Materials, Systems, and Methods for Encapsulating Thermal Barrier Materials

Abstract

The present disclosure relates to materials and systems for managing the problem of thermal runaway in energy storage systems. An exemplary embodiment includes an insulating layer that is encapsulated to form an insulating barrier. A support member is disposed around at least a portion of the insulating layer. The support member provides support to the insulating layer and allows the insulating layer to be easily encapsulated and installed in a battery module or battery pack.

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims the benefit and priority of U.S. Provisional Patent Application No. 63 / 218,205, filed on July 2, 2021, entitled "Materials, Systems, and Methods for Mitigation of Electrical Energy Storage Thermal Events", and U.S. Provisional Patent Application No. 63 / 284,917, filed on December 1, 2021, entitled "Materials, Systems, and Methods for Encapsulating Materials", the contents of which are hereby incorporated by reference in their entirety.

[0002] This disclosure generally relates to materials, systems, and methods for encapsulating materials. In particular, this disclosure relates to materials, systems, and methods for encapsulating a thermal barrier used between battery cells or battery modules in an energy storage system. This disclosure further relates to the encapsulation of aerogel thermal barriers. This disclosure further relates to battery modules or battery packs with one or more battery cells containing an encapsulated thermal barrier material, and similarly to systems including those battery modules or battery packs.

Background Art

[0003] It has been discovered that rechargeable batteries such as lithium-ion batteries have a wide range of applications in power-driven energy storage systems. Lithium-ion batteries (LIBs) are widely used when powering portable electronic devices such as mobile phones, tablets, laptops, and power tools, and, compared to conventional batteries, are also widely used when powering other high-current devices such as electric vehicles due to their high operating voltage, low memory effect, and high energy density. However, there are safety concerns because LIBs are susceptible to sudden failures under "severe conditions", such as when a rechargeable battery is overcharged (charged beyond the designed voltage), over-discharged, or operates or is exposed to high temperature and high pressure. As a result, the narrow operating temperature range and charge / discharge rate are limitations in the use of LIBs because the LIB can fail due to rapid self-heating or thermal runaway events when exposed to conditions outside the designed range of the LIB.

[0004] Thermal runaway can occur when the internal reaction rate increases to the point where more heat is generated than can be removed, leading to a further increase in both the reaction rate and heat generation. During thermal runaway, the high temperature induces a chain of exothermic reactions in the battery, causing the battery temperature to increase rapidly. In many cases, when thermal runaway occurs in one battery cell, the heat generated quickly heats up the cells in close proximity to the cell undergoing thermal runaway. Each additional cell added to the thermal runaway reaction traps additional energy to continue the reaction, causing thermal runaway propagation within the battery pack and ultimately leading to a major accident where a fire or explosion occurs. Rapid heat dissipation and effective blocking of the heat transfer path can be effective countermeasures to reduce the risks posed by thermal runaway propagation.

[0005] Based on an understanding of the mechanisms that lead to thermal runaway of batteries, many approaches are being explored with the goal of reducing safety risks through rational design of battery components. To prevent such cascading thermal runaway events from occurring, generally, LIBs are designed either to keep the stored energy low enough, or to utilize sufficient insulating materials between cells within a battery module or battery pack, or to insulate cells from thermal events that may occur in adjacent cells, or a combination thereof. The former strictly limits the amount of energy that can potentially be stored in such devices. The latter limits the effective energy density by restricting the way in which close cells can be installed.

[0006] Currently, several different means are being utilized to maximize energy density while taking precautions to prevent cascading thermal runaway. As one approach, sufficient insulation may be incorporated between cells or between clusters of cells. This approach is generally considered desirable for its safety benefits. However, in this approach, the upper limit of the achievable energy density is determined by the volume of the required insulator and the ability of the insulating material to contain heat.

[0007] Another approach is taken by using phase change materials. These materials undergo an endothermic phase change when they reach a specific temperature increase. The endothermic phase change absorbs some of the generated heat and thus cools the local area. Generally, for electrical energy storage devices, these phase change materials rely on hydrocarbon materials such as waxes and fatty acids. These systems are effective in cooling, but the systems themselves are flammable and thus not beneficial in preventing thermal runaway if ignition occurs within the storage device.

[0008] Incorporating expansion materials is another measure to prevent cascading thermal runaway. These materials expand when the specified temperature is exceeded, generating carbides designed to be lightweight and providing insulation when needed. These materials may be effective in providing insulation benefits, but the design of the storage device needs to be considered regarding the expansion of the materials.

[0009] Also, aerogel materials are being used as thermal barrier materials. Aerogel thermal barriers offer many advantages over other thermal barrier materials. Some of these benefits include favorable resistance to heat transfer and fire spread while minimizing the thickness and weight of the materials used. Aerogel thermal barriers also have favorable properties regarding compressibility, compression elasticity, and compliance. Some aerogel-based thermal barriers may be difficult to install between battery cells, especially in high-volume production situations, due to their lightweight and low stiffness. Additionally, aerogel thermal barriers tend to generate particulate matter (dust) that can be harmful to the electrical storage system, creating manufacturing challenges.

[0010] Since there are both favorable and other characteristics, and many different materials with many different characteristics are available, it will provide advantages to encapsulate the thermal barrier material while simplifying the manufacturing process and providing additional protection to both the battery cell and the thermal barrier. SUMMARY OF THE INVENTION

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

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

[0013] The support member can be a single support member made of an integrally molded material or can consist of two or more support pieces joined together to form the support member. In certain embodiments, the support member includes two support members positioned on opposite sides of the insulating layer. In another embodiment, the support member surrounds the outer perimeter of the insulating barrier. In another embodiment, the support member is substantially U-shaped.

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

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

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

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

[0018] In an aspect of the present disclosure, the insulating barrier includes one or more adhesive pads coupled to the encapsulation layer. The adhesive pads can provide a cushion between adjacent battery cells. Also, the adhesive pads can adhere to adjacent battery cells and suppress displacement of the insulating barrier with respect to the battery cells during manufacturing and use.

[0019] In another aspect of the present disclosure, the support member includes one or more alignment elements. The alignment elements couple to an alignment guide. During manufacturing and use of the battery module, the battery cells and the insulating barrier can be aligned by using the alignment guide in combination with the alignment elements.

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

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

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

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

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

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

[0026] In another aspect, a device or vehicle provided herein includes a battery module or battery pack according to any one of the above aspects. In some embodiments, the device is a laptop computer, PDA, mobile phone, tag scanner, audio device, video device, display panel, video camera, digital camera, desktop computer, military portable computer, military phone, laser rangefinder, digital communication device, classified information collection sensor, electronically integrated clothing item, night vision device, power tool, calculator, wireless, remote control device, GPS device, handheld TV and portable TV, car starter, flashlight, audio device, portable heating device, portable electric sweeper, or portable medical tool. In some embodiments, the vehicle is an electric vehicle.

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

[0028] The insulation barriers described herein may provide one or more advantages over existing thermal runaway mitigation measures. The insulation barriers described herein can minimize, or eliminate, thermal runaway propagation between cells, as well as assembly costs, without significantly affecting the energy density of a battery module or battery pack. The insulation barriers of the present disclosure can provide favorable properties regarding compression rate, compressive elasticity, and compliance that accommodate continued cell expansion during the life of the cell, while possessing favorable thermal properties under normal operating conditions and under thermal runaway conditions. The insulation barriers described herein are durable, easy to handle, have favorable resistance to heat transfer and fire spread while minimizing the thickness and weight of the materials used, and also have favorable properties regarding compression rate, compressive elasticity, and compliance.

[0029] Accordingly, reference is made to the accompanying drawings, which are described in general terms herein and which are not necessarily drawn to scale.

Brief Description of the Drawings

[0030]

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Best Mode for Carrying Out the Invention

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

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

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

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

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

[0036] The insulating layer can have several different physical properties that make it difficult to incorporate the insulating layer into a battery module or battery pack. For example, some insulating layers have a very low flexural modulus (e.g., less than 10 MPa), which makes it difficult to handle and position the material between battery cells. In addition, materials with a low flexural modulus can be difficult to operate, especially when using an automated encapsulation process. Other insulating layers can have a higher flexural modulus but can be brittle, making the insulating layer prone to breakage during the manufacture of the battery module or battery pack.

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

[0038] Embodiments of the insulating barrier are shown in FIG. 1. The insulating barrier 100 includes an insulating layer 110. The insulating layer 110 is surrounded by a support member 120. In certain embodiments, the support member 120 includes an opening 125 that is shaped to complement the perimeter of the insulating layer. The opening 125 can be sized to be approximately the same size as the insulating layer. During assembly, the insulating layer 110 can be placed in the opening 125 and held in place by the support member 120. For example, the support member 120 can have an opening that is the same dimension (length × width) as the corresponding dimension of the insulating layer, or slightly smaller than that dimension. In such embodiments, the insulating layer 110 fits inside the opening 125 of the support member 120 and is held in place by a friction fit. Alternatively, or in addition, the insulating layer can be coupled to the support member by using an adhesive (e.g., glue or tape) that attaches the insulating layer to the support member. A side view of the encapsulated insulating layer 110 disposed within the opening of the support member 120 is shown in FIG. 2.

[0039] The encapsulating layer 130 is attached to the support member 120 and covers at least one side of the insulating layer 110 with an encapsulating material. Preferably, the encapsulating layer 130 covers both sides of the insulating layer 110. In aspects of the present disclosure, the encapsulating layer 130 consists of two sheets of encapsulating materials 130a and 130b. In certain embodiments, the encapsulating layer(s) is attached to the support member and surrounds at least a portion of the insulating layer. In certain embodiments, when two sheets are used, the encapsulating sheets are attached to the support member and surround the insulating material.

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

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

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

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

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

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

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

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

[0048] In certain embodiments, the support member of the present disclosure has an onset temperature of thermal decomposition at about 300 °C or higher, about 320 °C or higher, about 340 °C or higher, about 360 °C or higher, about 380 °C or higher, about 400 °C or higher, about 420 °C or higher, about 440 °C or higher, about 460 °C or higher, about 480 °C or higher, about 500 °C or higher, about 515 °C or higher, about 550 °C or higher, about 600 °C or higher, or in a range between any two of these values. In the context of the present disclosure, for example, for a first composition having an onset temperature of thermal decomposition higher than that of a second composition, it would be contemplated that the first composition is an improvement over the second composition. It is contemplated herein that when adding one or more fire rating additives, the onset temperature of thermal decomposition of the composition or material increases compared to a composition that does not contain any fire rating additives.

[0049] In one embodiment, the support member can be formed from an expandable material. An expandable material is a material that expands when exposed to heat. In connection with a battery module, when a battery cell begins to fail, the temperature of the battery cell rapidly increases and can increase the temperature inside the module. This temperature increase can cause the expandable material used to form the support member to expand due to heat induction, creating a seal between adjacent battery cells. This expansion of the support member can potentially provide improved resistance to high-pressure gases and particulate matter released when a battery cell violently opens. Exemplary expandable materials are disclosed in U.S. Patent No. 3,513,114 to Hahn et al., U.S. Patent No. 5,487,946 to McGinniss et al., U.S. Patent No. 5,591,791 to Deogon, U.S. Patent No. 5,723,515 to Gottfried, U.S. Patent No. 6,790,893 to Nguyen et al., PCT Patent Application Publication No. WO94 / 17142 to Buckingham et al., PCT Patent Application Publication No. WO98 / 04639 to Janci, and PCT Patent Application Publication No. WO2020 / 077334 to Fleetwood et al., all of these patent documents are hereby incorporated by reference in their entirety.

[0050] In one embodiment, the support member has a thickness that is less than the thickness of the insulating layer. FIG. 5A shows a side view of the insulating layer 510 coupled to the support member 520. As can be seen, prior to assembly (without compression in the insulating layer), the support member 520 has a thickness that is less than the thickness of the insulating layer 510. As shown, the insulating layer consequently protrudes from the support member. As shown in FIG. 5B, during installation, at the start of the battery cell life cycle, the insulating layer contacts the battery cell and is slightly compressed. In some cases, it has been found that if the support member has a thickness greater than or equal to the thickness of the insulating layer, the support member contacts the battery cell and prevents the insulating layer from contacting the battery cell. The use of a support member thinner than the insulating layer can overcome this problem.

[0051] As shown in FIG. 5C, at the end of the battery cell life, the battery cell begins to expand. The configuration of the support member positioned around the periphery of the insulating layer allows the battery cell to expand and, in the present disclosure, compresses against the insulating layer that is more compressible than the support member. The ability of the battery cell to expand as it deteriorates helps prevent sudden failure of the battery cell housing.

[0052] The encapsulating layer is a single-layer or multi-layer material. The encapsulating layer can be in the form of a thin film, an envelope, or a bag. The encapsulating layer can be made from any material suitable for surrounding the insulating layer. The materials used to form the encapsulating layer can be selected from polymers, elastomers, or combinations thereof. Examples of suitable polymers such as polyethylene terephthalate (PET), polyethylene (PE), polyimide (PI), rubber, polypropylene, polyamide, and nylon have very low thermal conductivities (less than 1 W / m) that result in reducing the in-plane thermal conductivity across the system. In one embodiment, the encapsulating layer comprises a polyethylene terephthalate polymer.

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

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

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

[0056] Regardless of whether a single layer (polymer or metal) or a laminate layer is used, the encapsulation layer can encapsulate the insulation layer by attaching the encapsulation layer to at least a portion of the support member. The encapsulation layer can be attached by heat staking. As used herein, the term "heat staking" refers to the process of connecting two separate pieces of polymer material by melting them with heat. In the heat staking process, one or both of the polymer pieces are heated above the glass transition temperature of the material used to form one or both of the polymer pieces. Heating the polymer pieces above the glass transition temperature softens and melts the material of one or both of the pieces together with the other piece. In one embodiment, the encapsulation layer is attached to at least a portion of the support member using the heat staking process.

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

[0058] In another embodiment, two separate encapsulation sheets can be used to encapsulate the insulating layer. A first sheet can be placed in contact with the support member to cover one side of the insulating layer. A second sheet is then placed to cover the opposite side of the insulating layer and also contacts the opposite side of the support member. The first and second sheets are then heat staked to attach the sheets to at least a portion of the opposite side of the support member. In another embodiment, the first and second sheets are positioned on opposite sides of the insulating layer as described above. The first and second sheets extend beyond the support member and allow the sheets to contact each other. The ends of the encapsulation sheets are placed on top of each other and heat staked to surround the insulating layer with the encapsulation layer formed of the two encapsulation sheets.

[0059] FIG. 6 shows a system and method for generating a laminated encapsulation layer. In the embodiment shown in FIG. 6, the laminate is made from two polymer thin films that act as the outer surfaces of the laminate sheet. The metal foil is used as the thermal conduction / flame retardant layer. Two separate rolls of the two polymers of the thin film are sent to a laminator together with two separate metal foil sheets. The sheets are combined and sealed in a lamination step, and the metal foil is sandwiched between the two polymer sheets. The metal foil sheets are separated by a space that allows the laminate to be folded.

[0060] The laminate sheet is conveyed to a creasing device that creases the laminate sheet, enabling the laminate sheet to be folded into an envelope form. After creasing the laminate sheet, the sheet is extended and cut to an appropriate size for enclosing the insulating layer. After cutting, the laminate sheet is folded into an envelope shape, and the insulating layer and the surrounding support member are placed in the envelope-shaped encapsulation layer. Flaps formed at the edges of the laminate sheet are folded to seal the insulating layer and the support member within the laminate sheet. In a final step, the laminate sheet is heated to melt and dissolve the polymer layers together. Alternatively, during the final heating step, the laminate sheet can be melted and dissolved together with the support member. A heat staking process can be used for the final sealing step. In the heat staking process, a metal staking device is heated to a temperature above the glass transition temperature of the polymer. The metal staking device is pressed against the laminate sheet and, when cooled, melts and dissolves the contact portion of the laminate sheet. In a preferred embodiment, the polymer is polyethylene terephthalate (PET) and the metal foil is stainless steel.

[0061] The encapsulation member can reduce or eliminate the generation of dust or particulate material that has fallen from the insulating layer. Additionally, the encapsulation layer can be formed from a material that allows for marking or printing descriptions on the insulating barrier. Marking of the insulating layer is not necessarily possible.

[0062] The encapsulation layer may include at least one vent that allows air to flow in and out of the panel. The encapsulation member may include at least one filter for filtering particulate matter. In an exemplary embodiment, the encapsulation layer includes a vent that allows air to flow in and out of the panel and a particulate filter above the vent that keeps particulate matter within the encapsulation member. In another embodiment, the encapsulation layer includes an edge seal that includes at least one vent and at least one particulate filter. In a further embodiment, the encapsulation layer includes an edge seal that includes at least one vent and at least one particulate filter, the vent of the edge seal allows air to flow in and out of the inside and outside of the encapsulation member edge, and the filter captures and holds particulate matter in the air stream to prevent air pollution outside the encapsulation layer by the particulate matter.

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

[0064] In the embodiment shown in FIG. 7, one or both of the encapsulation layers include an extension portion 740 that extends beyond a portion of the support member toward the inner surface 750 (e.g., sidewall or top) of the housing containing the battery cell. During assembly, the inner surface starts at position 755a. At this position, the inner surface 755a contacts the extension portion 740a. When combining the housing that holds the battery cell or module (e.g., by placing the top on the housing), the inner surface 755a moves to position 755b. During this assembly process, the extension portion 740a bends to position 740b. In certain embodiments, the extension portion can be scored prior to use, such that when the extension portion contacts the interior of the housing, the extension portion automatically bends at the modified position, enabling the extension portion to form a seal.

[0065] As shown in FIG. 7, contact of the extension portion at position 740b with the inner surface of the housing at position 755b forms a seal between the battery cells 760. Forming a seal between the insulating barrier and the inner surface of the housing can help thermally isolate the battery cell from adjacent battery cells. This is particularly useful for preventing thermal runaway events in adjacent batteries caused by a battery cell undergoing thermal runaway.

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

[0067] FIG. 9A shows a top view of an insulating barrier disposed between two battery cells. In FIG. 9B, an adhesive pad is positioned between the insulating barrier and the battery cell to provide a cushion between the insulating barrier and the battery cell. The adhesive pad can be a single-sided adhesive pad or a double-sided adhesive pad. In an embodiment where the adhesive pad is on one side, an adhesive is used to adhere the adhesive pad to the encapsulation layer. The non-adhesive portion of the adhesive pad facing the adjacent battery cell remains stationary, providing a cushion between the insulating barrier and the battery cell. In a preferred embodiment, the double-sided adhesive pad is formed from double-sided adhesion. Similar to the single-sided adhesive pad, one side of the double-sided adhesive pad is attached to the encapsulation layer. The opposite side of the double-sided adhesive pad includes an adhesive surface used to adhere the adhesive pad to the battery cell. When the insulating barrier is adhered to the battery cell (by the adhesive pad), when combining battery modules (or battery packs), manufacturing can be assisted by maintaining alignment of the insulating barrier with the battery. Without an adhesive, the insulating barrier can slip out of alignment with the battery cell, and the manufacturer would need to periodically realign the insulating barrier with the battery cell.

[0068] As shown in FIG. 9, in a preferred embodiment, the double-sided adhesive pad is installed on the opposite side of the insulating barrier. The use of the opposing adhesive pads enables the insulating barrier to be adhered to both adjacent battery cells. This ensures that proper alignment is maintained between the battery cell and the insulating barrier throughout the manufacturing process. Also, using an adhesive can help maintain alignment of the battery cell with the insulating barrier during use of the battery cell. As described previously, during the life of the energy storage system, the battery cell expands. Considering the narrow tolerances inside the packed battery module or battery pack, the expansion of the battery cell can displace the insulating barrier from its aligned position. If there are adhesive pads that adhere the insulating barrier to the battery cell, it can help suppress or prevent displacement of the insulating barrier with respect to the battery cell during normal operation of the energy storage system.

[0069] Instead of using, or in addition to using, an adhesive to maintain a battery cell in alignment with an insulating barrier, an alignment system may be used to assist with alignment. In the embodiment shown in FIG. 10, one or more alignment guides 1040 are positioned inside a battery module (or battery pack) housing 1000. In one embodiment, the alignment guide may be a rod extending from one end of the housing to the opposite end of the housing, substantially perpendicular to the longitudinal axis of the battery cell and the insulating barrier. As shown in FIG. 2, the alignment element 145 may be formed in the support member. In this particular embodiment, the alignment element is an opening formed in the support member. The opening has a diameter equal to, or slightly larger than, the diameter of the alignment guide. During assembly, the insulating barrier is aligned with the battery cell by using the alignment element (e.g., the opening), and the insulating barrier can be moved into place along the alignment guide (e.g., the rod). Other types of alignment systems can be used that include alignment systems using protrusions / indentations as alignment guides / elements. Also, trays or channels can be used in the alignment system.

[0070] FIG. 9 further shows the advantages of using a support frame with an insulating layer. FIG. 9C shows an insulating layer positioned between two battery cells. In FIG. 9C, the support member is not attached to the insulating layer. As the battery cell expands, the insulating layer is compressed. As shown in FIG. 9C, this causes shear stress in the insulating layer, displacing the insulating layer and extending it away from the battery cell. In contrast, in FIG. 9B, the support member surrounds the sides of the insulating layer. When the battery cell begins to expand, the expansion of the insulating layer is contained by the support frame, preventing the insulating layer from extending beyond the battery cell. This can be particularly useful when the battery cells are packed in a narrow housing and the displacement of the insulating layer could affect the integrity of the housing and the electronics associated with the side walls of the housing.

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

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

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

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

[0075] The insulating layer, particularly the insulating layer containing an aerogel, tends to generate particulate matter (dust) that can be harmful to the electrical storage system, creating manufacturing challenges. As described above, the release of particulate matter can be mitigated by using an encapsulating layer. The encapsulating layer is generally sealed around the insulating layer so that particles and gases cannot enter or exit the encapsulating layer. During compression of the encapsulating layer, the encapsulating layer can fracture, releasing particles and gases into the battery module. To mitigate this issue, a particle capture member can be added to the support member. It can capture particles generated during compression of the insulator, and the particles are at least partially retained within the particle capture member. A particle capture member as used herein refers to a layer of material that can trap particles that collide with the material. Examples of materials used for the particle capture member include, but are not limited to, foams (open cell or closed cell), woven fabric materials, non-woven fabric materials (e.g., felt, batting, mat-like fabric), or mesh materials. Generally, the particle capture member is made of a material that allows gas to pass through the material while particles are retained by the particle capture member.

[0076] FIG. 15 shows an embodiment of an insulating barrier having an insulating layer 1110 at least partially surrounded by a support member 1120. The insulating barrier further includes openings at one or more corners that do not have a support member that allows air flow to exit the insulating layer during compression. The openings are filled with a particle capture member 1150, which can suppress or prevent particles (e.g., aerogel) from leaking out of the insulating barrier. In the embodiment shown in FIG. 15, the particle capture member 1150 can be larger than the support member and can partially overlap the support member. FIG. 16 shows an alternative embodiment of the support member having a particle capture member incorporated into an opening formed at a corner of the support member. In FIG. 16, the particle capture member has substantially the same size as the support member.

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

[0078] Figure 18 shows an alternative embodiment of the insulating barrier. In this embodiment, a T-shaped expansion support member 1120 is coupled to the insulating layer 1110 and the encapsulation layer 1130. This embodiment differs from the embodiment shown in Figure 17 in that the expansion support member 1120 is wound around the edge of the encapsulation layer 1130. Winding the support member around the edge of the encapsulation member helps to improve the isolation of the battery cells when the expansion support member is induced by a thermal runaway event.

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

[0080] Figure 20 shows an alternative embodiment of the insulating barrier. Similar to the insulating barrier of Figure 19, the insulating barrier of Figure 20 includes a large surface area to increase the contact of the encapsulation layer 1130 with the heat exchange element 1170. The encapsulation layer consists of two L-shaped pieces. The L-shaped pieces are disposed on opposite faces of the insulating barrier 1110. During use, there may be a small gap at the ends of the L-shaped encapsulation pieces. This gap allows some flexibility to occur in the encapsulation layer. As shown in Figure 20, when the battery cells expand during use, the bottom arms of the L-shaped encapsulation pieces move towards each other and eventually contact each other.

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

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

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

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

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

[0086] FIGS. 23 and 24 show alternative arrangements of the sealing tab 1265. In these embodiments, the sealing tab can be located on top of the housing and / or on the support member. In FIG. 23, the sealing tab is installed across the expansion material and bends towards the module housing. This arrangement of the sealing tab in this orientation provides additional heat and particle blockage during thermal runaway. As shown in the figure, during a thermal runaway event, the sealing tab expands between the battery cells and reacts to heat by forming a seal. In FIG. 24, the sealing tab is coupled to the support member and the housing. The sealing tab attached to the housing expands downward while the sealing tab on the support member expands upward. In a device having a single separation tab associated with a pair of adjacent battery cells, the separation tab can be used to block heat transfer and mass transfer in one direction. Two sealing tabs are installed adjacent to each other and can block heat transfer and mass transfer from both directions.

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

[0088] As used herein, "about" means "substantially" or "nearly" and, in relation to a recited numerical value or range, means ±5% of the numerical value. In certain embodiments, the term "about" may include conventional rounding according to the significant digits of the numerical value. Additionally, the phrase "about 'x' to 'y'" includes "about 'x' to about 'y'".

[0089] Within the context of the present disclosure, the terms "aerogel", "aerogel material", or "aerogel matrix" refer to a gel that includes a framework of interconnected structures in which a corresponding network of interconnected pores is integrated within the framework, encloses a gas such as air as a dispersed interstitial medium, and the gel is characterized by the following physical and structural properties (properties according to nitrogen porosimetry tests) resulting from the following aerogels of (a)-(c): (a) an average pore diameter ranging from about 2 nm to about 100 nm, (b) a porosity of at least 80% or more, and (c) a surface area of about 100 m 2 / g or more.

[0090] Accordingly, the aerogel materials of the present disclosure include any aerogel or other open-cell type material that satisfies the defined elements described in the foregoing paragraphs, and in other cases, include materials that can be classified as xerogels, cryogels, ambigels, microporous materials, etc.

[0091] Within the context of the present disclosure, references to "thermal runaway" generally refer to a sudden or rapid increase in cell temperature and pressure due to various operating factors, and thermal runaway can further result in the propagation of excessive temperatures throughout the associated module. Potential causes of thermal runaway in such systems can include, for example, cell defects and / or short circuits (both internal and external), overcharging, cell insulation breakdown or rupture such as in accident events, and excessive ambient temperatures (e.g., generally temperatures greater than 55 °C). In normal use, as a result of internal resistance, the cell heats up. In normal power / current loads and ambient operating conditions, the temperature within most Li-ion cells can be relatively easily controlled to remain within the range of 20 °C to 55 °C. However, under high power draw at high cell / ambient temperatures, as well as in burdensome conditions such as individual cell defects, local heat generation can increase suddenly. In particular, when the critical temperature is exceeded, the exothermic chemical reactions within the cell are activated. Further, generally, due to chemical exotherm, the temperature increases rapidly. As a result, the heat generation is much greater than the available heat dissipation. Due to thermal runaway, the cell vent and internal temperatures can exceed 200 °C.

[0092] Within the context of the present disclosure, the terms "flexible" and "flexibility" refer to the ability of a material or composition to bend or flex without macroscopic failure. The insulating layers of the present disclosure are capable of bending without macroscopic failure at at least 5 °, at least 25 °, at least 45 °, at least 65 °, or at least 85 °, and / or have a bend radius of less than 4 feet, less than 2 feet, less than 1 foot, less than 6 inches, less than 3 inches, less than 2 inches, less than 1 inch, or less than 0.5 inches without macroscopic failure. Similarly, the terms "highly flexible" or "high flexibility" refer to materials that are capable of bending up to at least 90 ° without macroscopic failure and / or have a bend radius of less than 0.5 inches. Further, the terms "classified flexibility" and "classified as flexible" refer to materials or compositions that can be classified as flexible according to ASTM C1101 (ASTM International, West Conshohocken, PA).

[0093] The insulating layer of the present disclosure can be flexible, can be of a higher degree of flexibility, and / or can be of a classified flexibility. Also, the aerogel composition of the present disclosure can also be drapable. In the context of the present disclosure, the terms "drapable" and "drapability" refer to the ability of a material having no macroscopic failure and a radius of curvature of about 4 inches or less to bend or flex by 90° or more. The insulating layer according to a particular embodiment of the present disclosure is flexible such that the composition is non-rigid, and the composition can be applied and conform to a three-dimensional surface or object, or can be preformed into various shapes and configurations to simplify installation or application.

[0094] Within the context of the present disclosure, the terms "thermal conductivity" and "TC" refer to a measure of the ability of a material or composition to transfer heat between two surfaces, either of a material or composition having a temperature difference between two surfaces. Thermal conductivity is specifically measured as the heat energy transferred per unit time and per unit surface area divided by the temperature difference. It is typically recorded in SI units as mW / m*K (milliwatts per meter per Kelvin). The thermal conductivity of a material can be determined by the following test methods known in the art. The test methods include, but are not limited to, Test Method for Steady-State Thermal Transmission Properties by Means of the Heat Flow Meter Apparatus (ASTM C518, ASTM International, West Conshohocken, PA), Test Method for Steady-State Heat Flux Measurements and Thermal Transmission Properties by Means of the Guarded-Hot-Plate Apparatus (ASTM C177, ASTM International, West Conshohocken, PA), Test Method for Steady-State Heat Transfer Properties of Pipe Insulation (ASTM C335, ASTM International, West Conshohocken, PA), Thin Heater Thermal Conductivity Test (ASTM C1114, ASTM International, West Conshohocken, PA), Standard Test Method for Thermal Transmission Properties of Thermally Conductive Electrical Insulation Materials (ASTM D5470, ASTM International, West Conshohocken,PA) includes Determination of thermal resistance by means of guarded hot plate and heat flow meter methods (EN 12667, British Standards Institution, United Kingdom), or Determination of steady-state thermal resistance and related properties - Guarded hot plate apparatus (ISO 8203, International Organization for Standardization, Switzerland). Depending on the method, which may give different results, within the context of the present disclosure, unless otherwise explicitly specified, the measured thermal conductivity is obtained in accordance with ASTM C518 (Test Method for Steady-State Thermal Transmission Properties by Means of the Heat Flow Meter Apparatus) at a temperature of approximately 37.5 °C at the ambient atmospheric pressure and when a compressive load of approximately 2 psi is applied. The measured values reported as per ASTM C518 generally correlate well with either of the measured values obtained as per EN12667 with any relevant adjustment for the compressive load.,

[0095] Also, the measured value of thermal conductivity can be obtained at a temperature of approximately 10 °C at the atmospheric pressure during compression. The measured value of thermal conductivity at 10 °C is generally 0.5 - 0.7 mW / mK lower than the corresponding measured value of thermal conductivity at 37.5 °C. In certain embodiments, the insulating layer of the present disclosure has a thermal conductivity of approximately 40 mW / mK or less, approximately 30 mW / mK or less, approximately 25 mW / mK or less, approximately 20 mW / mK or less, approximately 18 mW / mK or less, approximately 16 mW / mK or less, approximately 14 mW / mK or less, approximately 12 mW / mK or less, approximately 10 mW / mK or less, approximately 5 mW / mK or less, or in the range between any two of these values at 10 °C.

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

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

[0098] Within the context of the present disclosure, all thermal analyses and related definitions refer to measurements performed under conditions where air is at ambient pressure, starting at 25°C and rising at a rate of 20°C per minute up to a maximum of 1000°C. Therefore, when measuring and calculating the onset temperature of pyrolysis, the peak temperature of heat release, the peak temperature of heat absorption, etc., any changes in any of these parameters need to be taken into account (or the measurements need to be repeated under these conditions).

[0099] Within the context of the present disclosure, the terms "onset temperature of pyrolysis" and "TD" refer to the measured value of the minimum temperature of the ambient heat at which a rapid exothermic reaction from the decomposition of an organic material appears within the material or composition. Thermogravimetric analysis (TGA) can be used to measure the onset temperature of pyrolysis of the organic material within the material or composition. The TGA curve of the material shows the weight loss (% mass) of the material when the material is exposed to an increasing ambient temperature, and thus indicates pyrolysis. The onset temperature of pyrolysis of the material can be correlated with the intersection of the tangent lines of the following TGA curves: a straight line tangent to the baseline of the TGA curve, and a straight line tangent to the TGA curve at the maximum slope point during a rapid exothermic decomposition event related to the decomposition of the organic material. Within the context of the present disclosure, the measured value of the onset temperature of pyrolysis of the organic material is obtained using TGA analysis as provided in this paragraph, unless otherwise specified.

[0100] Also, differential scanning calorimetry (DSC) analysis can be used to measure the onset temperature of pyrolysis of the material. The DSC curve of the material shows the heat energy (mW / mg) released by the material when the material is exposed to a gradual increase in ambient temperature. The onset temperature of pyrolysis of the material can be correlated with the point on the DSC curve where ΔmW / mg (change in heat energy output) increases maximally, and thus the DSC curve indicates the amount of heat generation from the aerogel material. Within the context of the present disclosure, the measured value of the onset temperature of pyrolysis using DSC, TGA, or both is obtained using a temperature increase rate of 20 °C / min as further defined in the preceding paragraph, unless specifically stated otherwise. DSC and TGA each provide values similar to this onset temperature of pyrolysis, and by performing the tests simultaneously several times, the test results are obtained from both DSC and TGA.

[0101] Within the context of the present disclosure, the terms “flame time” and “TFLAME” refer to a measure of the duration of a flame of a material or composition under a pyrolysis state, and the “duration of the flame time” is the duration of the flame at any part of the visible portion of the test sample that lasts for 5 seconds or more. The flame time is generally recorded in units of seconds or minutes. The flame time of a material or composition can be determined by methods known in the art, including, but not limited to, Reaction to fire tests for building and transport products: Non-combustibility test (EN ISO 1182, International Organization for Standardization, Switzerland; EN adopted). Within the context of the present disclosure, the measured value of the flame time is obtained according to conditions equivalent to the EN ISO 1182 standard (Reaction to fire tests for building and transport products: Non-combustibility test) unless otherwise specified. In certain embodiments, the aerogel composition of the present disclosure has a flame time of about 30 seconds or less, about 25 seconds or less, about 20 seconds or less, about 15 seconds or less, about 10 seconds or less, about 5 seconds or less, about 2 seconds or less, or in the range between any two of these values. Within the context of this specification, for example, with respect to a first composition having a flame time shorter than that of a second composition, it would be contemplated that the first composition is improved over the second composition. In this specification, it is contemplated that when one or more fire rating additives are added as compared to a composition that does not contain any fire rating additives, the flame time of the composition is shortened.

[0102] Within the context of the present disclosure, the terms "mass loss" and "ΔM" refer to a measure of the amount of material, composition, or compound that is lost or incinerated under pyrolysis conditions. Mass loss is generally recorded in weight percent or wt%. The mass loss of a material, composition, or compound can be determined by methods known in the art, including, but not limited to, Reaction to fire tests for building and transport products: Non-combustibility test (EN ISO 1182, International Organization for Standardization, Switzerland; EN adopted). Within the context of the present disclosure, measurements of mass loss are obtained according to conditions equivalent to the EN ISO 1182 standard (Reaction to fire tests for building and transport products: Non-combustibility test), unless otherwise specified. In certain embodiments, the insulation layer or aerogel composition of the present disclosure may have a mass loss of about 50% or less, about 40% or less, about 30% or less, about 28% or less, about 26% or less, about 24% or less, about 22% or less, about 20% or less, about 18% or less, about 16% or less, or in the range between any two of these values. Within the context of this specification, for example, for a first composition having a mass loss that is less than the mass loss of a second composition, it would be contemplated that the first composition is improved over the second composition. In this specification, it is contemplated that when one or more fire rating additives are added, the mass loss of the composition decreases compared to a composition that does not contain any fire rating additives.

[0103] Within the context of the present disclosure, the term "peak heat release temperature" refers to a measured value of the temperature of the ambient heat at which heat release from decomposition is at a maximum. The peak heat release temperature of a material or composition can be measured using thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), or a combination thereof. DSC and TGA will each provide similar values of the peak heat release temperature. And, many times, the tests are run simultaneously so that the results are obtained from both DSC and TGA. In a typical DSC analysis, the heat flow is plotted against the temperature increase, and the peak heat release temperature is the temperature at which the highest peak of such a curve occurs. Within the context of the present disclosure, a measured value of the peak heat release temperature of a material or composition is obtained using TGA analysis as provided in this paragraph, unless otherwise specified.

[0104] In relation to heat-absorbing materials, the term "peak heat absorption temperature" refers to a measured value of the temperature of the ambient heat at which heat absorption from decomposition is at a maximum. The peak heat absorption temperature of a material or composition can be measured using thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), or a combination thereof. In a typical DSC analysis, the heat flow is plotted against the temperature increase, and the peak heat absorption temperature is the temperature at which the lowest peak of such a curve occurs. Within the context of the present disclosure, a measured value of the peak heat absorption temperature of a material or composition is obtained using TGA analysis as provided in this paragraph, unless otherwise specified.

[0105] Within the context of the present disclosure, the terms "low flammability" and "low flammable" refer to a material or composition that meets the following combination of characteristics: i) a furnace temperature rise of 50 °C or less, ii) a flame time of 20 seconds or less, and iii) a mass loss of 50 wt% or less. Within the context of the present disclosure, the terms "nonflammability" and "nonflammable" refer to a material or composition that meets the following combination of characteristics: i) a furnace temperature rise of 40 °C or less, ii) a flame time of 2 seconds or less, and iii) a mass loss of 30 wt% or less. As described herein, it is contemplated that the flammability of a composition (e.g., the combination of furnace temperature rise, flame time, and mass loss) will decrease depending on the inclusion of one or more fire rating additives.

[0106] Within the context of the present disclosure, the terms "low flammability" and "low flammable" refer to a low flammable material or composition having a total heat of combustion (HOC) of 3 MJ / kg or less. Within the context of the present disclosure, the terms "non-flammability" and "non-flammable" refer to a non-flammable material or composition having a heat of combustion (HOC) of 2 MJ / kg or less. As described herein, it is contemplated that the HOC of a composition may decrease depending on the inclusion of one or more fire rating additives.

[0107] Use of an insulating barrier inside a battery module or battery pack Lithium-ion batteries (LIBs) are considered to be one of the most important energy storage technologies due to their high operating voltage, low memory effect, and high energy density compared to conventional batteries. However, safety concerns are a significant barrier to the large-scale utilization of LIBs. Under extreme conditions, the exothermic reaction can result in heat release that may induce subsequent dangerous reactions. The situation worsens when heat release from an extreme cell can activate a chain reaction, leading to sudden thermal runaway.

[0108] With the continuous improvement of the energy density of LIBs, it has become increasingly urgent to enhance their safety with respect to the development of electrical devices, such as electric vehicles. The mechanisms behind safety issues vary for different battery chemical reactions. The present technology focuses on preparing an insulating barrier and the corresponding configuration for the prepared barrier to obtain favorable thermal and mechanical properties. The insulating barrier of the present technology provides effective heat dissipation measures both under normal conditions and under thermal runaway conditions, while ensuring the stability of LIBs under normal operating modes (e.g., withstanding the applied compressive stress).

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

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

[0111] The insulating barriers according to various embodiments of the present disclosure of a battery pack include a plurality of single battery cells or modules of battery cells to thermally isolate a single battery cell or a module of battery cells from each other. A battery module consists of a plurality of battery cells arranged in a single housing. A battery pack consists of a plurality of battery modules.

[0112] A battery module and a battery pack can be used to supply electrical energy to a device or a vehicle. Devices using a battery module or a battery pack include, but are not limited to, laptop computers, PDAs, mobile phones, tag scanners, audio devices, video devices, display panels, video cameras, digital cameras, desktop computers, military portable computers, military phones, laser rangefinders, digital communication devices, classified information collection sensors, electronically integrated clothing items, night vision devices, power tools, calculators, radios, remote control devices, GPS devices, handheld TVs and portable TVs, car starters, flashlights, audio devices, portable heating devices, portable electric vacuum cleaners, or portable medical tools. When used in a vehicle, the battery pack can be used for all-electric vehicles or in hybrid vehicles. Some embodiments of the invention related to the present invention are shown below. [Embodiment 1] An insulating barrier used in an electrical energy storage system, including at least one insulating layer, a support member surrounding at least a part of the insulating layer, and an encapsulating layer at least partially surrounding the insulating layer, wherein the encapsulating layer contacts at least a part of the support member, the insulating barrier. [Embodiment 2] The insulating barrier according to Embodiment 1, wherein the support member is made of a material different from the material used for the insulating layer. [Embodiment 3] The insulating barrier according to Embodiment 1 or 2, wherein the insulating barrier includes two support members positioned on opposite sides of the insulating layer. [Embodiment 4] The insulating barrier according to Embodiment 1 or 2, wherein the insulating barrier includes a U-shaped support member. [Embodiment 5] The insulating barrier according to Embodiment 1 or 2, wherein the insulating barrier includes a support member surrounding the outer periphery of the insulating barrier. [Embodiment 6] The insulating barrier according to any one of Embodiments 1 - 5, wherein the support member is made of a polymer material. [Embodiment 7] The insulating barrier according to any one of Embodiments 1 - 6, wherein the support member has a flexural modulus greater than the flexural modulus of the insulating layer. [Embodiment 8] The insulating barrier according to any one of Embodiments 1 - 7, wherein the support member has a flexural modulus greater than 100 MPa. [Embodiment 9] The insulating barrier according to any one of Embodiments 1 - 8, wherein the support member includes an expansion material. [Embodiment 10] The insulating barrier according to any one of Embodiments 1 - 9, wherein the support member includes one or more alignment elements, the alignment elements are coupled to an alignment guide, and the alignment guide aligns a plurality of insulating barriers and battery cells with each other. [Embodiment 11] The insulating barrier according to any one of Embodiments 1 - 10, wherein the support member has a thickness smaller than the thickness of the insulating layer. [Embodiment 12] The insulating barrier according to any one of Embodiments 1 - 11, wherein the insulating layer has a thermal conductivity of less than about 50 mW / m·K at 25 °C and less than about 60 mW / m·K at 600 °C through the thickness dimension of the insulating layer. [Embodiment 13] The insulating barrier according to any one of Embodiments 1 - 12, wherein the insulating layer includes an aerogel. [Embodiment 14] The encapsulation layer contains a polymer material, and is the insulation barrier according to any one of Aspects 1 to 13. [Aspect 15] The encapsulation layer contains a polymer material and a metal layer embedded in the polymer material, and is the insulation barrier according to any one of Aspects 1 to 13. [Aspect 16] The encapsulation layer is attached to the support member, and is the insulation barrier according to any one of Aspects 1 to 15. [Aspect 17] The encapsulation layer surrounds the insulation layer and the support member, and the encapsulation layer itself is sealed to form a housing that at least partially surrounds the insulation layer, and is the insulation barrier according to any one of Aspects 1 to 16. [Aspect 18] The insulation barrier further includes one or more adhesive pads coupled to the encapsulation layer, and is the insulation barrier according to any one of Aspects 1 to 17. [Aspect 19] The encapsulation layer includes an extending portion that extends beyond a part of the support member, and during use, the extending portion contacts an inner surface of a housing containing the insulation barrier, and is the insulation barrier according to any one of Aspects 1 to 18. [Aspect 20] An insulation barrier used in an electrical energy storage system, including at least one insulation layer, a support member surrounding at least a part of the insulation layer, the support member including an expansion material, the support member, and an encapsulation layer at least partially surrounding the insulation layer, the encapsulation layer contacting at least a part of the support member, and the encapsulation layer including a heat-conductive material, and is the insulation barrier. [Aspect 21] The insulation barrier includes two support members positioned on opposite sides of the insulation layer, and is the insulation barrier according to Aspect 20. [Aspect 22] The insulation barrier includes a U-shaped support member, and is the insulation barrier according to Aspect 20. [Aspect 23] The support member surrounds an outer periphery of the insulation barrier, and is the insulation barrier according to Aspect 20. [Aspect 24] The support member has a flexural modulus greater than that of the insulation layer, and is the insulation barrier according to any one of Aspects 20 to 23. [Aspect 25] The support member has a flexural modulus greater than 100 MPa, and is the insulation barrier according to any one of Aspects 20 to 24. [Aspect 26] The support member includes one or more alignment elements, the alignment elements are coupled to an alignment guide, and the alignment guide aligns a plurality of insulation barriers and battery cells with each other, and is the insulation barrier according to any one of Aspects 20 to 25. [Aspect 27] The support member has a thickness smaller than the thickness of the insulating layer, and the insulating barrier according to any one of aspects 20 to 26. [Aspect 28] The insulating layer has a thermal conductivity of less than about 50 mW / m·K at 25 °C and less than about 60 mW / m·K at 600 °C through the thickness dimension of the insulating layer, and the insulating barrier according to any one of aspects 20 to 27. [Aspect 29] The insulating layer includes an aerogel, and the insulating barrier according to any one of aspects 20 to 28. [Aspect 30] The encapsulating layer includes a polymer material and a metal layer embedded in the polymer material, and the insulating barrier according to any one of aspects 20 to 29. [Aspect 31] The encapsulating layer is attached to the support member, and the insulating barrier according to any one of aspects 20 to 30. [Aspect 32] The encapsulating layer surrounds the insulating layer and the support member, and the encapsulating layer itself is sealed to form a housing that at least partially surrounds the insulating layer, and the insulating barrier according to any one of aspects 20 to 31. [Aspect 33] The insulating barrier further includes one or more adhesive pads coupled to the encapsulating layer, and the insulating barrier according to any one of aspects 20 to 32. [Aspect 34] An insulating barrier for use in an electrical energy storage system, at least one insulating layer, a support member surrounding at least a portion of the insulating layer, an encapsulating layer at least partially surrounding the insulating layer, one or more sealing tabs coupled to the support member, and includes, the encapsulating layer contacts at least a portion of the support member, the encapsulating layer includes a thermally conductive material, the sealing tab is made of a shape memory material, and when exposed to heat, the sealing tab extends away from the support member, the insulating barrier. [Aspect 35] The sealing tab is substantially stationary with respect to the support member in a first position, the sealing tab extends away from the support member in a second position, and the sealing tab moves from the first position to the second position when exposed to heat, and the insulating barrier according to aspect 34. [Aspect 36] The sealing tab is made of a shape memory nickel-titanium alloy, and the insulating barrier according to aspect 34. [Aspect 37] The insulating barrier includes two support members positioned on opposite sides of the insulating layer, and the insulating barrier according to any one of aspects 34 to 36. [Aspect 38] The insulating barrier includes a U-shaped support member, and the insulating barrier according to any one of aspects 34 to 36. [Aspect 39] The support member is the insulation barrier according to any one of Aspects 34 to 36, which surrounds the outer periphery of the insulation barrier. [Aspect 40] The support member is the insulation barrier according to any one of Aspects 34 to 39, which has a flexural modulus greater than that of the insulation layer. [Aspect 41] The support member is the insulation barrier according to any one of Aspects 34 to 40, which includes an expansion material. [Aspect 42] The support member is the insulation barrier according to any one of Aspects 34 to 41, which has a flexural modulus greater than 100 MPa. [Aspect 43] The support member includes one or more alignment elements, the alignment elements are coupled to an alignment guide, and the alignment guide aligns a plurality of insulation barriers and battery cells with each other. The insulation barrier according to any one of Aspects 34 to 42. [Aspect 44] The support member is the insulation barrier according to any one of Aspects 34 to 43, which has a thickness smaller than the thickness of the insulation layer. [Aspect 45] The insulation layer has a thermal conductivity of less than about 50 mW / m·K at 25°C and less than about 60 mW / m·K at 600°C through the thickness dimension of the insulation layer. The insulation barrier according to any one of Aspects 34 to 44. [Aspect 46] The insulation layer includes an aerogel. The insulation barrier according to any one of Aspects 34 to 45. [Aspect 47] The encapsulation layer includes a polymer material and a metal layer embedded in the polymer material. The insulation barrier according to any one of Aspects 34 to 46. [Aspect 48] The encapsulation layer is attached to the support member. The insulation barrier according to any one of Aspects 34 to 47. [Aspect 49] The encapsulation layer surrounds the insulation layer and the support member, and the encapsulation layer itself is sealed to form a housing that at least partially surrounds the insulation layer. The insulation barrier according to any one of Aspects 34 to 48. [Aspect 50] The insulation barrier according to any one of Aspects 34 to 49, further including one or more adhesive pads coupled to the encapsulation layer. [Aspect 51] A battery module, including a plurality of battery cells and one or more insulation barriers according to any one of Aspects 1 to 50, wherein at least one insulation barrier is disposed between adjacent battery cells. The battery module. [Aspect 52] The battery cell is disposed in a housing, the one or more sealing tabs are coupled to the housing, the sealing tabs are made of a shape memory material, and when exposed to heat, the sealing tabs extend away from the housing toward the one or more insulation barriers, the battery module according to aspect 51. [Aspect 53] A power system including one or more battery modules according to aspect 51 or 52. [Aspect 54] A device or vehicle including the battery module according to aspect 51 or 52. [Aspect 55] The device is a laptop computer, PDA, mobile phone, tag scanner, audio device, video device, display panel, video camera, digital camera, desktop computer, military portable computer, military phone, laser rangefinder, digital communication device, classified information collection sensor, electronically integrated clothing, night vision device, power tool, calculator, wireless, remote control device, GPS device, handheld TV and portable TV, car starter, flashlight, acoustic device, portable heating device, portable electric vacuum cleaner, or portable medical tool, the device according to aspect 54. [Aspect 56] The vehicle is an electric vehicle, the vehicle according to aspect 54. [Aspect 57] A method of encapsulating an insulating layer used between battery cells of an electrical energy storage system, surrounding at least a portion of the insulating layer with a support member, forming an encapsulating layer over at least a portion of the insulating layer and the support member, the encapsulating layer contacting at least a portion of each of the support members, the forming, comprising the method. [Aspect 58] Forming the encapsulating layer comprises covering at least a portion of the insulating layer and the support member with the encapsulating layer, attaching at least a portion of the encapsulating layer to at least a portion of the support member, comprising the method according to aspect 57. [Aspect 59] By heating the encapsulating layer while the encapsulating layer is in contact with the support member, the encapsulating layer is attached to at least a portion of the support member, the method according to aspect 58. [Aspect 60] The encapsulating layer is held in contact with the support member by a heating element, the method according to aspect 59. [Aspect 61] Forming the encapsulating layer comprises covering at least a portion of the insulating layer and the support member with the encapsulating layer, Connecting two or more separate portions of the encapsulation layer together to form a housing that surrounds at least a portion of the insulating layer and the support member; The method according to aspect 57, including this. [Aspect 62] The method according to aspect 57, wherein while the two or more separate portions of the encapsulation layer are in contact, the two or more separate portions are attached together by heating the two or more separate portions. [Aspect 63] The method according to any one of aspects 57 to 62, wherein at least one metal layer is disposed between the two or more separate portions of the encapsulation layer. [Aspect 64] The method according to aspect 63, wherein at least one metal layer is embedded between the two or more separate portions of the encapsulation layer. [Aspect 65] The method according to aspect 63 or 64, further including the step of forming a bend in the at least one metal layer to provide an extension extending from the insulating layer. [Aspect 66] The method according to aspect 61, wherein the two or more separate portions are held together by a pair of elements on opposite sides of the two or more separate portions, and at least one of the elements is heated. [Aspect 67] The method according to any one of aspects 57 to 66, wherein at least a portion of the encapsulation layer is attached to the support member by an adhesive. [Aspect 68] The method according to any one of aspects 57 to 67, wherein the encapsulation layer completely surrounds the insulating layer and the support member.

Claims

1. An insulating barrier used in an electrical energy storage system, comprising at least one insulating layer, a support member surrounding at least a part of the insulating layer, the support member including at least one alignment element coupled to an alignment guide, the support member, and an encapsulating layer at least partially surrounding the insulating layer, wherein the encapsulating layer contacts at least a part of the support member, the insulating barrier.

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

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

4. The insulating barrier according to claim 1, wherein the insulating barrier includes a U-shaped support member.

5. The insulating barrier according to claim 1, wherein the insulating barrier includes a support member surrounding the outer periphery of the insulating barrier.

6. The insulating barrier according to claim 1, wherein the support member is made of a polymer material.

7. The insulating barrier according to claim 1, wherein the support member has a flexural modulus greater than the flexural modulus of the insulating layer.

8. The insulating barrier according to claim 1, wherein the support member has a flexural modulus greater than 100 MPa.

9. The insulating barrier according to claim 1, wherein the support member includes an expansion material.

10. The alignment guide aligns a plurality of insulating barriers and battery cells with each other, the insulating barrier according to claim 1.

11. The insulating barrier according to claim 1, wherein the support member has a thickness smaller than the thickness of the insulating layer.

12. The insulating barrier according to claim 1, wherein the insulating layer has a thermal conductivity of less than about 50 mW / m·K at 25°C and less than about 60 mW / m·K at 600°C through the thickness dimension of the insulating layer.

13. The insulating barrier according to claim 1, wherein the insulating layer includes an aerogel.

14. The insulating barrier according to claim 1, wherein the encapsulating layer includes a polymer material.

15. The insulating barrier according to claim 1, wherein the encapsulating layer includes a polymer material and a metal layer embedded in the polymer material.

16. The insulating barrier according to claim 1, wherein the encapsulating layer is attached to the support member.

17. The encapsulation layer surrounds the insulating layer and the support member, and the encapsulation layer itself is sealed to form a housing that at least partially surrounds the insulating layer. The insulating barrier according to claim 1.

18. The insulating barrier according to claim 1, further comprising one or more adhesive pads coupled to the encapsulation layer.

19. The encapsulation layer includes an extending portion that extends beyond a part of the support member, and during use, the extending portion contacts the inner surface of the housing containing the insulating barrier. The insulating barrier according to claim 1.

20. An insulating barrier for use in an electrical energy storage system, at least one insulating layer, and a support member that surrounds at least a part of the insulating layer, the support member includes an expansion material, and the support member includes at least one alignment element coupled to an alignment guide. The support member, an encapsulation layer that at least partially surrounds the insulating layer, wherein the encapsulation layer contacts at least a part of the support member, and the encapsulation layer includes a heat conductive material. The insulating barrier.

21. The insulating barrier according to claim 20, wherein the insulating barrier includes two support members positioned on opposite sides of the insulating layer.

22. The insulating barrier according to claim 20, wherein the insulating barrier includes a U-shaped support member.

23. The insulating barrier according to claim 20, wherein the support member surrounds the outer periphery of the insulating barrier.

24. The insulating barrier according to claim 20, wherein the support member has a flexural modulus greater than that of the insulating layer.

25. The insulating barrier according to claim 20, wherein the support member has a flexural modulus greater than 100 MPa.

26. The alignment guide aligns a plurality of insulating barriers and battery cells with each other. The insulating barrier according to claim 20.

27. The insulating barrier according to claim 20, wherein the support member has a thickness smaller than the thickness of the insulating layer.

28. The insulating layer has a thermal conductivity of less than about 50 mW / m·K at 25°C and less than about 60 mW / m·K at 600°C throughout the thickness dimension of the insulating layer. The insulating barrier according to claim 20.

29. The insulating barrier according to claim 20, wherein the insulating layer includes an aerogel.

30. The encapsulation layer includes a polymer material and a metal layer embedded in the polymer material. The insulating barrier according to claim 20.

31. The encapsulation layer is attached to the support member, the insulating barrier according to claim 20.

32. The encapsulation layer surrounds the insulating layer and the support member, and the encapsulation layer itself is sealed to form a housing that at least partially surrounds the insulating layer, the insulating barrier according to claim 20.

33. The insulating barrier according to claim 20, further comprising one or more adhesive pads coupled to the encapsulation layer.

34. An insulating barrier for use in an electrical energy storage system, At least one insulating layer, and A support member surrounding at least a portion of the insulating layer, the support member including at least one alignment element coupled to an alignment guide, the support member, and An encapsulation layer at least partially surrounding the insulating layer, and One or more sealing tabs coupled to the support member, comprising The encapsulation layer contacts at least a portion of the support member, the encapsulation layer includes a thermally conductive material, The sealing tab is made of a shape memory material, and when exposed to heat, the sealing tab extends away from the support member, the insulating barrier.

35. The sealing tab is substantially stationary with respect to the support member in a first position, the sealing tab extends away from the support member in a second position, and the sealing tab moves from the first position to the second position when exposed to heat, the insulating barrier according to claim 34.

36. The insulating barrier according to claim 34, wherein the sealing tab is made of a shape memory nickel-titanium alloy.

37. The insulating barrier according to claim 34, wherein the insulating barrier includes two support members positioned on opposite sides of the insulating layer.

38. The insulating barrier according to claim 34, wherein the insulating barrier includes a U-shaped support member.

39. The insulating barrier according to claim 34, wherein the support member surrounds the outer periphery of the insulating barrier.

40. The insulating barrier according to claim 34, wherein the support member has a flexural modulus greater than the flexural modulus of the insulating layer.

41. The insulating barrier according to claim 34, wherein the support member includes an expansion material.

42. The insulating barrier according to claim 34, wherein the support member has a flexural modulus greater than 100 MPa.

43. The alignment guide aligns a plurality of insulating barriers and battery cells with each other, the insulating barrier according to claim 34.

44. The support member has a thickness smaller than the thickness of the insulating layer, the insulating barrier according to claim 34.

45. The insulating layer has a thermal conductivity of less than about 50 mW / m·K at 25°C and less than about 60 mW / m·K at 600°C through the thickness dimension of the insulating layer, the insulating barrier according to claim 34.

46. The insulating layer includes an aerogel, the insulating barrier according to claim 34.

47. The encapsulating layer includes a polymer material and a metal layer embedded in the polymer material, the insulating barrier according to claim 34.

48. The encapsulating layer is attached to the support member, the insulating barrier according to claim 34.

49. The encapsulating layer surrounds the insulating layer and the support member, and the encapsulating layer itself is sealed to form a housing that at least partially surrounds the insulating layer, the insulating barrier according to claim 34.

50. The insulating barrier according to claim 34, further comprising one or more adhesive pads coupled to the encapsulating layer.

51. A battery module, a plurality of battery cells, one or more insulating barriers according to any one of claims 1 to 50, wherein at least one insulating barrier is disposed between adjacent battery cells, the battery module.

52. The battery cells are disposed in a housing, the one or more sealing tabs are coupled to the housing, the sealing tabs are made of a shape memory material, and when exposed to heat, the sealing tabs extend away from the housing toward the one or more insulating barriers, the battery module according to claim 51.

53. A power system including one or more battery modules according to claim 51.

54. A device or vehicle including the battery module according to claim 51.

55. The device according to claim 54, wherein the device is a laptop computer, a PDA, a mobile phone, a tag scanner, an audio device, a video device, a display panel, a video camera, a digital camera, a desktop computer, a military portable computer, a military phone, a laser rangefinder, a digital communication device, a confidential information collection sensor, an electronically integrated clothing item, a night vision device, a power tool, a calculator, a wireless device, a remote control device, a GPS device, a handheld TV and a portable TV, a car starter, a flashlight, an acoustic device, a portable heating device, a portable electric vacuum cleaner, or a portable medical tool.

56. The vehicle according to claim 54, wherein the vehicle is an electric vehicle.

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