A, twice the cross-sectional area is equal to the second interface 217 + the third interface 213.

[0039] The first Y-axis 252 shows the uncompressed thickness in millimeters of a thermal barrier such as thermal barrier 214 in Figure 2A, or thermal barriers 110 and 160 in Figures 1A and 1B (respectively). The second Y-axis 254 shows the compressed thickness in millimeters of a thermal barrier such as thermal barrier 214 in Figure 2A, or thermal barriers 110 and 160 in Figures 1A and 1B (respectively). In some embodiments, the compressed thickness may range from about 10% to about 100% of the uncompressed thickness. In one embodiment, the compressed thickness may be greater than about 90%, greater than about 70%, greater than about 50%, greater than about 30%, or greater than about 10% of the uncompressed thickness. In one example, the compressed thickness is greater than 50% of the uncompressed thickness.

[0040] In examples where the thermal barrier (214, 214', 110, 160) contains aerogel, the thermal conductivity may not be substantially affected by compression. It should be understood that "the thermal conductivity may not be substantially affected by compression" means that the thermal conductivity in the compressed state may be within 10 percent of the thermal conductivity in the uncompressed state. In some embodiments, the thermal barrier after compression exhibits a lower thermal conductivity compared to the thermal conductivity before compression. In one embodiment, the thermal conductivity after compression is about 20% lower than the thermal conductivity before compression (e.g., when compression is under a pressure of about 50 PSI). In other words, the thermal conductivity of the aerogel barrier is robust to compression. In some embodiments, since battery cells expand and contract, robustness to compression may be advantageous in applications of thermal barriers to battery cells. In some embodiments, the thermal barriers disclosed herein may maintain thermal protection throughout the entire range of compression caused by the expansion and contraction of the battery cell, e.g., through volume changes of the battery during charging and discharging. Some aerogel materials may exhibit very low thermal conductivity in both the compressed and uncompressed states. In some embodiments, the thermal barrier includes a thermal conductivity of less than about 0.03 W / (m·K), less than about 0.025 W / (m·K), less than about 0.02 W / (m·K), less than about 0.15 W / (m·K), or less than about 0.10 W / (m·K). In one embodiment, the thermal barrier including aerogel includes a thermal conductivity of less than about 0.02 W / (m·K).

[0041] Graph 250 in Figure 2C shows that the ratio (slope of the illustrated line) is independent of the number of cell subdivisions and the number of thermal barriers. For example, the slope of the first line 270 using the uncompressed Y-axis 252 is 8 mm / 25 kWh / m 2 This is 320cm. 3 / kilowatt-hours (cm²) 3 It decreases to ( / kWh). In other words, the volume of the heat barrier divided by the amount of energy stored defines a ratio equal to the slope of the line.

[0042] In one example, the first line 270 in FIG. 2C indicates a ratio (gradient) that defines the thickness of a thermal barrier configured to prevent a thermal runaway condition from spreading from a first cell or cell subdivision across the thermal barrier to an adjacent cell or cell subdivision. In certain aspects, at a given cell surface energy density, any thickness of the thermal barrier above line 270 is sufficient to prevent thermal runaway from spreading beyond the thermal barrier. Conversely, in certain aspects, any thickness below line 270 may not be sufficient to prevent thermal runaway from spreading beyond the thermal barrier. Given sufficient time when the thickness is below line 270, thermal runaway may spread beyond the thermal barrier. As shown in FIG. 2C, for a cell surface energy density of 25 kWh / m 2 and an energy storage system with an uncompressed thermal barrier thickness of at least 8 mm prevents thermal runaway from spreading beyond the thermal barrier. Similarly, as shown in FIG. 2C, an uncompressed thermal barrier thickness of at least 4 mm prevents thermal runaway from spreading beyond the thermal barrier. Referring further to FIG. 2C, for a cell surface energy density of 25 kWh / m 2 , a thermal barrier having an uncompressed thickness less than 8 mm, or a compressed thickness less than 4 mm, may delay the spread of thermal runaway beyond the thermal barrier; thermal runaway may eventually escape confinement by the thermal barrier over time.

[0043] In one example, the second line 260 in Figure 2C represents a percentage (gradient) that defines the thickness of a thermal barrier configured to delay a thermal runaway condition from breaking through the thermal barrier to the next adjacent battery cell or cell sub-cell by 5 minutes. A 5-minute delay may be considered acceptable in some battery-powered devices, such as automobiles. As shown in Figure 2C, at a given cell surface energy density, any thermal barrier thickness above line 260 is sufficient to delay a thermal runaway condition from breaking through the thermal barrier by at least 5 minutes. Therefore, a thermal barrier thickness below line 260 may not be sufficient to delay a thermal runaway condition from breaking through the thermal barrier by at least 5 minutes. A thermal runaway condition may break through the thermal barrier in less than 5 minutes if the thermal barrier thickness is below line 260. As shown in Figure 2C, for example, at a cell surface energy density of 25 kWh / m², 2 Considering an energy storage system, an uncompressed thermal barrier thickness of at least 5 mm will delay thermal runaway from breaking through the thermal barrier by at least 5 minutes. Similarly, as shown in Figure 2C, 25 kWh / m 2 In the case of this energy storage system, a compressed thermal barrier thickness of at least 2.5 mm delays thermal runaway from breaking through the thermal barrier by at least 5 minutes. Furthermore, referring to Figure 2C, 25 kWh / m 2 In the case of energy storage systems, an uncompressed thickness of less than 5 mm, or a compressed thickness of less than 2.5 mm, may not be sufficient to delay thermal runaway from spreading beyond the thermal barrier for at least 5 minutes.

[0044] In this embodiment, the slopes of lines 260 and 270 in Figure 2C are used to determine the minimum volume of the thermal barrier of the battery module 200, which may delay (line 260) or prevent (line 270) thermal runaway from breaking through the thermal barrier. It will be understood that certain conditions apply to using the slopes of the lines in Figure 2C in the volume calculation, namely, that only stored energy "protected" by the thermal barrier included in the calculation must be included. Energy can move across the thermal barrier in one direction at a time. (Theorem of Thermodynamics) 2(Based on the law of thermal energy transfer.) For example, as shown in Figure 2D, one side of cell subdivision 210 is not "protected" by the thermal barrier. The energy stored in a battery cell or battery module is the rated energy or nominal energy. The energy released during thermal runaway can, in some cases, be several times greater than the rated energy or nominal energy. Assuming that the memory cell is thermally homogeneous, the "unprotected" side of cell subdivision 210 accounts for half of the energy stored in the cell subdivision. If we assume that thermal energy is transferred to the left side in Figure 2D, half of the energy stored in each cell is related to the size of the two thermal barriers 214. If we assume that thermal energy is transferred from both sides of cell subdivision 212, then the energy can be transferred through the thermal barrier in one direction at once, so cell subdivision 210 is considered "unprotected". In both analytical methods, the total amount of stored energy related to setting the size of the two thermal barriers using the slope of the lines in Figure 2C is the total storage amount of one cell subdivision 210 or 212. Therefore, the total amount of stored energy to be included in the calculations for the systems shown in Figures 2A and 2D is the stored energy of one cell sub-section 210 or 212. An example of how to determine the minimum volume of the thermal barrier of the battery module 200 shown in Figures 2A and 2D is as follows: The slope of line 260 is approximately 200 cm. 3 This is expressed as kilowatt-hours, and is calculated by dividing the volume of the thermal barrier (cm³) by the amount of energy (kilowatt-hours) stored in cell subdivision 212. 3 The slope of line 260 is at least approximately 200 cm for each kilowatt-hour of energy stored in the "protected" portion of the battery module 200, in order to delay the occurrence of thermal runaway by at least approximately 5 minutes. 3 This shows that a thermal barrier of this volume is required. As an example, assume that the energy stored in cell subdivision 212 is 0.275 kWh. 0.275 kWh × 200 cm³ / kWh = 55 cm³. Similarly, the slope of line 270 is approximately 320 cm. 3 This is per kilowatt-hour, which is at least 320 cm 3This indicates that a thermal barrier of a certain volume is required for each kilowatt-hour of energy stored in the "protected" portion of the battery module 200 to prevent thermal runaway from breaking through the thermal barrier. A battery module 200 having a ratio of thermal barrier volume to the "protected" energy storage greater than the ratio (gradient) of line 260 provides at least a 5-minute delay before thermal runaway breaks through the thermal barrier. A battery module 200 having a ratio of thermal barrier volume to the "protected" energy storage greater than the ratio (gradient) of line 270 can prevent thermal runaway from breaking through the thermal barrier for a period of time starting from the onset of thermal runaway. In some embodiments, the period of time may be longer than 24 hours. In some embodiments, the period of time may be longer than 48 hours. In some embodiments, the period of time may be longer than 72 hours. In some embodiments, the period of time may be longer than 96 hours. In some embodiments, the period of time may be longer than 2 weeks.

[0045] Line 270, 320cm 3 / Kilowatt-hour ratio and line 260 200cm 3 The percentage of / kilowatt-hours is shown in illustrative Graph 250, but the present invention is not limited thereto. The material properties of the insulating material (e.g., aerogel, resin, polymer, foam, mica, ceramic) and the structural arrangement of the material may affect the properties of the thermal barrier (e.g., thermal conductivity), and thus may affect the specific percentage (slope) in Graph 250 of Figure 2C. In some embodiments, the percentage (slope) of line 260 is about 100 cm 3 / kilowatt-hour ~ approximately 350cm 3 It extends to kilowatt-hours. In some aspects, the ratio (gradient) of line 270 is approximately 150 cm. 3 / kilowatt-hour ~ approximately 500cm 3 It extends to kilowatt-hours. In some embodiments, the volume of the thermal barrier within the battery module 200 is approximately 100 cm³. 3 / kilowatt ~ approximately 500cm 3 / kilowatt, 150cm 3 / kilowatt ~ approximately 350cm 3 / kilowatt, or 200cm 3 / kilowatt ~ approximately 320cm3 / kilowatt. In one example, the intermediate region 262 between lines 260 and 270 in Graph 250 shows the design envelope of the thermal barrier in a battery module where the barrier effectiveness specification is between a 5-minute delay (indicated by line 260) and a substantially unlimited containment time (indicated by line 270). In one embodiment, a substantially unlimited containment time may be at least about 8 hours. In one embodiment, a substantially unlimited containment time may be at least about 24 hours. In one embodiment, a substantially unlimited containment time may be at least about 96 hours. In one embodiment, a substantially unlimited containment time may be at least about 8 to 96 hours.

[0046] Figure 3 shows an exploded view of an example of a battery module 300. The battery module 300 includes several battery cells 302, each containing electrodes 304. Each battery cell 302 has a cross-sectional area equal to the product of its height 307 and width 306. In the example in Figure 3, each cell 302 has a thickness 308.

[0047] One or more thermal barriers 310 are shown between battery cells 302. One or more thermal barriers 310 have a thickness 312. In some embodiments, each thermal barrier 310 has a height substantially equal to the height 307 of the battery cell and a width substantially equal to the width 306 of the battery cell as shown in Figure 3 with respect to the battery cell 302. In some embodiments based on the diagram in Figure 3, the volume of a given thermal barrier 310 is defined as the product of the height 307, the width 306, and the thickness 312. In some embodiments based on the proportions shown in Figure 2C, the volume of a given thermal barrier 310 divided by half the amount of energy stored in the battery cell adjacent to the thermal barrier 310 defines a proportion shown by the slopes of lines 260 and 270, respectively, on graph 250 in Figure 2C. Similarly, the volume of the thermal barrier 310 within the battery module 300, divided by half the total amount of energy stored in all the battery cells 302 of the battery module 300 protected by the thermal barrier 310, defines the ratio shown by lines 260 and 270 on graph 250 in Figure 2C.

[0048] It should be understood that the total energy related to the calculation of the slope of the total volume of the thermal barrier multiplied by the total energy can be reduced by a correction factor for the number of ends protected by the thermal barrier. If two ends are covered by the thermal barrier, the number of cells included in the calculation of the total energy related to the thermal barrier sizing increases by 1. If one end is covered by the thermal barrier, the number of cells included in the calculation of the total energy related to the thermal barrier sizing is not corrected. If neither end is covered by the thermal barrier, the number of cells included in the calculation of the total energy related to the thermal barrier sizing decreases by 1. It will be further understood that as the number of cells increases, the error introduced by not applying the correction factor may be negligible. The percentage of potential error in the calculation of thermal barrier sizing is approximately 1 divided by the number of cells (or cell subdivisions) and multiplied by 100. Therefore, if there are 5 cells (or cell subdivisions) in the module, an error of less than + / -20% may be introduced by not considering the final effect. Therefore, if there are 10 cells (or cell subdivisions) in a module, an error of less than + / -10% may be introduced by not considering the final impact. Therefore, if there are 50 cells (or cell subdivisions) in a module, an error of less than + / -2% may be introduced by not considering the final impact.

[0049] The demonstration using the battery module 300 shown in Figure 3, along with Graph 250 in Figure 2C, follows below. [Table 1] [Table 2-1] [Table 2-2] [Table 3]

[0050] Table 3 shows the total volume of the thermal barrier (TV) calculated using the total energy correction in the example. TB )(82.6cm 3 ) The TV calculated in Table 2 for three thermal barriers using line 260 TB (82.5cm 3 This shows that it is the same as ). 0.1 cm is negligible. 3 The difference is caused by the difference in rounding of intermediate values ​​in the calculation. Thus, the equivalence of the results from the surface density method and the total energy method disclosed herein is demonstrated.

[0051] Figure 4 shows an exploded view of another example of a battery module 400. The battery module 400 includes one or more thermal barriers 410 having a height-to-width ratio of 406 to 407 that is greater than approximately 1.5. The height-to-width ratio greater than approximately 1.5 is designed to fit similarly designed battery cells 402. Battery cells 402 with such a ratio have an increased surface area (e.g., height 407 × width 406) compared to battery cells with a height-to-width ratio of less than approximately 1.5. The increase in the surface area of ​​battery cells 402 requires a smaller volume of thermal barrier 410, according to graph 250 in Figure 2C. As a result, the battery module 400 includes a thermal barrier 410 for every few battery cells 402 instead of all the other battery cells, as shown in Figure 3.

[0052] The battery module 400 in Figure 4 includes several battery cells 402, each containing an electrode 404. In the example in Figure 4, the several battery cells 402 are divided into several cell subdivisions 401, each cell subdivision 401 containing multiple battery cells 402 separated by one or more thermal barriers 410. Each battery cell 402 defines a cross-sectional area equal to a height of 407 × a width of 406. In the example in Figure 4, each cell subdivision 401 has a thickness of 408.

[0053] As described above, one or more thermal barriers 410 are shown between the battery cells 402. One or more thermal barriers 410 have a thickness 412. In some embodiments, each thermal barrier 410 has a height substantially the same as the height 407 shown in Figure 4 with respect to the cell subdivision 401 and a width substantially the same as the width 406. In some embodiments based on the diagram in Figure 4, the volume of a given thermal barrier 410 may be defined as the product of the height 407, the width 406, and the thickness 412. The volume of a given thermal barrier 410 divided by half the amount of energy stored in the cell subdivision adjacent to the thermal barrier 410, according to the ratio shown in Figure 2C, defines the ratio shown by the slopes of lines 260 and 270, respectively, on graph 250 in Figure 2C. Similarly, the volume of the thermal barrier 410 within the battery module 400 and / or all cell subdivisions 401 of the battery module 400, divided by half the amount of energy stored in all the battery cells 402 of the battery module 400 protected by the thermal barrier 410, defines the proportion shown by lines 260, 270 on graph 250 in Figure 2C.

[0054] As disclosed herein, it should be understood that the total energy related to the calculation of the slope of the total volume of the thermal barrier × total energy can be reduced by a correction factor for the number of edges protected by the thermal barrier.

[0055] The demonstration using the battery module 400 shown in Figure 4, along with Graph 250 in Figure 2C, follows below. [Table 4] [Table 5-1] [Table 5-2]

[0056] Given a battery module, a thermal barrier TV TB The total volume can be calculated using line 260 to delay thermal runaway (e.g., breaking through the thermal barrier) by 5 minutes. (Thermal Barrier TV)TB The total volume can be calculated using line 270 to prevent thermal runaway from breaking through the thermal barrier. In one embodiment, the thermal barrier TV TB The total volume can be implemented in a single thermal barrier that divides the battery module into two sub-sections. Alternatively, the thermal barrier TV TB The total volume could be two thermal barriers dividing the battery module into three sub-sections, or three thermal barriers dividing the battery module into four sub-sections. TB The total volume may be implemented as up to X-1 thermal barriers dividing the battery module into X sub-sections, each sub-section having at least one battery cell, where X is the number of battery cells in the battery module. cell_sub It should be understood that these can be interchangeably used in this disclosure to represent the number of cell subdivisions. Each subdivision may contain an equal number of battery cells or a different number of battery cells. Thermal barrier(s) TV TB The total volume is determined not by the size of the individual subdivisions, but by the total energy (E T ) is based on the heat barrier (multiple options possible) TV TB The total volume does not necessarily change by implementing different numbers of thermal barriers or subdivisions. Total energy (E T If the ) remains unchanged, the average thermal barrier thickness is reduced by dividing the battery module into more subdivisions separated by more thermal barriers. As long as the total volume of the thermal barrier meets the requirements of lines 260 and 270 in Figure 2C, the thermal barrier provides a 5-minute delay in thermal runaway (line 260) or prevents thermal runaway from breaking through the thermal barrier (line 270).

[0057] If cell subdivisions are not of equal size (with respect to energy), it should be understood that the thermal barrier associated with the non-uniformly sized subdivisions will have corresponding variations in thickness. (Thermal barrier(s) TV) TB The total volume is proportional to the size of the corresponding cell subdivision and is implemented in each individual thermal barrier.

[0058] In the example shown in Table 6, if the total energy stored in all battery cells within the battery module is E*, the total thickness T of the thermal barrier required for the battery module can be calculated by the slope of line 260 or line 270 in Figure 2C. The total volume of the thermal barrier V required for the battery module is calculated by multiplying T by the surface area of ​​the thermal barrier (A). BHT This is calculated by multiplying by ). If the battery module is divided into two sub-sections by one thermal barrier, the volume V' and thickness T' of each thermal barrier are V and T, respectively. The required volume V' and thickness T' of each thermal barrier are V / 2 and T / 2, respectively, if the battery module is divided into three sub-sections by two thermal barriers (assuming each of the three sub-sections is of equal size with respect to energy). The maximum number of thermal barriers is X-1, where X is the total number of battery cells in the battery module. In such a case (i.e., when the maximum number of thermal barriers are implemented), each sub-section has exactly one battery cell. In other words, each battery cell is separated from other battery cells by thermal barriers. The volume V' and thickness T' of each thermal barrier are V / (X-1) and T / (X-1). In this case, there are no thermal barriers at the ends of the battery module.

[0059] The demonstration using battery modules 300 and 400, shown in Figures 3 and 4, along with graph 250 in Figure 2C, follows below. The energy of each cell is 0.275 kWh. The area of ​​the heat transfer surface of each cell subdivision (A CSHT ) is calculated by multiplying the height of 0.091m by the width of 0.400m, which is 0.0364m 2 This is equal to 2. The number of heat transfer surfaces for each cell subdivision is 2. [Table 6-1] [Table 6-2]

[0060] Figure 5 shows an exploded view of another example of a battery module 500. The battery module 500 includes one or more thermal barriers 510 located in a housing 520. The length of the thermal barriers 510 extends across the entire width of the housing 520, thereby dividing the housing 520 into multiple compartments. The multiple compartments contain subdivisions of battery cells 502, preventing heat transfer between them under extreme conditions. Extreme conditions may include, but are not limited to, mechanical damage, overheating, and thermal runaway.

[0061] The battery module 500 in Figure 5 includes several battery cells 502. In the example in Figure 5, several battery cells 502 are divided into several cell subdivisions 501, each cell subdivision 501 containing multiple battery cells 502 separated by one or more thermal barriers 510. In some embodiments, each thermal barrier 510 has substantially the same height and width as each of the battery cells 502 shown in Figure 5. In one embodiment based on the diagram in Figure 5, several battery cells 502 and several cell subdivisions 501 are located within a housing 520. The width of the battery cells 502 extends across the entire width of the housing 520. In one embodiment, the housing 520 includes a thermal barrier material. In one example, the thermal barrier material included in the housing 520 includes an aerogel material. In one example, a lid 522 is further included, which, in combination with the housing 520, completely encloses several battery cells 502 and several cell subdivisions 501. In one example, the lid 522 includes a thermal barrier material. For example, the thermal barrier material contained in the lid 522 includes an aerogel material. While parts of the housing 520 and lid 522 may include thermal barrier material, it should be understood that parts of the housing 520 and lid 522 may or may not be thermal barrier 510.

[0062] According to the proportions shown in Figure 2C, the volume of a given thermal barrier 510 divided by half the amount of energy stored in the cell sub-compartments adjacent to the thermal barrier 510 defines the proportion shown by the slopes of lines 260 and 270, respectively, on graph 250 in Figure 2C. Similarly, the volume of the thermal barrier 510 within the battery module 500 divided by half the amount of energy stored in all the battery cells 502 and / or all the cell sub-compartments 501 of the battery module 500 protected by the thermal barrier 510 defines the proportion shown by lines 260 and 270 on graph 250 in Figure 2C.

[0063] As disclosed herein, it should be understood that the total energy related to the calculation of the slope of the total volume of the thermal barrier 510 × total energy can be reduced by a correction factor for the number of ends protected by the thermal barrier. Figure 6 shows another example of a battery module 600 in exploded view. One or more thermal barriers 610 are integrated with the housing 620 in Figure 6. The thermal barriers 610 integrated with the housing 620 divide the housing into multiple compartments. Each compartment limits the subdivision of the battery cells 602. The limiting of the integrated thermal barriers 610 restricts the relative motion of the battery cells 602 relative to the corresponding compartments in which the battery cells 602 are located, and is reduced during operation and under extreme conditions (e.g., thermal runaway or mechanical shock). The relative motion of the battery cells 602 can be reduced by the buffering effect of the elastic integrated thermal barriers 610. The elastic, integrated thermal barrier 610 supports the battery cell 602 in a fixed position within the housing 620, and can reduce the relative motion between the battery cell 602 and the corresponding compartment of the housing 620 compared to the relative motion without the thermal barrier 610.

[0064] The battery system 600 includes several battery cells 602. In the example of Figure 6, several battery cells 602 are divided into several cell subdivisions 601, and each cell subdivision 601 includes several battery cells 602 separated by one or more thermal barriers 610. In some embodiments, each thermal barrier 610 has substantially the same height and width as substantially the same as each of the battery cells 602 shown in Figure 6. In some embodiments based on the diagram in Figure 6, several battery cells 602 and several cell subdivisions 601 are located within a housing 620. In one example, the housing 620 includes a thermal barrier material. In one example, the thermal barrier material included in the housing 620 includes an aerogel material. In the example of Figure 6, one or more thermal barriers 610 are integrally formed with the housing 620. In one example, a lid 622 is further included, which, in combination with the housing 620, completely encloses several battery cells 602 and several cell subdivisions 601. In one example, the lid 622 includes a thermal barrier material. In one example, the heat barrier material contained in the lid 622 includes an aerogel material.

[0065] According to the proportions shown in Figure 2C, the volume of a given thermal barrier 610 divided by half the amount of energy stored in the cell sub-compartments adjacent to the thermal barrier 610 defines the proportion shown by the slopes of lines 260 and 270, respectively, on graph 250 in Figure 2C. Similarly, the volume of the thermal barrier 610 within the battery module 600 divided by half the amount of energy stored in all the battery cells 602 and / or all the cell sub-compartments 601 of the battery module 600 protected by the thermal barrier 610 defines the proportion shown by lines 260 and 270 on graph 250 in Figure 2C.

[0066] As disclosed herein, it should be understood that the total energy related to the calculation of the slope of the total volume of the thermal barrier 510 × total energy can be reduced by a correction factor for the number of edges protected by the thermal barrier.

[0067] Figure 7A shows an exploded view of an example of a battery pack 700. The battery pack 700 includes a cooling channel 710 integrated within a housing 720, and a thermal barrier 712 between the battery cells 702. The cooling channel 710 contains a coolant flowing through it to remove heat from the battery pack 700. The combination of the cooling channel 710 and the thermal barrier 712 works together to prevent thermal runaway by removing excess heat and preventing heat transfer between compartments.

[0068] The battery pack 700 includes several battery modules 728. One or more of the modules 728 include several battery cells 702 separated by one or more thermal barriers 712. In one embodiment, the thermal barriers 712 are separate from the battery pack 700 and are assembled to the battery pack 700. In other words, the thermal barriers 712 are not integrated within the housing 720. The non-integrated thermal barriers 712 may provide flexibility in the battery pack assembly process.

[0069] Figure 7A shows an example of how the battery pack 700 may be assembled. Arrow 726 indicates that each thermal barrier 712 is positioned between two battery cells 702. The two battery cells 702 are positioned within a compartment defined by the housing 720, their respective cooling channels 710, and optionally a lid 722.

[0070] In the example shown in Figure 7A, several battery cells 702 are located within a housing 720. In one embodiment, the housing 720 includes a thermal barrier material. In one example, the thermal barrier material included in the housing 720 includes an aerogel material. In one example, a lid 722 is further included, which, in combination with the housing 720, completely encloses several battery cells 702 and several battery modules 728. In one example, the lid 722 includes a thermal barrier material. In one example, the thermal barrier material included in the lid 722 includes an aerogel material.

[0071] In one embodiment, for the purpose of analyzing the sizing and consistency of the thermal barriers within the disclosure, a cell subdivision 701 may include a portion of a plurality of battery modules 728. For example, as shown in Figure 7B, each cell subdivision 701 includes a cooling channel 710 located between two battery cells 702.

[0072] In the example in Figure 7A, several additional cooling channels 710 are included. Some of the cooling channels 710 are shown to isolate one or more of the battery modules 728 from each other. At least one surface of a battery cell 702 is in direct contact with a cooling channel 710. In other words, a thermal barrier 712 exists between the battery cells 702, but not between the battery cells 702 and the cooling channels 710. Including several cooling channels 710 can further facilitate temperature regulation within the battery pack 700.

[0073] One example of a cooling channel includes an active cooling channel through which a medium such as a fluid or air is pushed out, thereby regulating the amount of cooling. Another example of a cooling channel includes a passive cooling channel through which the interior of the channel 710 is exposed to the external environment, and heat is passively removed through the movement of air, thereby regulating the amount of cooling. Additional examples of cooling channels include heat-absorbing materials contained within the cooling channel, such as phase-change materials, other heat-absorbing materials, or combinations thereof.

[0074] Figure 8 shows another example of the battery pack 800 in an exploded view.

[0075] The battery pack 800 in Figure 8 includes several battery modules 801. One or more modules 801 include several battery cells 802 separated by one or more thermal barriers 812. In the example in Figure 8, several battery cells 802 are located within a housing 820. In the example shown in Figure 8, each battery module 801 includes three or more battery cells 802, each cell 802 separated by a thermal barrier 812, but the disclosure is not limited thereto. Multiple battery cells 802 may be included in cell subdivisions, as shown in other examples above. Depending on the electrical and thermal needs of the device powered by the battery pack 800, different numbers of battery cells 802 may be used within each battery module 801. In some embodiments, the thickness and volume of the thermal barrier 812 within each battery module 801 are determined according to lines 260 and 270 of graph 250 in Figure 2C.

[0076] In one embodiment, the housing 820 includes a thermal barrier material. In one example, the thermal barrier material included in the housing 820 includes an aerogel material. In one example, a lid 822 is further included, which, in combination with the housing 820, completely encloses several battery cells 802 and several battery modules 801. In one example, the lid 822 includes a thermal barrier material. In one example, the thermal barrier material included in the lid 822 includes an aerogel material.

[0077] According to the ratio shown in Figure 2C, the volume of a given heat barrier 812, when divided by half the amount of energy stored in the battery cell 802 adjacent to the heat barrier 812, defines the ratio shown by the slopes of lines 260 and 270, respectively, on graph 250 in Figure 2C.

[0078] In the example in Figure 8, several cooling channels 810 are further included. Some cooling channels 810 are shown to isolate one or more battery modules 801 from each other. Including several cooling channels 810 further facilitates temperature regulation within the battery pack 800. An example of a cooling channel includes an active cooling channel through which a medium such as a fluid or air is pushed out to regulate the amount of cooling. Another example of a cooling channel includes a passive cooling channel through which the inside of the channel 810 is exposed to the external environment and heat is passively removed through the movement of air to regulate the amount of cooling. In some embodiments, a cooling channel may include one or more of a coolant, a phase change material, a conductive material, an expandable material, and a fire extinguishing material.

[0079] In some embodiments, the cooling channel may have a heat-absorbing material stored or sealed within the cooling channel. In some embodiments, the heat-absorbing material may include a phase-change material, a crystalline hydrate, another heat-absorbing material, or a combination thereof. As used herein, “phase-change material” means a substance that absorbs sufficient energy in a phase transition to provide useful cooling. A phase transition can be from one state of a substance (e.g., solid, liquid, or gas) to another state of substance. A phase transition can also be between non-classical states of a substance, such as crystalline compatibility, and a phase-change material transitions from a state compatible with one crystalline structure to another compatible state that may be in a different energy state.

[0080] Figure 9 shows an exploded view of another example of the battery pack 900. The battery pack 900 includes a thermal barrier 910 between two cooling channels 912 and 913. The thermal barrier 910 separates the housing 920 into multiple compartments, limiting the propagation of thermal runaway to adjacent compartments. The cooling channels 912 and 913 adjacent to (i.e., in direct contact with) the thermal barrier 910 remove excess heat under extreme conditions such as overheating and thermal runaway.

[0081] In one embodiment shown in Figure 9, the battery pack 900 includes several battery modules 901. One or more of the modules 901 include several battery cells 902. In the example of Figure 9, the first cooling channel 912 and the second cooling channel 913 are located on the opposite side of several thermal barriers 910. As in the example described above, including the cooling channels 912 and 913 further facilitates temperature regulation within the battery pack 900. An example of a cooling channel includes an active cooling channel through which a medium such as fluid or air is pushed out to regulate the amount of cooling. Another example of a cooling channel includes a passive cooling channel through which the interior of the cooling channels 912 and 913 is exposed to the external environment, and heat is passively removed through the movement of air, allowing the amount of cooling to be regulated.

[0082] In the example in Figure 9, several battery cells 902 are located within a housing 920. In one example, the housing 920 includes a thermal barrier material (e.g., within a thermal barrier 910). In one example, the thermal barrier material included in the housing 920 includes an aerogel material. In one example, a lid 922 is further included, which, in combination with the housing 920, completely encloses several battery cells 902 and several battery modules 901. In one example, the lid 922 includes a thermal barrier material. In one example, the thermal barrier material included in the lid 922 includes an aerogel material.

[0083] According to Figure 2C, the volume of a given heat barrier 910, when divided by half the amount of energy stored in the battery cell 902 adjacent to the heat barrier 910, defines the ratio shown by the slopes of lines 260 and 270 on graph 250 in Figure 2C.

[0084] The battery modules and / or battery packs described above may be used in several electronic devices. Figure 10 shows an exemplary electronic device 1000 that includes a battery module 1010. The battery module 1010 is coupled to a functional electronic device 1020 by a circuit 1012. In the illustrated example, the battery module 1010 and the circuit 1012 are housed in a housing 1002. A charging port 1014 is shown that is coupled to the battery module 1010 to facilitate recharging of the battery module 1010 when needed.

[0085] For example, the functional electronic device 1020 includes devices such as semiconductor devices equipped with transistors and memory circuits. Examples of devices include, but are not limited to, telephones, computers, display screens, and navigation systems.

[0086] Figure 11 illustrates another electronic system utilizing a battery module, including a thermal management system disclosed herein. An electric vehicle 1100 is illustrated in Figure 11. The electric vehicle 1100 includes a chassis 1102 and wheels 1122. In the illustrated example, each wheel 1122 is coupled to a drive motor 1120. A battery module 1110 is shown, coupled to the drive motor 1120 by a circuit 1106. A charging port 1104 is shown, coupled to the battery module 1110 to facilitate recharging of the battery module 1110 when needed.

[0087] Examples of electric vehicles 1100 include, but are not limited to, consumer vehicles such as automobiles and trucks. Commercial vehicles such as tractors and semi-trucks are also within the scope of this disclosure. Although four-wheeled vehicles are shown, the present invention is not limited to them. For example, two-wheeled vehicles such as motorcycles and scooters are also within the scope of this disclosure.

[0088] To better illustrate the methods and apparatus disclosed herein, a non-limiting list of embodiments is provided herein.

[0089] Embodiment 1 includes a battery module. The battery module includes a plurality of battery cells, which are divided into cell subdivisions, each cell subdivision having a plurality of battery cells. The battery module includes a thermal barrier positioned adjacent to at least one of the cell subdivisions, the thermal barrier including an interface in contact with at least one of the cell subdivisions, the interface defining a cross-sectional area, and the volume of the thermal barrier being equal to the thickness of the thermal barrier multiplied by the cross-sectional area. The volume of the thermal barrier divided by half the amount of energy stored in the cell subdivision is 100 to 500 cm³. 3 Defines the percentage within the range of / kilowatt-hours.

[0090] Embodiment 2 includes the battery module of Embodiment 1, wherein the volume of the thermal barrier is an incompressible volume defined by the uncompressed thickness of the thermal insulating material.

[0091] In aspect 3, the ratio is approximately 100 cm 3 / kilowatt-hour ~ approximately 350cm 3 The battery module according to any one of embodiments 1 to 2 includes a range of kilowatt-hours that delays the propagation of thermal runaway across the thermal barrier by at least about 5 minutes.

[0092] In aspect 4, the ratio is approximately 150 cm 3 / kilowatt-hour ~ approximately 500cm 3 The battery module includes a function that extends up to kilowatt-hours and prevents thermal runaway from propagating across a thermal barrier, as described in any one of embodiments 1 to 2.

[0093] Embodiment 5 includes a battery module according to any one of Embodiments 1 to 4, wherein the volume of the thermal barrier is the compressed volume of the thermal insulating material, defined by the compressed thickness of the thermal insulating material relative to the uncompressed thickness of the thermal insulating material, and the compressed volume is greater than 50% of the uncompressed volume.

[0094] Embodiment 6 is a compressed volume of thermal insulating material, where the volume of the thermal barrier is defined by the compressed thickness of the thermal insulating material relative to the uncompressed thickness of the thermal insulating material, and the ratio is approximately 50 cm³. 3 / kilowatt-hour ~ approximately 250cm 3 Includes a battery module according to any one of embodiments 1 to 5, in the range of / kilowatt-hours.

[0095] Embodiment 7 includes a battery module according to any one of Embodiments 1 to 6, wherein the thermal barrier has a thermal conductivity of less than approximately 0.02 W / (m·K).

[0096] Embodiment 8 includes a battery module according to any one of Embodiments 1 to 7, wherein the thermal barrier comprises an aerogel.

[0097] Embodiment 9 includes a battery module according to any one of Embodiments 1 to 8, wherein the aerogel comprises silica aerogel.

[0098] Embodiment 10 includes a battery module according to any one of Embodiments 1 to 9, wherein each cell subdivision contains one cell, and the cell subdivisions are separated by each example of a thermal barrier.

[0099] Embodiment 11 includes a battery module according to any one of Embodiments 1 to 10, wherein at least a portion of the cell subdivision includes a plurality of battery cells.

[0100] Embodiment 12 includes a battery module according to any one of Embodiments 1 to 11, wherein the battery cell comprises a lithium nickel manganese cobalt (NMC) oxide battery cell.

[0101] Embodiment 13 includes a battery module according to any one of Embodiments 1 to 12, wherein several battery cells include prismatic battery cells.

[0102] Embodiment 14 includes a battery module according to any one of Embodiments 1 to 13, further comprising a housing and a lid for housing cell subdivisions, wherein a thermal barrier is integrated with the housing.

[0103] Embodiment 15 includes a battery module. The battery module includes a plurality of battery cells, wherein the cross-sectional area of ​​the battery cells within a plurality of battery cells defines a heat transfer surface, one or more thermal barriers divide the plurality of battery cells into several cell subdivisions, each of which has a cell subdivision energy storage capacity, and one or more thermal barriers are formed from a volume of thermal insulating material. The surface energy density is equal to half the cell subdivision energy storage capacity divided by the cross-sectional area, and the volume of thermal insulating material divided by half the cell subdivision energy storage capacity is at least 320 cm³. 3 A battery module that defines the ratio of kilowatt-hours.

[0104] Embodiment 16 includes the battery module according to Embodiment 15, wherein the proportion is multiplied by a thickness compression coefficient to adjust the proportion to the compression of one or more thermal barriers.

[0105] Embodiment 17 has a thickness compression coefficient of 50 percent and a ratio of at least 160 m 3 Includes a battery module according to any one of embodiments 15 to 16, wherein the output is / kilowatt-hours.

[0106] Embodiment 18 includes a battery pack. The battery pack includes a large number of battery modules, each battery module having a housing that includes a plurality of battery cells, the cross-sectional area of ​​the battery cells within the plurality of battery cells defines a heat transfer surface, and one or more thermal barriers, the one or more thermal barriers, which divide the plurality of battery cells into several cell subdivisions, each having a cell subdivision energy storage capacity, and the one or more thermal barriers, which are formed from a volume of thermal insulating material. The surface energy density is equal to half the cell subdivision energy storage capacity divided by the cross-sectional area, and the volume of thermal insulating material divided by half the cell subdivision energy storage capacity is 100 cm³. 3 / kilowatt-hours ~ 500cm 3 A battery pack that defines a percentage in the range of / kilowatt-hours, in which at least two battery modules within a number of battery modules are separated by cooling channels within the housing.

[0107] Embodiment 19 includes the battery pack according to Embodiment 18, wherein the cooling channel includes one or more of the following: a coolant, a phase change material, a conductive material, an expanding material, and a fire extinguishing material.

[0108] Embodiment 20 includes a battery pack according to any one of embodiments 18 to 19, wherein the cooling channel comprises two cooling walls separated by a thermal barrier.

[0109] Embodiment 21 includes a battery pack according to any one of Embodiments 18 to 20, wherein the cell subdivision energy storage capacity used to define the ratio is the capacity of energy stored in the battery cells of the cell subdivision minus the energy removed by the cooling channels.

[0110] The above description is intended to be illustrative, not restrictive. For example, the above embodiments (or one or more of them) may be used in combination with each other. Other embodiments may be used, for example, by a person skilled in the art considering the above description. The abstract is provided in accordance with 37 C. FR § 1.72(b) to enable the reader to quickly grasp the essence of the technical disclosure. It is submitted with the understanding that it is not used to interpret or limit the scope or meaning of the claims. Also, in the embodiments for carrying out the invention described above, various features may be grouped together to streamline the disclosure. This should not be interpreted as meaning that any disclosed feature not claimed is essential to any claim. Rather, the subject matter of the invention is not in all the features of any particular disclosed embodiment. Accordingly, the following claims are incorporated into the embodiments for carrying out the invention herein, and each claim is a separate embodiment, and it is intended that such embodiments can be combined with each other in various combinations or variations. The scope of the invention should be determined by referring to the appended claims, as well as the full scope of the equivalents to which such claims are granted.

[0111] While the subject matter of the invention has been described with reference to specific 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 present invention may be referred to herein, individually or collectively, solely for convenience, but this is not intended to arbitrarily limit the scope of this application to a single disclosure or inventive concept when multiple inventions are actually disclosed.

[0112] The embodiments illustrated herein are described in sufficient detail to enable those skilled in the art to implement the disclosed teachings. Other embodiments may be utilized and derived therefrom, so as to be structural and logical substitutions and modifications without departing from the scope of this disclosure. Accordingly, the embodiments for carrying out the invention should not be constrained, and the scope of the various embodiments is defined only by the sufficient scope of the equivalents to which such claims are granted, in addition to the appended claims.

[0113] As used herein, the term “or” may be interpreted either inclusively or exclusively. Furthermore, for resources, processes, or structures described herein as a single example, multiple examples may be provided. Moreover, the boundaries between various resources, processes, modules, engines, and datastores are somewhat arbitrary, and certain processes are shown in the context of a particular exemplary configuration. Other assignments of functionality are conceivable and may fall within the scope of various embodiments of this disclosure. In general, structures and functionalities represented as separate resources in exemplary configurations may be implemented as combined structures or resources. Similarly, structures and functionalities represented as single resources may be implemented as separate resources. These and other variations, modifications, additions, and improvements are within the scope of the embodiments of this disclosure represented by the appended claims. Accordingly, the specification and drawings should be considered illustrative rather than restrictive.

[0114] The above description for illustrative purposes is based on reference to specific exemplary embodiments. However, the above exemplary description is not intended to be exhaustive, nor is it intended to limit possible exemplary embodiments to the exact forms disclosed. Many variations and modifications are conceivable in light of the above teachings. The exemplary embodiments have been selected and described in order to best illustrate the principles involved and their practical applications, thereby enabling those skilled in the art to best utilize the various exemplary embodiments having various forms as suitable for their particular intended use.

[0115] Furthermore, 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, a first contact can be called a second contact, and similarly, a second contact can be called a first contact. The first and second contacts are both contacts, but they are not the same contact.

[0116] The terms used in describing exemplary embodiments herein are for the sole purpose of describing specific exemplary embodiments and are not intended to be limiting. Where used in the description of these exemplary embodiments and in accompanying examples, the singular forms “a,” “an,” and “the” are intended to also include the plural forms unless the context otherwise explicitly indicates. The terms “and / or” as used herein are also understood to refer to and encompass any possible combination of one or more of the items shown that are related. The terms “comprise” and / or “comprising,” when used herein, specify the presence of the described features, integers, steps, actions, elements, and / or components, but do not exclude the presence of one or more other features, integers, steps, actions, elements, components, and / or groups thereof.

[0117] As used herein, the term “if” may be interpreted, depending on the context, as “when,” “upon,” “in response to determining,” or “in response to detecting.” Similarly, the phrase “if it is determined” or “if a stated condition or event” may be interpreted, depending on the context, as “upon determining,” “in response to determining,” “upon detecting,” or “in response to detecting.”

Claims

1. It is a battery module, A plurality of battery cells, wherein the plurality of battery cells are divided into cell subdivisions, and each cell subdivision has a large number of the battery cells, A thermal barrier disposed adjacent to at least one of the cell subdivisions, wherein the thermal barrier includes an interface that contacts the at least one of the cell subdivisions, and the interface defines a cross-sectional area of ​​the thermal barrier, The volume of the heat barrier is equal to the thickness of the heat barrier multiplied by the cross-sectional area. The volume of the heat barrier, when divided by half the amount of energy stored in the cell subdivision, is 100 to 500 cm³. ３ The battery module defines a percentage within the range of kilowatt-hours.

2. The battery module according to claim 1, wherein the volume of the thermal barrier is an incompressible volume defined by the uncompressed thickness of the thermal insulating material.

3. The aforementioned ratio is approximately 100 cm ３ / kilowatt-hours to approximately 350 cm ３ The battery module according to claim 2, wherein the thermal runaway is delayed for at least about 5 minutes for the propagation of the thermal barrier, up to a kilowatt-hour.

4. The aforementioned ratio is approximately 150 cm ３ / kilowatt-hours to approximately 500 cm ３ The battery module according to claim 2, which prevents thermal runaway from propagating across the thermal barrier up to kilowatt-hours.

5. The battery module according to claim 1, wherein the volume of the thermal barrier is the compressed volume of the thermal insulating material defined by the compressed thickness of the thermal insulating material relative to the uncompressed thickness of the thermal insulating material, and the compressed volume is greater than 50% of the uncompressed volume.

6. The volume of the thermal barrier is the compressed volume of the thermal insulating material, defined by the compressed thickness of the thermal insulating material relative to the uncompressed thickness of the thermal insulating material, and the ratio is 50 cm ３ / kilowatt-hours to 250cm ３ The battery module according to claim 1, wherein the range is in the range of kilowatt-hours.

7. The battery module according to claim 1, wherein the thermal barrier has a thermal conductivity of less than approximately 0.02 W / (m·K).

8. The battery module according to claim 1, wherein the thermal barrier includes an aerogel.

9. The battery module according to claim 8, wherein the aerogel comprises silica aerogel.

10. The battery module according to claim 1, wherein each cell subdivision contains one cell, and the cell subdivisions are separated by each example of the thermal barrier.

11. The battery module according to claim 1, wherein at least a portion of the cell subdivision includes a plurality of battery cells.

12. The battery module according to claim 1, further comprising a housing and a lid for housing the cell subdivisions, wherein the thermal barrier is integrated with the housing.

13. It is a battery module, A plurality of battery cells, wherein the cross-sectional area of ​​the battery cells within the plurality of battery cells defines a heat transfer surface, The thermal barrier comprises one or more thermal barriers that divide the plurality of battery cells into cell subdivisions within a plurality of cell subdivisions, each of which cell subdivisions has a cell subdivision energy storage capacity, and the one or more thermal barriers are formed from a volume of thermal insulating material. The surface energy density is equal to half of the cell subdivision energy storage capacity divided by the cross-sectional area. The volume of the thermal insulating material obtained by dividing the aforementioned cell subdivision energy storage capacity by half is at least 320 cm³. ３ The battery module defines the ratio of kilowatt-hours.

14. The battery module according to claim 13, wherein the ratio for compression of one or more thermal barriers is adjusted by multiplying the ratio by a thickness compression coefficient.

15. The thickness compression coefficient is 50 percent and the ratio is at least 160 cm ３ / kilowatt-hour, and the battery module according to claim 14.

16. It is a battery pack, A number of battery modules within the housing, where each battery module is A plurality of battery cells, wherein the cross-sectional area of ​​the battery cells within the plurality of battery cells defines a heat transfer surface, The plurality of battery modules comprises one or more thermal barriers that divide the plurality of battery cells into cell subdivisions within several cell subdivisions, each of which cell subdivisions has a cell subdivision energy storage capacity, and the one or more thermal barriers are formed from a volume of thermal insulating material, The surface energy density is equal to half of the cell subdivision energy storage capacity divided by the cross-sectional area. The volume of the thermal insulating material obtained by dividing the aforementioned cell subdivision energy storage capacity by half is 100 cm³. ３ / kilowatt-hours to 500cm ３ Define the proportion of the range / kilowatt-hours, The battery pack wherein at least two of the battery modules in the plurality of battery modules are separated by a cooling channel in the housing.

17. The battery pack according to claim 16, wherein the cooling channel includes one or more of the following: a coolant, a phase change material, a conductive material, an expanding material, and a fire extinguishing material.

18. The battery pack according to claim 16, wherein the cooling channel includes two cooling walls separated by a thermal barrier.

19. The battery pack according to claim 16, wherein the cell subdivision energy storage capacity used to define the ratio is obtained by subtracting the energy removed by the cooling channel from the energy capacity stored in the battery cell of the cell subdivision.

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