Mitigation of thermal propagation in secondary batteries

Abstract

Battery modules, battery packs, and associated methods are disclosed. In one aspect, configurations are shown that include a number of battery cells arranged adjacent to one another to form a battery module. In one aspect, configurations are shown that include cylindrical battery cells. In one aspect, configurations are shown that include a thermal barrier adjacent to at least some of the number of cylindrical battery cells. Selected configurations include a thermal barrier that is woven within the number of battery cells.

Description

MITIGATION OF THERMAL PROPAGATION IN SECONDARY BATTERIESCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of priority to U.S. Provisional Patent Application Serial No. 63 / 545,055 entitled “SYSTEMS AND METHODS FOR MITIGATION OF THERMAL PROPAGATION IN CYLINDRICAL CELL BATTERY SYSTEMS / ’ filed October 20, 2023. the disclosure of which is incorporated herein in its entirety by reference.Technical Field

[0002] The present disclosure relates generally to materials. In particular, the present disclosure relates to systems and methods for thermal management in secondary battery systems.Background

[0003] A number of battery types, such as lithium-ion batteries (LIBs) are widely used in powering portable electronic devices such as cell phones, tablets, laptops, power tools and other high-current devices such as electric vehicles because of their high working voltage, low memory effects, and high energy density compared to traditional batteries. However, use of LIB raises safety concerns as this ty pe of batten- is susceptible to catastrophic failure caused by excessive heat energy triggering a self-sustaining exothermic reaction within the LIBs commonly known as “thermal runaway.”Brief Description of the Drawings

[0004] FIG. 1 A shows a batten- module in accordance with some aspects.

[0005] FIG. IB shows another battery module in accordance with some aspects.

[0006] FIG. 2 shows another battery module in accordance with some aspects.

[0007] FIG. 3 shows another battery module in accordance with some aspects.

[0008] FIG. 4 shows another battery module in accordance with some aspects.

[0009] FIG. 5 shows another battery7module in accordance with some aspects.

[0010] FIG. 6 shows another battery module in accordance with some aspects.

[0011] FIG. 7 shows a battery' pack in accordance with some aspects.

[0012] FIG. 8A shows a thermal barrier in accordance with some aspects.

[0013] FIG. 8B shows a battery module including the thermal barrier of Figure 8A in accordance with some aspects.

[0014] FIG. 9 shows another battery module in accordance with some aspects.

[0015] FIG. 10 shows a battery pack in accordance with some aspects.

[0016] FIG. 11 shows an electronic device in accordance with some aspects.

[0017] FIG. 12 shows an electric vehicle in accordance with some aspects.Detailed Description

[0018] The following description and the drawings sufficiently illustrate specific aspects to enable those skilled in the art to practice them. Other aspects may incorporate structural, logical, electrical, process, and other changes.Portions and features of some aspects may be included in, or substituted for, those of other aspects. Aspects set forth in the claims encompass all available equivalents of those claims.

[0019] The present disclosure is directed to an energy storage system (e g., a battery7system) including multiple battery7cells and one or more thermal barriers disposed therebetween. The multiple battery cells are separated into subdivisions by thermal barriers to mitigate thermal runaway propagation from one subdivision to an adjacent subdivision in extreme cases. The thermal barrier reduces heat transfer between subdivisions during regular operations of the energy7storage system. The energy storage system may further include coolingchannels between the subdivisions and / or between the multiple battery' cells to further regulate heat flow during regular operation of the energy storage system.

[0020] The thermal barriers may include one or more layers selected from a heat resistant layers, thermal conductive materials, resilient layers, protective layers, and / or other functional layers as described in detail below, to further regulate heat transfer and to mitigate thermal runaway damages.Heat resistant layers

[0021] The thermal barriers include heat resistant layers to reduce thermal communication between battery cells and battery modules. Heat resistant layers may include heat insulation materials as described below provide a barrier to heat transfer between cells as a result of their low thermal conductivity (lower than 60 milliWatts / meter-K (mW / m-K). Heat resistant layers described herein are responsible for containing and controlling heat flow from heat-generating parts in small spaces and to prevent or resist fire propagation. That is, heat resistant layers described herein may reduce heat transfer between cells and / or cell subdivisions to reduce the risk of thermal runaway from occurring. Heat resistant layers described herein may be used for products in the fields of electronic, industrial and automotive technologies.

[0022] In aspects of the present disclosure, the heat resistant layer may also include the ability to function as a flame / fire deflector layer either by itself or in combination with other materials that enhance performance of containing and controlling heat flow. In some aspects, the heat resistant layer may itself be resistant to flame and / or hot gases and further include entrained particulate materials that modify or enhance the ability to resist flame / fire, endure exposure to hot gases for a period of time without a significant reduction in structural integrity or heat resistant value, and / or the ability to prevent heat transfer.

[0023] One highly effective insulation material that may be used in a heat resistant layer is an aerogel. Aerogels describe a class of material based upon their structure, namely low density, open cell structures, large surface areas (often 900 m2 / g or higher) and subnanometer scale pore sizes. The pores may be filled with gases such as air. Aerogels can be distinguished from other porous materials by their physical and structural properties. Although an aerogelmaterial is an insulation material, other thermal insulation material layers may also be used with aspects described below.

[0024] Selected aspects of aerogel formation and properties are described. In several aspects, a precursor material is gelled to form a network of pores that are filled with solvent. The solvent is then extracted, leaving behind a porous matrix. A variety of different aerogel compositions are known, and they may be inorganic, organic and inorganic / organic hybrid. Inorganic aerogels are generally based upon metal alkoxides and include materials such as silica, zirconia, alumina, and other oxides. Organic aerogels include, but are not limited to, urethane aerogels, resorcinol formaldehyde aerogels, and polyimide aerogels.

[0025] Inorganic aerogels may be formed from metal oxide or metal alkoxide materials. The metal oxide or metal alkoxide materials may be based on oxides or alkoxides of any metal that can form oxides. Such metals include, but are not limited to silicon, aluminum, titanium, zirconium, hafnium, yttrium, vanadium, cerium, and the like. Inorganic silica aerogels are traditionally made via the hydrolysis and condensation of silica-based alkoxides (such as tetraethoxylsilane), or via gelation of silicic acid or water glass. Other relevant inorganic precursor materials for silica based aerogel synthesis include, but are not limited to metal silicates such as sodium silicate or potassium silicate, alkoxysilanes, partially hydrolyzed alkoxysilanes, tetraethoxylsilane (TEOS). partially hydrolyzed TEOS, condensed polymers of TEOS, tetramethoxylsilane (TMOS), partially hydrolyzed TMOS, condensed polymers of TMOS, tetra-n- propoxysilane, partially hydrolyzed and / or condensed polymers of tetra-n- propoxysilane, polyethylsilicates, partially hydrolyzed poly ethy silicates, monomeric alkydalkoxy silanes, bis-trialkoxy alkyl or aryl silanes, polyhedral silsesquioxanes, or combinations thereof.

[0026] In certain aspects of the present disclosure, pre-hydrolyzed TEOS, such as Silbond H-5 (SBEI5, Silbond Corp), which is hydrolyzed with a water / sihca ratio of about 1.9-2, may be used as commercially available or may be further hydrolyzed prior to incorporation into the gelling process. Partially hydrolyzed TEOS or TMOS, such as polyethysilicate (Silbond 40) or poly methylsilicate may also be used as commercially available or may be further hydrolyzed prior to incorporation into the gelling process.

[0027] Inorganic aerogels can also include gel precursors comprising at least one hydrophobic group, such as alkyl metal alkoxides, cycloalkyl metal alkoxides, and aryl metal alkoxides, which can impart or improve certain properties in the gel such as stability and hydrophobicity. Inorganic silica aerogels can specifically include hydrophobic precursors such as alkylsilanes or arylsilanes. Hydrophobic gel precursors may be used as primary precursor materials to form the framework of a gel material. However, hydrophobic gel precursors are more commonly used as co-precursors in combination with simple metal alkoxides in the formation of amalgam aerogels. Hydrophobic inorganic precursor materials for silica based aerogel synthesis include, but are not limited to trimethyl methoxysilane (TMS). dimethyl dimethoxysilane (DMS), methyl trimethoxysilane (MTMS), trimethyl ethoxysilane, dimethyl diethoxysilane (DMDS), methyl triethoxysilane (MTES), ethyl triethoxysilane (ETES), diethyl diethoxy silane, dimethyl diethoxysilane (DMDES), ethyl triethoxysilane, propyl trimethoxysilane, propyl triethoxysilane, phenyl trimethoxysilane, phenyl triethoxysilane (PhTES), hexamethyldisilazane and hexaethyldisilazane, and the like. Any derivatives of any of the above precursors may be used and specifically certain polymeric of other chemical groups may be added or cross-linked to one or more of the above precursors.

[0028] Organic aerogels are generally formed from carbon-based polymeric precursors. Such polymeric materials include, but are not limited to resorcinol formaldehydes (RF), polyimide, polyacrylate, polymethyl methacrylate, acrylate oligomers, polyoxyalkylene, polyurethane, polyphenol, polybutadiane, trialkoxysilyl-terminated polydimethylsiloxane, polystyrene, polyacrylonitrile, polyfurfural, melamine-formaldehyde, cresol formaldehyde, phenol-furfural, polyether, polyol, polyisocyanate, polyhydroxybenze, polyvinyl alcohol dialdehyde, polycyanurates, polyacrylamides, various epoxies, agar, agarose, chitosan, and combinations thereof. As one aspect, organic RF aerogels are typically made from the sol-gel polymerization of resorcinol or melamine with formaldehyde under alkaline conditions.

[0029] Organic / inorganic hybrid aerogels are mainly comprised of (organically modified silica (“ormosil’') aerogels. These ormosil materials include organic components that are covalently bonded to a silica network. Ormosils are typically formed through the hydrolysis and condensation oforganically modified silanes, R— Si(OX)3, with traditional alkoxide precursors, Y(0X)4. In these formulas, X may represent, in some aspects, CH3, C2H5. C3H7, C4H9; Y may represent, in one aspect. Si, Ti, Zr, or Al; and R may be any organic fragment such as methyl, ethyl, propyl, butyl, isopropyl, methacrylate, acrylate, vinyl, epoxide, and the like. The organic components in ormosil aerogel may also be dispersed throughout or chemically bonded to the silica network.

[0030] Aerogels can be formed from flexible gel precursors. Various flexible layers, including flexible fiber-reinforced aerogels, can be readily combined and shaped to give pre-forms that when mechanically compressed along one or more axes, give compressively strong bodies along any of those axes.

[0031] One method of aerogel formation includes batch casting. Batch casting includes catalyzing one entire volume of sol to induce gelation simultaneously throughout that volume. Gel-forming techniques include adjusting the pH and / or temperature of a dilute metal oxide sol to a point where gelation occurs. Suitable materials for forming inorganic aerogels include oxides of most of the metals that can form oxides, such as silicon, aluminum, titanium, zirconium, hafnium, yttrium, vanadium, and the like. Particularly preferred are gels formed primarily from alcohol solutions of hydrolyzed silicate esters due to their ready availability and low cost (alcogel). Organic aerogels can also be made from melamine formaldehydes, resorcinol formaldehydes, and the like.

[0032] In one aspect, aerogel materials may be monolithic, or continuous throughout a structure or layer. In other aspects, an aerogel material may include a composite aerogel material with aerogel particles that are mixed with a binder or carrier. Other additives may be included in a composite aerogel material, including, but not limited to, surfactants that aid in dispersion of aerogel particles within a binder or carrier. A composite aerogel slurry7may be applied to a supporting plate such as a mesh, felt, web. other reinforcing materials, combinations thereof and then dried to form a composite aerogel structure.

[0033] As noted above, an aerogel may be organic, inorganic, or a mixture thereof. In some aspects, the aerogel includes a silica-based aerogel. One or more layers in a thermal barrier may include a reinforcement material. The reinforcing material may be any material that provides resilience,conformability, or structural stability to the aerogel material. Aspects of reinforcing materials include, but are not limited to, open-cell macroporous framework reinforcement materials, closed-cell macroporous framework reinforcement materials, open-cell membranes, honeycomb reinforcement materials, polymeric reinforcement materials, and fiber reinforcement materials such as discrete fibers, woven materials, non-woven materials, needled non- wovens, battings, webs, mats, and felts.

[0034] The reinforcement material can be selected from organic polymer-based fibers, inorganic fibers, carbon-based fibers or a combination thereof. Inorganic fibers may be selected from glass fibers, rock fibers, metal fibers, boron fibers, ceramic fibers, basalt fibers, other inorganic fibers, or combinations thereof. The organic polymer-based fibers may be selected from polyester polypropylene fibers, acrylic fibers, polyvinyl chloride fibers, aramid fibers, spandex fibers, nylon fibers, pre-oxidized fibers, pre-oxidized polyacrylonitrile (OP AN) fibers, other organic fibers, or combinations thereof. In some aspects, the reinforcement material can include a plurality of layers of material.Thermally conductive layers

[0035] The thermal barriers may include thermal conductive layers in addition to the heat resistant layers. Thermally conductive layers may be combined w ith heat resistant layers to improve the durability of a heat resistant layer to heat by conducting and / or diffusing heat away from the heat source, thereby reducing the temperature of the heat resistant layer at any one point. In some aspects, a thermally conductive layer may conduct heat energy to a desired external location, such as external heat dissipating fins, a heat dissipating housing, a heat sink, or other external structure that dissipates heat away from a heat resistant layer. In some aspects, thermally conductive layer may facilitate conveying heat to outside ambient air. In one aspect, a thermally conductive layer or layers helps to dissipate heat away from a localized heat source (e.g., a flame escaping a battery, a reaction site within a battery in runaway) within a battery' module or pack. Aspects of high thermal conductivity materials include carbon fiber, carbon nanotubes, graphene, graphite, pyrolytic graphite sheets,silicon carbide, metals including but not limited to copper, stainless steel, aluminum, and the like, as well as combinations thereof.

[0036] In one aspect, a thermally conductive layer may be coupled to a heat sink to aid in the distribution and removal of heat. It will be appreciated that there are a variety of heat sink types and configurations, as well as different techniques for coupling the heat sink to the thermally conductive layer, and that the present disclosure is not limited to the use of any one type of heat sink / coupling technique. For aspect, at least one thermally conductive layer of the multilayer materials disclosed herein can be in thermal communication with an element of a cooling system of a battery module or pack, such as a cooling plate or cooling channel of the cooling system. For another aspect, at least one thermally conductive layer can be in thermal communication with other elements of the battery pack, battery module, or battery system that can function as a heat sink, such as the walls of the pack, module or system, or with other ones of the multilayer materials disposed between battery cells. Thermal communication between the thermally conductive layer and heat sink elements within the battery system can allow for removal of excess heat from the battery cell or cells adjacent to the multilayer material to the heat sink, thereby reducing the effect, severity, or propagation of a thermal event that may generate excess heat. In addition to removal of heat, a thermally conductive layer can spread, or dissipate heat from a region of high heat concentration to a larger region of lower heat concentration.Resilient lavers

[0037] The thermal barriers may further include resilient layers in addition to the thermal conductive layers and the heat resistant layers. In some aspects, a resilient layer compresses in response to dimensional expansion of batteries (or other adjacent components) during the regular operation of one or more battery cells. In some aspects, a resilient layer may rebound to within 50%, 25%, or even 10% of its original (pre-compressed) thickness. Returning to near its original thickness is advantageous for maintaining pressure on the faces of the batteries, which may improve the performance of the batteries. In one aspect, during a charge, the battery cells may expand, and during a discharge, the cells may shrink. In one aspect, the resilient layer may also absorb permanent volumeexpansion caused by any batery cell degradation and / or thermal runaway. Resilient material layers may include, but are not limited to, foam, fiber, fabric, sponge, spring structures, rubber, polymer, other suitable materials, and combinations thereof.Protective layers

[0038] The thermal barriers may further include protective layers in addition to the resilient layers, the thermal conductive layers, and the heat resistant layers. In one aspect, protective layers with resistance to thermal runaway ejecta or particles may be included to protect the thermal barrier layers from damage during a thermal runaway event. Protective layers may include polymers such as Polyvinylchloride (PVC), PVC elastomeric materials, PVC rigid materials, rubber, Polyvinylchloride (PVC), PVC elastomeric materials, PVC rigid materials; inorganic materials such as mica, ceramic, talc, kaolin, vermiculite, graphite, biotite, sericite, illite, phlogopite, chlorite, aluminum silicate minerals; metals such as stainless steel, titanium, aluminum; other suitable materials; and combinations thereof.Lateral weave thermal barriers

[0039] Figure 1 A shows one aspect of selected components of a batery module 100. The module 100 includes a number of cylindrical batery cells 102 arranged adjacent to one another. Although cylindrical battery cells are shown, the present disclosure can be used with other battery configurations, such as prismatic cells, pouch cells, rectangular cells, oval cells, flat cells, other suitable cell format, and combinations thereof. In the aspect shown in Figures 1 A and IB, cylindrical batery cells 102 are arranged in a particular manner that provides dense packing of batery cells 102, which provides a smaller volume in an end user device such as an electric vehicle or other electric device. A hexagonal lateral (in X-Y plane) arrangement of battery cells 102 is shown. In a hexagonal arrangement, there are no linear pathways through a middle portion of the number of cylindrical batery7cells 102. In aspects where the bateries are prismatic or pouch cells, there may be a linear pathw ay through a middle portion of the number of batery cells 102.

[0040] The battery' cells 102 of Figure 1A have a first end 103 and a second end 104 of the battery cells, as defined by long axis 101. The battery cells 102 are arranged such that long axis first ends 103 of the cylindrical battery cells are located in a top plane 106, and long axis second ends 104 of the cylindrical battery' cells are located in a bottom plane 108.

[0041] The module 100 of Figure 1 A, further shows a cooling channel 110 that is adjacent to lateral sides (sides parallel to Z-axis) of at least some of the cells 102. In aspects, cooling channels, such as cooling channel 110 are enclosed structures (conduits, pipes, hollow passages having a parallel piped cross-section) through which a heat transfer medium can be flowed so as to remove heat from batteries. In the aspect shown, the cooling channel 110 passes between lateral sides of at least some of the cells 102. In one aspect, the cooling channel 110 is continuous, and has a first inlet / outlet 112 and as second inlet / outlet 114. In other configurations, multiple cooling channels are included with multiple inlet / outlet ports. In operation, a cooling medium, such as a cooling liquid or gas, passes through the cooling channel 110 in either direction between the first inlet / outlet 112 and the second inlet / outlet 114, and heat from the cells 102 is passed to the cooling medium, which in turn passes to an external component, such as a heat sink or heat transfer device. Although a cooling channel 110 is included in the aspect of Figure 1A, other configurations are within the present disclosure that do not include a cooling channel 1 10.

[0042] Figure IB shows a top view of the module 100 from Figure 1A. A number of rows 120 A, 120B, 120C are defined by the arrangement of the cells 102. As noted above, in the aspect shown, no linear paths exist through the cells 102. As such, the cooling channel 110 is woven between rows (120 A, 120B, 120C) of the cells 102. In the aspect, of Figures 1A and IB, the cooling channel 110 is configured with a lateral weave (weave direction in X-Y plane vertical to Z-axis). The long axis first ends 103 and the long axis second ends 104 (not shown) are exposed on a top and bottom of the module 100 as the cooling channel 1 10 weaves laterally (in X-Y plane vertical to Z direction) through the module 100. A lateral weave is described in contrast to a horizontal weave (in Y -Z plane vertical to X plane or in X-Z plane vertical to Y plane), which covers at least some of either the long axis first ends 103 and the long axis second ends 104. Horizontal weave configurations are described in more detail below.

[0043] Figure 2 shows an aspect of selected components of a battery' module 200. The module 200 includes a number of cylindrical battery cells 202 arranged adjacent to one another. A cooling channel 210 that is adjacent to lateral sides (sides parallel to Z-axis) of at least some of the cells 202. In the aspect shown, the cooling channel 210 passes between lateral sides of at least some of the cells 202. In one aspect, the cooling channel 210 is continuous, and has a first inlet / outlet 212 and as second inlet / outlet 214. The cooling channel 210 of Figure 2 illustrates a lateral weave (in X-Y plane vertical to Z plane), where the cooling channel passes within the number of cylindrical battery' cells 202, but does not cover a top or bottom plane of the number of cylindrical battery cells 202. In one aspect, the cooling channel 210 can be divided into multiple segments, each of which includes an inlet and / or outlet. In such examples, the segments of cooling channels 210 can be disposed between adjacent rows of battery' cells, alternating rows of battery' cells, or any variation thereof. The segments of cooling channel 210 can extend in one direction, i.e., having an inlet on one side of the array of battery cells and an outlet on the opposite side of the arrays of battery' cells. The segments of cooling channel 210 can, in some examples, extend in two directions, i.e., having an inlet and an outlet on the same side of the array of battery cells.

[0044] The module 200 further includes at least one thermal barrier adjacent to at least some of the number of cylindrical battery cells 202. In the aspect of Figure 2, the thermal barrier includes at least one separated thermal barrier portions 230A, 230B, 230C, 230D, 230E (collectively referred to as thermal barrier 230). In Figure 2, the thermal barrier portions 230A, 230B, 230C, 230D, 230E pass between lateral sides (sides parallel to Z-axis) of at least some of the cylindrical battery cells 202. The thermal barrier 230 weaves at an angle of 0 to 90 degrees in the X-Y plane between two rows of battery' cells 200. The thermal barrier portions 230A, 230B, 230C, 230D, 230E of Figure 2 illustrate a lateral weave (in X-Y plane vertical to Z direction), where the thermal barrier portions 230A, 230B, 230C, 230D, 230E pass within the number of cylindrical battery cells 202, but are not in contact with a top or bottom plane of the number of cylindrical battery' cells 202. In some aspects, such as where battery cells 202 are prismatic or pouch cells, the thermal barrier portions 230 A,230B, 230C, 230D, 230E may be flat sheets parallel to Z-axis instead of a lateral weave.

[0045] In portion 240 of the module 200 of Figure 2, the thermal barrier portions 230A, 230B, 230C pass between every other row of batten cells 202,5 while the cooling channel 210 also passes between every other row of battery cells 202. In the configuration of Figure 2. the thermal barrier portions 230A.230B. 230C are interleaved within sections of the cooling channel 210. In other words, each row of battery cells 202 is separated from the adjacent rows by the cooling channel 210 on one side and by the thermal barrier on the opposite side 10 in portion 240 of the module 200. The cooling channel 210 contacts the battery cells 202 without thermal barriers disposed therebetween to maximize the cooling efficiency of the cooling channel 210. The thermal barrier portions230A, 230B, 230C divide the module 200 into subdivisions. Each subdivision is separated by a portion of thermal barriers 230A, 230B, or 230C to prevent heat15 transfer and thermal runaway propagation from one subdivision to the next. This configuration allows the cooling channel 210 to be continuous, while also providing thermal separation between subdivisions that contains any flames, ejecta, gasses, or other thermal runaway products in an event of failure.

[0046] In portion 250 of the module 200 in Figure 2, the thermal barrier portions 230D, 20 230E contact first portions of the cooling channels 210 that are not in contact with the battery cells 202. Second portions of the cooling channel 210 contact the batten- cells 202 without thermal barrier 230 therebetween. In other words, the first portions of a cooling channel 210 that are separated from battery cells 202 by thermal barrier portions (e.g.. 230D, 230E, and analogs) periodically25 alternate with the second portions that are in contact with battery cells 202 at a periodicity and dimension determined by the size (e.g., diameter) of the battery cells 202 and the spacing between the battery- cells 202. This configuration enables effective cooling of the battery cells 202 from contact between the cooling channel 210 and a battery cell 202 while still providing heat isolation30 during a thermal runaway event by the presence of thermal barrier portions 230D, 230E and their un-numbered analogs in portion 250 of Figure 2.

[0047] In some aspects, the thermal barrier portions 230D, 230E have a curved shaped that conforms to the contours of the weave of the cooling channel 210. In one aspect, the thermal barrier portions 230D and 230E (and their periodicallydisposed analogs) are disposed on opposite sides of the cooling channel 210 in an alternating pattern, as illustrated in portion 250 of Figure 2. Alternating the side of the cooling channel 210 on which thermal barrier portions 230D and 230E are placed is due to the location of the battery cells 202 in adjacent rows.5 Multiple thermal barrier portions on the same sides of the cooling channel 210 as thermal barrier portion 230D may alternate with multiple thermal barrier portions analogous to 230E along the weaving direction of the cooling channel 210. Although, for convenience, Figure 2 shows both variations of thermal barrier portions, i.e., 230A / B / C and 230C / D, it is understood that these aspects10 may be used separately from one another or in any combination.

[0048] In other aspects, in which the battery cells 202 have a different configuration than the one shown in Figure 2, the thermal barrier portions 230D and 230E are disposed on one side of the cooling channel 210 for other configurations of the battery cells 202 to achieve the same effect as shown in Figure 2. Namely that, 15 for any configuration of battery cells 202, thermal barrier portions (analogous to portions 230D, 230E) may be disposed in a periodic array between battery cells while still preserving contact between the battery cells and a proximate cooling channel 210. As indicated above, this preserves heat removal by athermal transfer fluid passing through the cooling channel 210 while also providing 20 protection for the cells from a proximate thermal runaway event.

[0049] The thermal barrier 230 may be encapsulated entirely or partially to reduce dust generated from the thermal barrier 230. In one aspect, a surface layer may be disposed over one major surface of the thermal barrier 230 facing the battery cells 202, while the opposite major surface of the thermal barrier 25 facing the cooling channel 210 may directly contact the cooling channel 210.Such a configuration reduces particulate contamination (e.g., dust) from a thermal barrier 230 by using the surface layer on one major surface of the thermal barrier to contain dust and by using cooling channel (instead of another surface layer) on the other major surface to contain dust. In one aspect, the minor 30 surfaces of the thermal barrier 230 are encapsulated together with the major surfaces of the thermal barrier 230 to further prevent dust from the thermal barrier 230 from contaminating the battery region. In one aspect, the thermal barrier 230 attaches to the cooling channel 210 and / or the battery cells 202 by an adhesive, such as a pressure sensitive adhesive, double sided tape, other suitableadhesive, and combinations thereof. The encapsulation layer and / or the surface layer may be a fireproof coating including one or more materials such as aerogel, flame retardants, and / or phase change materials. Alternatively, the encapsulation layer and / or the surface layer may be a film including one or more materials selected from polymer and metal. In further aspects, the encapsulation layer and / or the surface layer may be a UV curable polymer, such as polyester, acrylate, urethane acrylate, acrylate polyol, vinyl ester, methacrylate, other suitable UV curable polymers, and combinations thereof. Figure 3 shows another aspect of selected components of a battery module 300. The module 300 includes a number of cylindrical battery' cells 302 arranged adjacent to one another. A cooling channel 310 that is adjacent to lateral sides (sides parallel to Z-axis) of at least some of the cells 302. In one aspect, the cooling channel 310 is in contact with the lateral sides of the cells 302. In the aspect shown, the cooling channel 310 passes betw een lateral sides of at least some of the cells 302. In one aspect, the cooling channel 310 is continuous, and has a first inlet / outlet 312 and as second inlet / outlet 314.

[0050] The module 300 further includes at least one thermal barrier adjacent to at least some of the number of cylindrical battery' cells. In the aspect of Figure 3, the thermal barrier includes multiple separated thermal barrier portions 330A, 330B. In Figure 3, the thermal barrier portions 330A, 330B pass between lateral sides (sides parallel to Z-axis) of at least some of the cylindrical battery cells 302 in a lateral weave (in X-Y plane vertical to Z direction).

[0051] In the module 300 of Figure 3, the thermal barrier portions 330A, 330B pass between every other row of battery cells 302, while the cooling channel 310 passes between every row of battery' cells 302. In the configuration of Figure 3, the thermal barrier portions 330A, 330B are interleaved within sections of the cooling channel 310. In other words, the battery' cells 302 in certain rows may contact cooling channel 310 at the lateral sides, while the battery cells 302 in other rows may contact the cooling channel 310 at one lateral side and contact thermal barrier portions 330A, 330B in the opposite lateral side. The thermal barrier portions 330A, 330B divide module 300 into subdivisions, and prevent heat and / or other thermal runaway ejecta from traveling between the subdivisions.

[0052] In one aspect, module 300 comprises the thermal barrier portions 330A. 330B without the cooling channel 410. In one aspect, module 300 comprises the thermal barrier portions 330A, 330B in contact with the cooling channel 410. In contrast to the configuration of Figure 2, in the module 300, the thermal barrier portions 330A, 330B are located along (e.g., in contact with) at least one lateral side (sides parallel to Z-axis, and / or the major sides) of the cooling channel 310. In one aspect thermal barrier portions are located along both lateral sides (sides parallel to Z-axis, and / or the major sides) of the cooling channel 310.

[0053] This configuration allows the cooling channel 310 to be continuous, while also providing thermal separation that contains any flames, ejecta, gasses, or other byproducts in an event of failure (e.g., thermal runaway). In contrast to the configuration of Figure 2, in the module 300, the cooling channel is in direct contact with more lateral surfaces of the cells 302 to improve the cooling efficiency.

[0054] Figure 4 shows another aspect of selected components of a battery module 400. The module 400 includes a number of cylindrical battencells 402 arranged adjacent to one another. A cooling channel 410 that is adjacent to lateral sides (sides parallel to Z-axis) of at least some of the cells 402. In the aspect shown, the cooling channel 410 passes between lateral sides of at least some of the cells 402. In one aspect, the cooling channel 410 is in physical contact with the lateral sides of the battery cells 402. In one aspect, the cooling channel 410 is continuous throughout the battery module 400, and has a first inlet / outlet 412 and a second inlet / outlet 414. In one aspect, one or both of the first inlet / outlet 412 and a second inlet / outlet 414 are located at the comers of the battery module 400 for easier connection.

[0055] The module 400 further includes at least one thermal barrier 430 adjacent to at least some of the number of battery’ cells (e.g., cylindrical battery cells). In one aspect, the lateral sides of the thermal barrier 430 are in physical contact with the lateral sides of the battery cells (e.g., cylindrical battery' cells) in at least some row s. In the aspect of Figure 4, the thermal barrier is continuous (e.g., continuous throughout the module 400) and is located along at least one lateral side (sides parallel to Z-axis, and / or major surface) of the cooling channel 410.

[0056] In Figure 4, the thermal barrier 430 passes between lateral sides (sides parallel to Z-axis) of at least some of the cylindrical battery cells 402 in a lateral weave (weave curving directions vertical to Z-axis). In some aspects, such as where the battery cells are prismatic or pouch cells, the thermal barrier 430 passes between lateral sides (sides parallel to Z-axis) of the battery' cells in a straight lines and may curve around at the end of a battery cell row. The thermal barrier 430 weaves at an angle of 0 to 90 degrees the X-Y plane between two rows of battery cells 402. The thermal barrier 430 curves 180 degree at the end of the row and weave to the next row of the battery' cells 402. In the module 400 of Figure 4, the thermal barrier 430 passes between every other row of battery cells 402, and mirrors the cooling channel 410. In one aspect, the thermal barrier 430 and the cooling channel 410 are stacked together (e.g., by their lateral sides) and weave through the rows of battery cells 402 in the same route. In some aspects, the thermal barrier 430 passes between every few rows of battery cells 402. In this configuration, the thermal barrier 430 separates the battery cells 402 into subdivisions and prevents heat transfer and thermal runaway propagation from one subdivision to adjacent subdivisions. In the aspect shown in Figure 4, each subdivision includes two rows of battery' cells 402. In a first subdivision, the lateral sides of the battery cells 402 in both rows contact cooling channel 410. In a second subdivision adjacent to the first subdivision, the lateral sides of the battery cells 402 in both rows contact thermal barrier 430.

[0057] The configuration of Figure 4 provides manufacturing advantages, in that the cooling channel 410 and thermal barrier 430 can be laminated together, then later included within the battery cells 402 for easier installation. In one aspect, module 400 comprises the thermal barrier 430 without the cooling channel 410.

[0058] Figure 5 shows another aspect of selected components of a battery module 500. The module 500 includes a number of cylindrical battery' cells 502 arranged adjacent to one another. A first cooling channel 510A and a second cooling channel 510B are shown adjacent to lateral sides (sides parallel to Z-axis) of at least some of the cells 502. In the aspect shown, the cooling channels 510A. 510B pass between lateral sides of at least some of the cells 502. In one aspect, the cooling channels 510A, 510B are continuous (e.g., continuousthroughout the batten' module 500), and inlet / outlets at a first end 512 and at a second end 514. In one aspect, the first end 512 and the second end 514 are positioned at comers of the battery module 500.

[0059] The module 500 further includes at least one thermal barrier 530 adjacent to at least some of the number of cylindrical battery cells. In the aspect of Figure 5, the thermal barrier 530 is continuous (e.g., continuous throughout the battery module 500). In one aspect, the thermal barrier includes a first portion disposed between a first subset of the battery cells and a second subset of the battery cells, a second portion disposed between the second subset of the battery cells and a third subset of the battery cells, and a third portion connection the first portion and the second portion, wherein the first portion, the second portion and the third portion wraps around three lateral sides of the second subset of the battery cells.

[0060] In some aspect, the thermal barrier 530 is located along at least one lateral side of the cooling channels 510A, 510B. More specifically, in the module 500 of Figure 5, the thermal barrier 530 is laminated between the cooling channels 510A, 510B. In Figure 5, the thermal barrier 530 passes between lateral sides of at least some of the cylindrical battery' cells 502. In the module 500 of Figure 5, the thermal barrier 530 passes between every other row of battery cells 502, and mirrors the cooling channels 510A. 510B.

[0061] Similar to the aspect of Figure 4, the configuration of Figure 5 provides manufacturing advantages, in that the cooling channels 510A, 510B and thermal barrier 530 can be laminated together, then later included within the battery cells 502. In the configuration of Figure 5. the cooling channel 510A and 510B, but not the thermal barrier 530, directly contact the lateral side of the battery cells 502. In other words, the lateral sides of the battery cells 502 physically contact the lateral sides of the cooling channel 510A, 510B but do not physically contact the thermal barrier 530. Such configuration improves the cooling efficiency while containing thermal runaway within subdivisions of the battery cells 502 divided by the thermal barrier 530.Thermal barriers wrapping around battery systems

[0062] Figure 6 shows another aspect of selected components of a battery system 600. The system 600 includes a module 610 of battery cells 612arranged adjacent to one another. The module 610 may be any of the aspects described with respect to Figures 1A-5. The cells 612 are arranged such that long axis first ends (such as the first end 103 in Figure 1) of the cylindrical battery cells are located in a top plane 613, and long axis second ends (such as the second end 104 in Figure 1) of the cylindrical battery cells are located in a bottom plane 615. The system 600 of Figure 6 further includes a housing 602 that defines a cavity 604 into which the module 610 is placed. A lid 606 is shown to further enclose the module 610 within the housing 602. Cylindrical battery cells 612 are used to illustrate the configuration of the module 610. However, the configuration of Figure 6 can also be applied to other batterytypes. such as prismatic battery cells or pouch cells.

[0063] The system 600 further includes at least one thermal barrier 630 adjacent to at least some of the number of cylindrical batten cells. The thermal barrier 630 comprises any of the components and configurations described above with respect to Figures 1 A-5. such as cooling channel(s), a heat resistant layer, a conductive layer, and a resilient layer. The system 600 of Figure 6 shows the at least one thermal barrier 630 wrapped around at least the top plane 613 and the bottom plane 615 of the module 610.

[0064] In the system 600 of Figure 6, the thermal barrier 630 further wraps around one or more sides of the module 610. In one aspect, the thermal barrier 630 wraps around four sides of the module 610 while leaving two sides not wrapped. Such a configuration simplifies assembly process while still providing thermal runaway protection by the thermal barrier 630. In one aspect, the thermal barrier 630 wraps around all six sides of the module 610. In one aspect, the thermal barrier 630 is a tube with a rectangular cross section. The inclusion of the thermal barrier 630 provides an increased level of containment of any heat, flames, gasses, ejecta, or other byproducts of thermal runaway, in the event of a failure (e g., thermal runaway) in one or more cells 612 within the module 610.

[0065] Figure 7 shows another aspect of selected components of a battery system 700. The battery system 700 includes a number of modules described with respect to Figures 1A-6, including a first module 710A and a second module 710B. The modules 710A. 710B include a number of battery cells 712 arranged adjacent to one another. The system 700 of Figure 7 furtherincludes a housing 702 that defines a number of cavities 704 into which the modules 710A, 710B, and other modules are placed. A lid 706 is shown to further enclose the module 610 within the housing 602.

[0066] Similar to the configuration of Figure 6, the system 700 further includes a number of thermal barriers 730 adjacent to at least some of the number of battery cells 712. The system 700 of Figure 7 shows the number of thermal barriers 730 wrapped around at least a top plane and a bottom plane of each module. The inclusion of the number of thermal barriers 730 provides an increased level of containment of any heat, flames, gasses, ejecta, or other byproducts in the event of a failure (e.g., thermal runaway) in one or more battery cells 712 in any of the modules 710A, 710B. or other modules. Cylindrical battery cells 712 are used to illustrate the configuration of the modules 710A, 710B, however, the configuration of Figure 7 can also be applied to other battery types, such as prismatic battery cells or pouch cells.Horizontal weave thermal barriers

[0067] Figure 8A shows a thermal barrier 830 in a configuration further illustrated in Figure 8B. The thermal barrier 830 may comprise the same materials and configuration as the thermal barriers described with respect to Figures 1A-7. such as cooling channels, insulation layer, a conductive layer, protective layer, and / or a resilient layer. In one aspect, the thermal barrier 830 includes a heat insulation material, such as an aerogel material, although the disclosure is not so limited.

[0068] Figure 8B shows selected components of a battery module 800. The module 800 includes a number of cylindrical battery cells 802 arranged adjacent to one another. The battery module 800 may be any of the battery modules described with respect to Figures 1-7. The cells 802 are arranged such that long axis first ends (such as the first end 103 in Figure 1) of the cylindrical battery cells are located in a top plane 804. and long axis second ends (such as the second end 104 in Figure 1) of the cylindrical battery cells are located in a bottom plane 806.

[0069] A cooling channel 810 is shown adjacent to lateral sides (sides parallel to Z-axis) of at least some of the cells 802. although a cooling channel is not required in other aspects of the present disclosure. In the aspect shown, thecooling channel 810 passes between lateral sides of at least some of the cells 802. The module 800 of Figure 8B further shows the thermal barrier 830 from Figure 8A incorporated into the module 800.

[0070] The module 800 of Figure 8B shows a thermal barrier 830 that is continuous. In one aspect, the thermal barrier 830 is continuous throughout the battery module 800. The thermal barrier 830 of Figure 8B illustrates a horizontal (in X-Y plane) weave configuration. In the honzontal weave of Figure 8B, the thermal barrier 830 is located within the battery module 800 between at least some of the battery cells 802. In the horizontal weave of Figure 8B, the thermal barrier 830 is adjacent to at least some of the cells 802 along the top plane 804, and along the bottom plane 806. With the horizontal weave of Figure 8B. the thermal barrier 830 transitions, or weaves, between the top plane 804 and the bottom plane 806. In one aspect, the thermal barrier includes a first portion disposed between a first subset of the battery cells and a second subset of the battery cells, a second portion disposed between the second subset of the battery’ cells and a third subset of the battery cells, and a third portion connection the first portion and the second portion, wherein the first portion, the second portion and the third portion wraps around three lateral sides of the second subset of the battery cells.

[0071] One advantage of a horizontal weave as shown in Figure 8B includes the ability of the thermal barrier 830 to thermally isolate selected portions of the cells 802, while at the same time, allowing the cooling channel 810 to w eave laterally between the cells 802. In other words, the thermal barrier 830 divides the battery module 800 into multiple (e.g.. four) subdivisions 840A, 840B, 840C, 840D by weaving vertically between the top plane 804 and bottom plane 806. The thermal barrier 830 prevents heat transfer and / or thermal propagation between the subdivisions 840 A, 840B, 840C, 840D. At the same time, the cooling channel 810 weaves along and physically contacts the lateral sides of the battery cells 802. As such, the cooling channel 810 contacts the lateral sides (parallel to z-direction) of the battery cells 802 with limited blocking by thermal barrier 830 between the cooling channel 810 and the battery cells 802. Subdivisions 840A, 840B, 840C, 840D may each have a cooling channel 810 with inlet and outlet dedicated to each subdivision. Alternatively, Subdivisions 840 A, 840B, 840C, 840D may share one cooling channel 810weaving through all of the Subdivisions 840 A, 840B, 840C, 840 continuously with only one inlet and one outlet for all four subdivisions.

[0072] Cylindrical battery cells 802 are used to illustrate the configuration of the modules 840 A, 840B, 840C, 840D, however, the configuration of Figure 8 can also be applied to other battery ty pes, such as prismatic battery cells or pouch cells.Horizontal weave thermal barrier in batten' system

[0073] Figure 9 shows selected components of a battery system 900. The system 900 includes a battery module 910 including a number of battery cells 912 arranged adjacent to one another. The cells 912 are arranged such that long axis first ends (such as the first ends 103 in Figure 1) of the cylindrical battery cells are located in a top plane, and long axis second ends (such as the second ends 104 in Figure 1) of the cylindrical battery cells are located in a bottom plane. The system 900 of Figure 9 further includes a housing 902 that defines a cavity 904 into which the module 910 is placed. A lid 906 is shown to further enclose the module 910 within the housing 902.

[0074] In selected configurations, a lid cushion 908 is further included between the battery module 910 and the lid 906. The lid cushion 908 protects the battery module 910 from mechanical damage during operation or extreme conditions such as thermal runaway. The lid cushion 908 also protects the lid 906 and other components thereabove (not shown) from particle bombardments during a thermal runaway event. The lid cushion 908 may comprise the same materials as the thermal barriers described with respect to Figures 1A-8B. In one aspect, the lid cushion further includes a rigid layer to withstand particle bombardments in the case of thermal runaway. The rigid layer may comprise Polyvinylchloride (PVC), PVC elastomeric materials, PVC rigid materials, rubber, stainless steel, aluminum, titanium, titanium alloys, other metal or metal alloys, graphite, mica, and combinations thereof. In one aspect, the lid cushion 908 includes an aerogel material. In one aspect, the lid cushion 908 includes a resilient material. In one aspect, the lid cushion 908 includes a laminate that includes multiple layers mentioned above. One aspect includes a layer of a thermal barrier and a layer of a resilient material.

[0075] The module 910 of Figure 9 shows a thermal barrier 930. The thermal barrier 930 of Figure 9 illustrates a horizontal weave configuration, such as the one illustrated with respect to Figures 8A and 8B. In the horizontal weave of Figure 9, the thermal barrier 930 is located within the battery module 910 between at least some of the battery' cells 912. In the horizontal weave of Figure 9, the thermal barrier 930 is adjacent to at least some of the cells 912 along a top plane and along a bottom plane. In one aspect, the thermal barrier 930 physically contacts and covers at least a portion of the top plane and a portion of the bottom plane of the battery' module 910. The horizontal weave of Figure 9 also divides the cells 912 within the module 910 laterally into a number of (e.g., four) subdivisions as the thermal barrier 930 weaves between the top plane and the bottom plane. The thermal barrier 930 prevents heat or thermal runaway ejecta of one subdivision from traveling to other subdivision.

[0076] Figure 10 shows selected components of another battery system 1000. Compared to the system illustrated in Figure 9 with one battery module 910 in the housing 902, the system 1000 includes a number of battery modules 1010, each including a number of battery cells 1012 arranged adjacent to one another. The cells 1012 are arranged such that long axis first ends (such as the first ends 103 in Figure 1) of the cylindrical battery cells are located in a top plane, and long axis second ends (such as the second ends 104 in Figure 1) of the cylindrical battery cells are located in a bottom plane. The system 1000 of Figure 10 further includes a housing 1002 that defines a number of cavities 1004 into which the modules 1010 are placed. A lid 1006 is shown to further enclose the module 1010 within the housing 1002. In selected configurations, a lid cushion 1008 is further included between the battery modules 1010 and the lid 1006. The lid cushion 1008 covers more than one battery modules 1010. In one aspect, all the battery modules 1010 share one lid cushion 1008. In one aspect, the lid cushion 1008 includes an insulation material, such as an aerogel material. Similar to the aspect of Figure 9. in one aspect, the lid cushion 1008 includes a resilient material to provide additional cushion for operation. In one aspect, the lid cushion 1008 includes a laminate that includes multiple layers mentioned above. One aspect includes a layer of a thermal barrier and a layer of a resilient material.

[0077] The modules 1010 of Figure 10 include a thermal barrier 1030.The thermal barrier 1030 of Figure 10 illustrates a horizontal weave configuration illustrated in Figures 8A to 9. In the horizontal weave of Figure 10, the thermal barriers 1030 are located within each batten- module 1010 between at least some of the cylindrical battery- cells 1012. In the horizontal weave of Figure 10, the thermal barrier 1030 is adjacent to at least some of the cells 1012 along a top plane and along a bottom plane. In one aspect, the thermal barrier 1030 contacts and covers at least a portion of the top plane and a portion of the bottom plane. The horizontal weave of Figure 10 also divides the cells 1012 within the module 910 into a number of (e.g., four) subdivisions as the thermal barriers 1030 weaves between the top plane and the bottom plane.

[0078] Cylindrical battery cells are used to illustrate the configuration of the modules, however, the configurations of Figure 9 and Figure 10 can also be applied to other battery types, such as prismatic battery- cells or pouch cells.

[0079] Battery modules and / or battery packs as described above are used in a number of electronic devices. Figure 11 illustrates an aspect electronic device 1100 that includes a battery module 1110. The battery module 1110 is coupled to functional electronics 1120 by circuitry- 1112. In the aspect shown, the battery module 1110 and circuitry 1112 are contained in a housing 1102. A charge port 1114 is shown coupled to the battery module 1110 to facilitate recharging of the battery module 1 1 10 when needed.

[0080] In one aspect, the functional electronics 1120 include devices such as semiconductor devices with transistors and storage circuits. Aspects include, but are not limited to, telephones, computers, display screens, navigation systems, other electronics, and combinations thereof.

[0081] Figure 12 illustrates another electronic system that utilizes battery modules that include thermal management systems as described above. An electric vehicle 1200 is illustrated in Figure 12. The electric vehicle 1200 includes a chassis 1202 and wheels 1222. In the aspect shown, each wheel 1222 is coupled to a drive motor 1220. A battery module 1210 is shown coupled to the drive motors 1220 by circuitry 1206. A charge port 1204 is shown coupled to the battery module 1210 to facilitate recharging of the battery module 1210 when needed.

[0082] Aspects of electric vehicle 1200 include, but are not limited to. consumer vehicles such as cars, trucks, or other electric vehicles. Commercial vehicles such as tractors and semi-trucks are also within the scope of the invention. Although a four wheeled vehicle is shown, the invention is not so limited. In one aspect, two wheeled vehicles such as motorcycles and scooters are also within the scope of the invention.

[0083] To better illustrate the method and apparatuses disclosed herein, a non-limiting list of aspects is provided here:Aspect 1. A battery system, comprising: a number of battery' cells arranged adjacent to one another to form a battery' module, wherein the battery cells include: long axis first ends in a top plane. long axis second ends in a bottom plane, and lateral sides between the first plane and the second plane; and a thermal barrier passing betw een at least some of the number of battery cells in a weave.

[0084] Aspect 2. The battery system of aspect 1, the thermal barrier is wnapped around at least the top and bottom plane of the battery module.

[0085] Aspect 3. The battery system of aspect 1, further including a cooling channel passing between lateral sides of at least some of the battery cells.

[0086] Aspect 4. The battery system of aspect 1, wherein the thermal barrier is adjacent to the cooling channel.

[0087] Aspect 5. The battery system of aspect 1, wherein the battery cells are cylindrical cells.

[0088] Aspect 6. The battery system of aspect 1, wherein the thermal barrier includes a horizontal weave.

[0089] Aspect 7. The battery system of aspect 1, wherein the thermal barrier having a first portion disposed in the top plane over a first subset of the battery cells, a second portion disposed in the bottom plan under a second subset of the battery cells, and a third portion connection the first portion and the second portion disposed vertically parallel to the long axis between the first subset of the battery' cells.

[0090] Aspect 8. The battery system of aspect 1. wherein the thermal barrier includes a lateral weave contacting the lateral sides of the battery' cells.

[0091] Aspect 9. The battery system of aspect 1, The battery system of claim 1. wherein the thermal barrier having a first portion disposed between a first subset of the battery cells and a second subset of the battery cells, a second portion disposed between the second subset of the battery cells and a third subset of the battery cells, and a third portion connection the first portion and the second portion. wherein the first portion, the second portion and the third portion wraps around three lateral sides of the second subset of the battery cells.

[0092] Aspect 10. The battery' system of aspect 1, wherein the thermal barrier includes multiple separated thermal barrier portions.

[0093] Aspect 11 . wherein the thermal barrier is woven between every other row of battery' cells.

[0094] Aspect 12. wherein the thermal barrier is continuous within the battery system.

[0095] Aspect 13. A battery system, comprising: a number of battery cells arranged adjacent to one another with first long axis ends of the battery cells in a top plane and second long axis ends of the battery' cells in a bottom plane; a cooling channel that passes between lateral sides of at least some of the battery cells; and a thermal barrier located along at least one lateral side of the cooling channel.

[0096] Aspect 14. The battery system of aspect 13, wherein the thermal barrier is located laterally between two cooling channels.

[0097] Aspect 15. The battery system of aspect 13, wherein the thermal barrier is woven between rows of battery cells.

[0098] Aspect 16. The battery’ system of aspect 13, wherein the thermal barrier is woven between every other row of battery cells.

[0099] Aspect 17. A battery pack, comprising: a plurality of battery modules, located within a housing, each battery module including: a number of battery' cells arranged adjacent to one another to form a battery' module with first long axis ends of the battery cells in a top plane and second long axis ends of the battery cells in a bottom plane; a cooling channel that passes between lateralsides of at least some of the battery cells: and a thermal barrier adjacent to at least some of the number of battery cells.

[0100] Aspect 18. The battery pack of aspect 17, wherein each battery module is located within a separate compartment of the housing.

[0101] Aspect 19. The battery' pack of aspect 17, wherein the thermal barrier includes a horizontal weave.

[0102] Aspect 20. The battery pack of aspect 17. wherein the thermal barrier includes a lateral weave.

[0103] Aspect 21. The battery pack of aspect 17, wherein the lateral sides of at least some of the cylindrical battery cells contact both the cooling channel and the thermal barrier.

[0104] Aspect 22. The battery pack of aspect 17, wherein the lateral sides of at least some of the cylindrical battery cells contact the thermal barrier only without contacting the cooling channel.

[0105] Aspect 23. A battery’ system, comprising: a number of battery cells arranged adjacent to one another to form a battery module with a top plane and a bottom plane; and a thermal barrier adjacent to at least some of the number of battery’ cells.

[0106] Aspect 24. The battery system of aspect 23, wherein the thermal barrier is wrapped around at least the top and bottom plane of the battery module.

[0107] Aspect 25. The battery system of aspect 23, wherein the thermal barrier is located within the battery module between at least some of the battery cells.

[0108] Aspect 26. The battery system of aspect 25, wherein the thermal barrier is woven within at least some of the battery’ cells.

[0109] Aspect 27. The battery' system of aspect 26, wherein the thermal barrier includes a horizontal weave.

[0110] Aspect 28. The battery system of aspect 26, wherein the thermal barrier includes a lateral weave.

[0111] Aspect 29. The battery' system of aspect 26, wherein the thermal barrier is woven between rows of battery cells.

[0112] Aspect 28. The battery system of aspect 26, wherein the thermal barrier is woven between every' other row of battery cells.

[0113] Aspect 29. The batten' system of aspect 28, wherein the thermal barrier includes multiple separated thermal barrier portions.

[0114] Aspect 30. The battery system of aspect 29, wherein the battery system further includes a cooling channel, and wherein the multiple separated thermal barrier portions are interleaved within the cooling channel.

[0115] Aspect 31. A battery’ system, comprising: a number of battery cells arranged adjacent to one another; a cooling channel that passes between lateral sides of at least some of the battery cells; and a thermal barrier located along at least one lateral side of the battery' cells.

[0116] Aspect 32. The battery' system of aspect 31, wherein the thermal barrier is located laterally between two cooling channels.

[0117] Aspect 33. The battery system of aspect 31, wherein the thermal barrier is woven between rows of battery' cells.

[0118] Aspect 34. The battery' system of aspect 31, wherein the thermal barrier is woven between every other row of battery cells.

[0119] Aspect 35. The battery system of aspect 31, wherein the thermal barrier and the cooling channel are located between different rows of battery cells.

[0120] Aspect 36. The battery system of aspect 31, wherein the thermal barrier and the cooling channel are located between alternating rows of battery cells.

[0121] Aspect 37. A battery' pack, comprising: one or more battery' modules, located within a housing, each battery' module including: a number of battery cells arranged adjacent to one another to form a battery’ module with a top plane, a bottom plane, and side planes; and a thermal barrier adjacent to at least some of the number of battery' cells.

[0122] Aspect 38. The battery' pack of aspect 37, wherein the thermal barrier separates each battery module into a separate compartment of the housing.

[0123] Aspect 39. The battery pack of aspect 37, wherein the battery' pack further includes a cooling channel, and wherein the cooling channel is routed through one or more battery modules continuously.

[0124] Aspect 40. The battery pack of aspect 39. wherein cooling channel is configured to flow laterally.

[0125] Aspect 41. The batten' pack of aspect 37, wherein the thermal barrier includes a horizontal weave, the horizontal weave covers a top plane of a first module, and a bottom plane of a second module adjacent to the first module.

[0126] Aspect 42. The battery pack of aspect 37, wherein the thermal barrier w raps around the top plane, the bottom plane and the side planes of the battery module.

[0127] Aspect 43. The battery pack of aspect 37. wherein housing includes a body to contain the battery modules and a lid to cover the battery modules in the body, and wherein the housing further comprises a lid cushion betw een the battery module and the lid.

[0128] Aspect 44. The battery pack of aspect 43. wherein the lid cushion comprises an aerogel material.

[0129] Aspect 45. The battery pack of aspect 43, wherein the housing comprises a lid cushion for each battery module.

[0130] Aspect 46. The battery’ pack of aspect 43. wherein the housing comprises a lid cushion to cover more than one battery module.

[0131] The above description is intended to be illustrative, and not restrictive. In one aspect, the above-described aspects (or one or more aspects thereof) may be used in combination with each other. Other aspects can be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to allow' the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it w ill not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may' lie in less than all features of a particular disclosed aspect. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate aspect, and it is contemplated that such aspects can be combined with each other in various combinations or permutations. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

[0132] Although an overview of the inventive subject matter has been described with reference to specific aspect aspects, various modifications and changes may be made to these aspects without departing from the broader scope of aspects of the present disclosure. Such aspects of the inventive subject matter may be referred to herein, individually or collectively, by the term “invention” merely for convenience and without intending to voluntarily limit the scope of this application to any single disclosure or inventive concept if more than one is, in fact, disclosed.

[0133] The aspects illustrated herein are described in sufficient detail to enable those skilled in the art to practice the teachings disclosed. Other aspects may be used and derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of this disclosure. The Detailed Description, therefore, is not to be taken in a limiting sense, and the scope of various aspects is defined only by the appended claims, along with the full range of equivalents to which such claims are entitled.

[0134] As used herein, the term “or” may be construed in either an inclusive or exclusive sense. Moreover, plural instances may be provided for resources, operations, or structures described herein as a single instance. Additionally, boundaries between various resources, operations, modules, engines, and data stores are somewhat arbitrary, and particular operations are illustrated in a context of specific illustrative configurations. Other allocations of functionality are envisioned and may fall within a scope of various aspects of the present disclosure. In general, structures and functionality presented as separate resources in the aspect configurations may be implemented as a combined structure or resource. Similarly, structures and functionality presented as a single resource may be implemented as separate resources. These and other variations, modifications, additions, and improvements fall within a scope of aspects of the present disclosure as represented by the appended claims. The specification and drawings are. accordingly, to be regarded in an illustrative rather than a restrictive sense.

[0135] The foregoing description, for the purpose of explanation, has been described with reference to specific aspects. However, the illustrative discussions above are not intended to be exhaustive or to limit the possible aspect aspects to the precise forms disclosed. Many modifications and variationsare possible in view of the above teachings. The aspects were chosen and described in order to best explain the principles involved and their practical applications, to thereby enable others skilled in the art to best utilize the various aspects with various modifications as are suited to the particular use contemplated.

[0136] It will also be understood that, although the terms "first. ” ‘"second,” and so forth may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. In one aspect, a first contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, without departing from the scope of the present aspects. The first contact and the second contact are both contacts, but they are not the same contact.

[0137] The terminology used in the description of the aspects herein is for the purpose of describing particular aspects only and is not intended to be limiting. As used in the description of the aspects and the appended aspects, the singular forms ‘'a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and / or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “comprises” and / or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0138] As used herein, the term “if’ may be construed to mean “when” or “upon” or “in response to determining” or “in response to detecting,” depending on the context. Similarly, the phrase “if it is determined” or “if [a stated condition or event] is detected” may be construed to mean “upon determining” or “in response to determining” or “upon detecting [the stated condition or event]” or “in response to detecting [the stated condition or event],” depending on the context.

Claims

AMENDED CLAIMS received by the International Bureau on 19 May 2025 (19.05.2025)1. A batery system, comprising: a number of batery cells arranged in a plurality of adjacent rows to form a batery module, wherein the batery cells include: long axis first ends in a top plane, long axis second ends in a botom plane, and lateral sides between the top plane and the botom plane; and a thermal barrier woven between the lateral sides of at least some of the number of batery cells within every other row of the plurality of adjacent rows of the batery cells in the batery module.

2. The batery system of claim 1, wherein the thermal barrier is wrapped around at least the top plane and the botom plane of the batery module.

3. The batery system of claim 1, further including a cooling channel passing between lateral sides of at least some of the batery cells.

4. The batery system of claim 3, wherein the thermal barrier is adjacent to the cooling channel.

5. The batery system of claim 3, wherein the thermal barrier includes multiple separate portions contacting the cooling channel on both sides of the cooling channel.

6. The batery system of claim 1, wherein the batery cells are cylindrical cells.

7. The batery system of claim 1, wherein the thermal barrier includes a horizontal weave contacting the long axis first ends of the batery cells.

8. The batery system of claim 1, wherein the thermal barrier has a first portion disposed in the top plane over a first subset of the batery cells, a second portion disposed inthe bottom plane under a second subset of the battery cells, and a third portion connecting the first portion and the second portion disposed vertically parallel to a long axis between the first subset of the battery cells and the second subset of the battery cells.

9. (Cancelled)10. The battery system of claim 1, wherein the thermal barrier has: a first portion disposed between a first subset of the battery cells and a second subset of the battery cells, a second portion disposed between the second subset of the battery cells and a third subset of the battery cells, and a third portion connected to both the first portion and the second portion, wherein the first portion, the second portion and the third portion wrap around three lateral sides of the second subset of the battery cells.

11. The battery system of claim 1, wherein the thermal barrier includes multiple separated thermal barrier portions.

12. (Cancelled)13. The battery system of claim 1, wherein the thermal barrier is continuous within the battery system.

14. A battery system, comprising: a number of battery cells arranged in adjacent rows, wherein individual ones of the number of battery cells are arranged adjacent to one another with first long axis ends of the battery cells in a top plane and second long axis ends of the battery cells in a bottom plane; a cooling channel that passes between lateral sides of at least some of the battery cells; anda thermal barrier woven between lateral sides of at least some of the number of battery cells within every other row, the thermal barrier also adjacent to portions of the cooling channel.

15. The battery system of claim 14, wherein the thermal barrier is located laterally between two cooling channels.

16. - 23. (Cancelled)

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