System, method, and devices for battery module venting and protection

Abstract

Battery modules, battery packs, thermal barriers and associated methods are disclosed. A device may include a plurality of battery cells within a module housing, at least one of the battery cells including a cell venting area. A device may include at least one spacer between battery cells in the number of battery cells. A device may include a tab locally adjacent to the cell venting area on an edge of a cell, the tab extending past the edge of the cell in a region that is only a fraction of the edge.

Description

SYSTEM, METHOD, AND DEVICES FOR BATTERY MODULE VENTING AND PROTECTIONCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Application S.N. 63 / 564.437, filed March 12, 2024, the contents of which is incorporated by reference herein in its entirety.TECHNICAL FIELD

[0002] The present disclosure relates generally to materials, systems and methods for preventing or mitigating thermal events, such as thermal runaway issues, in energy storage systems. In particular, the present disclosure provides thermal barriers and materials and structures. The present disclosure further relates to a battery module or pack with one or more battery cells that includes the thermal barriers, as well as systems including those battery modules or packs. Examples described generally may include aerogel materials.BACKGROUND

[0003] 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, safety is a concern as LIBs are susceptible to catastrophic failure under "abuse conditions” such as when a rechargeable battery is overcharged (being charged beyond the designed voltage), over-discharged, operated at or exposed to high temperature. Although LIBs are used as an example, the technology' of the present disclosure may be used with any type of battery.

[0004] To prevent cascading thermal runaway events from occurring, there is a need for effective insulation and heat dissipation strategies to address these and other technical challenges of LIBs.BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Figure 1 A shows a battery module in accordance with some aspects.

[0006] Figure IB shows another battery module in accordance with some aspects.

[0007] Figures 2A to 2X show a spacer in accordance with some aspects.

[0008] Figure 3A shows another battery module in accordance with some aspects.

[0009] Figure 3B shows a spacer in accordance with some aspects.

[0010] Figure 3C show s an exploded view of a spacer in accordance with some aspects.

[0011] Figure 4 shows selected portions of a battery module in accordance with some aspects.

[0012] Figure 5 shows selected portions of a battery module in accordance with some aspects.

[0013] Figure 6A show's selected portions of a battery module in accordance with some aspects.

[0014] Figure 6B show s a spacer in accordance with some aspects.

[0015] Figure 7A shows selected portions of a battery module in accordance with some aspects.

[0016] Figure 7B shows a cross-section view of the battery module from Figure 7A in accordance with some aspects.

[0017] Figure 8 shows selected portions of a battery’ module in accordance with some aspects.

[0018] Figure 9A shows selected portions of a battery module in accordance with some aspects.

[0019] Figure 9B show s a cross-section view of the battery module from Figure 9A in accordance with some aspects.

[0020] Figure 10A shows a cross-section view of a battery module in accordance with some aspects.

[0021] Figure 10B shows a cross-section view of the battery module from FIG. 10A during a thermal event in accordance with some aspects.

[0022] Figure 11 shows an electronic device in accordance with some aspects.

[0023] Figure 12 shows an electric vehicle in accordance with some aspects.

[0024] Figures 13A to 13B depict a battery module in accordance with some aspects.

[0025] Figures 14A to 14C depict a battery module in accordance with some aspects.DETAILED DESCRIPTION

[0026] The following description and the drawings sufficiently illustrate specific embodiments to enable those skilled in the art to practice them. Other embodiments may incorporate structural, logical, electrical, process, and other changes. Portions and features ofsome embodiments may be included in, or substituted for, those of other embodiments. Embodiments set forth in the claims encompass all available equivalents of those claims.

[0027] A thermal barrier (also referred to as a “spacer” herein) can be used in battery modules to compartmentalize individual battery cells, or groups of battery cells in a battery device, such as a battery module or a battery7pack. Multiple battery cells that are coupled together are referred to in the present disclosure as battery modules. However, devices and methods described can be used in any of several types of multiple battery cell arrangements, which may be termed battery' packs, battery systems, etc.

[0028] The thermal barrier may comprise one or more of insulation materials (e.g., insulation layer or insulator layer), thermal conductor materials (e.g., conductive layer), resilient materials (e.g., resilient layer), etc. as described in examples below.

[0029] Insulation materials

[0030] Insulation materials as described below can be used as a single heat-resistant layer (e.g., insulation layer or insulator layer), or in combination with other layers that provide additional function to a multilayer configuration, such as mechanical strength, compressibility, heat dissipation / conduction. etc. Insulation layers described herein are responsible for reliably containing and controlling heat flow from heat-generating parts in small spaces and to provide safety7and prevention of fire propagation for such products in the fields of electronic, industrial and automotive technologies.

[0031] In some aspects of the present disclosure, the insulation layer functions as a flame / fire deflector layer either by itself or in combination with other materials that enhance performance of containing and controlling heat flow. For example, the insulation layer may itself be resistant to flame and / or hot gases and further include entrained particulate materials that modify or enhance heat containment and control.

[0032] An insulation layer may include or consist essentially of any kind of insulation layer commonly used to separate battery7cells or battery7modules. Exemplary7insulation layers include, but are not limited to, polymer based thermal barriers (e.g., polypropylene, polyester, polyimide, and aromatic polyamide (aramid)), phase change materials, intumescent materials, aerogel materials, mineral based barrier (e.g.. mica), and inorganic thermal barriers (e.g.. fiberglass containing barriers).

[0033] One aspect of a highly effective insulation layer includes 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 sub nanometer scale pore sizes. The pores may be filled with gases such as air. Aerogels can be distinguished from other porous materialsby their physical and structural properties. Although an aerogel material is an exemplary insulation material the invention is not so limited. Other thermal insulation material layers may also be used in aspects of the present disclosure.

[0034] Selected examples of aerogel formation and properties are described herein. 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.

[0035] Inorganic aerogels may be formed from metalloid oxide, metal oxide, or metal alkoxide materials. The metalloid oxide, 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 polyethysilicates, monomeric alkylalkoxy silanes, bis-trialkoxy alkyl or aryl silanes, polyhedral silsesquioxanes, or combinations thereof.

[0036] In certain embodiments of the present disclosure, pre-hydrolyzed TEOS, such as Silbond H-5 (SBH5, Silbond Corp), which is hydrolyzed with a water / silica 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 polymethylsilicate may also be used as commercially available or may be further hydrolyzed prior to incorporation into the gelling process.

[0037] 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 suchas 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 dimethoxy silane (DMS), methyl trimethoxysilane (MTMS), trimethyl ethoxysilane, dimethyl diethoxysilane (DMDS). methyl triethoxysilane (MTES), ethyl triethoxysilane (ETES). diethyl diethoxysilane, dimethyl diethoxysilane (DMDES), ethyl tri ethoxy silane, 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.

[0038] 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. tnalkoxysilyl-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 example, organic RF aerogels are typically made from the solgel polymerization of resorcinol or melamine with formaldehyde under alkaline conditions.

[0039] 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 of organically modified silanes, R-Si(OX)3, with traditional alkoxide precursors, Y(0X)4. In these formulas, X may represent, for example, CH3, C2H5, C3H7, C4H9; Y may represent, for example, 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.

[0040] Aerogels can be formed from flexible gel precursors. Various flexible layers, including flexible fiber-reinforced aerogels, can be readily combined and shaped to give preforms that when mechanically compressed along one or more axes, give compressively strong bodies along any of those axes.

[0041] 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 metalloids or 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.

[0042] In one example, aerogel materials may be monolithic, or continuous throughout a structure or layer. In other examples, 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 (also referred to as reinforcement material) such as a mesh, felt, web, etc. and then dried to form a composite aerogel structure.

[0043] Reinforcement

[0044] As noted above, an aerogel may be organic, inorganic, or a mixture thereof. In some examples, the aerogel includes a silica-based aerogel. One or more layers in a thermal barrier may include reinforcement material (also referred to as a “supporting plate7’). The reinforcing material may be any material that provides resilience, conformability, or structural stability to the aerogel material. Examples 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.

[0045] The reinforcement material can be selected from organic polymer-based fibers, inorganic fibers, carbon-based fibers or a combination thereof. The 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, acry lic 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 examples, the reinforcement material can include a plurality’ of layers of material.

[0046] Dielectric Reinforcing Layer

[0047] The thermal barrier may further include a dielectric reinforcing layer in addition to the thermal insulation materials (e.g., insulation layer) described above. The dielectric reinforcing layer provides mechanical strength to the thermal barrier in addition to other functions. Its low electrical conductivity prevents inadvertent electric short circuits in the battery module or pack. The dielectric reinforcing layer comprises dielectric materials and dielectric polymers. For example, the dielectric reinforcing layer can include materials selected from ceramics, glass, rubber, oil, paper, resins, epoxy resins, plastics, and polymers, such as polyethylene, polypropylene, polytetrafluoroethylene, polyvinylchloride (PVC). PVC elastomeric materials, PVC rigid materials, other dielectric materials, and combinations thereof.

[0048] Alternatively, the dielectric reinforcing layer may comprise mica. The advantage of using mica as dielectric reinforcing layers includes the low thermal conductivity and abundant availability of such materials at a low cost. Mica also occurs naturally in sheets or sheet-like forms that provide good structural properties at a low cost. In contrast to powdered dielectric materials, sheets of mica are mechanically strong, and provide the desired reinforcement and encapsulation for the insulator layer. In one aspect, the dielectric reinforcing layer includes a mica plate, mica paper, or a mica sheet. In one aspect, the dielectric reinforcing layer includes mica particles bound together with binders (e.g., a polymer binder) to form a structural sheet. In one aspect, the dielectric reinforcing layer is flexible and bents during an extreme event, such as thermal runaway. In one aspect, the binders may include a silicone- based polymer, although the disclosure is not so limited. Silicone polymers have the advantage of high heat resistance, and low thermal conductivity.

[0049] Thermal Conduction

[0050] The thermal barrier may further include a thermal conduction layer (also referred to as conductive layer) in addition to the thermal insulation materials and the dielectric reinforcing layer described above. Thermally conductive layers in combination with thermal insulating layers are effective at channeling unwanted heat to a desired external location, such as external heat dissipating fins, a heat dissipating housing, or other external structure to dissipate unwanted heat to outside ambient air. In one example, a thermally conductive layer(s) helps to dissipate heat away from a localized heat load within a battery module or pack. Examples of high thermal conductivity materials include carbon fiber, carbon nanotubes,graphene, graphite, pyrolytic graphite sheets, silicon carbide, metals and metal alloys including but not limited to copper, stainless steel, aluminum, and the like, as well as combinations thereof.

[0051] To aid in the distribution and removal of heat, in at least one embodiment the thermally conductive layer is coupled to a heat sink. 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 example, 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 example, 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 battery 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.

[0052] The thermally conductive layer can replace the dielectric reinforcing layer in the applications where heat conduction is needed in addition to the mechanical function of supporting other layers in the thermal barrier.

[0053] Resilient Materials

[0054] The thermal barrier may further include resilient materials in addition to thermal insulating layers, thermal conductive layers, and dielectric reinforcing layer as discussed above. One or more resilient material layers may also be included adjacent to battery cells or between battery cells. In one example, a resilient layer absorbs any volume expansion during the regular operation of one or more battery cells. For example, during a charge, the battery cells may expand, and during a discharge, the battery cells may shrink. In one example, the resilient layer may also absorb permanent volume expansion caused by any battery 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.

[0055] Thermal Barriers with Tabs

[0056] The thermal barrier may further include tabs in addition to thermal insulating layers, thermal conductive layers, resilient materials, and dielectric reinforcing layer. The tabs are positioned around the venting areas of the battery cells in a battery module or pack to reinforce the venting area to prevent mechanical and chemical damage during a thermal runaway event. The tabs may further form a safe pathway for the thermal runaway ejecta to exit the battery housing safely without propagating to adjacent battery cells.

[0057] Figure 1A shows one example of a battery module 100. The module 100 includes a stack of battery' cells 102. In one example, the stack of battery' cells 102 includes lithium-ion battery cells 102, although other battery' cell types are within the scope of the present disclosure. Several configurations of battery cells 102 are possible. In one example, the stack of battery' cells 102 includes prismatic battery' cells or pouch battery cells, although the disclosure is not so limited. In one example, the stack of lithium-ion battery cells 102 includes lithium nickel manganese cobalt (NMC) oxide battery' cells, although the disclosure is not so limited. The number of battery cells 102 are grouped into a number of battery cell subdivisions 112, 114. The battery subdivisions 112. 1 14 may each include one or more battery cells. For example, the battery' subdivisions 112, 114 in Figure 1A include 3 battery cells and 2 battery' cells respectively. As noted above, it is desirable to stop or mitigate thermal runaway conditions that can occur in battery cells such as lithium-ion battery cells 102. A thermal barrier 110 is shown located between adjacent battery cell subdivisions 112, 114 to stop or mitigate thermal runaway between battery cell subdivisions 112, 1 14.

[0058] The battery' cells 102 in Figure 1A each include electrical terminals 104. Although battery cells 102 with terminals 104 on a top surface of the battery' cells 102 are shown in the example of Figure 1A. other configurations are also within the scope of the invention, including, but not limited to other aspects illustrated in Figures below.

[0059] One convenient term to use when discussing thermal barriers between cells is a “lateral footprint.” In the present disclosure, the lateral footprint of a component refers to the area of a major surface of the component as defined by the perimeter of the component. As shown in Figure 1A, major surfaces of the battery cells 102 and the thermal barrier 110 are those surfaces in the Y-Z plane (referring to the reference axis in the Figure 1A). For clarity and convenience of explanation, the term battery' cell (equivalently “battery'” or “cell”) lateral footprint (“footprint”) refers to a major surface of the battery' cell in the Y-Z plane. Analogously, the thermal barrier (also referred to as spacer) lateral footprint (“footprint”) refers to a major surface of the thermal barrier in Y-Z plane. In some aspects described below, athermal barrier may be fabricated from multiple laminated layers, each of which may have its corresponding lateral footprint (i.e. , an insulator lateral footprint, a dielectric reinforcing layer lateral footprint). The lateral footprint of a thermal barrier (or spacer) with multiple laminated layers is the overlapping footprints of all layers of the thermal barrier, such as the overlapped footprints of all layers in Y-Z plane in Figure 1A. In other words, the lateral footprint of the thermal barrier is the lateral footprint of a first layer plus the portions of the lateral footprints of other layers extending away (not overlapping with) any other layers. In some aspects, a thermal barrier may be adjacent to a tab, where the tab may have its own footprint defined as the major surface (e.g., largest surface in Y-Z plane in Figure 2) of the tab. The lateral footprint of a thermal barrier with a tab is defined as the overlapping footprints of the thermal barrier and the tab in Y-Z plane. In other words, the lateral footprint of a thermal barrier with a tab is the lateral footprint of the thermal barrier plus the portions of the lateral footprint of the tab extending away from (does not overlap with) the thermal barrier. For clarity, “minor surfaces” are those surfaces that are orthogonal to the major surfaces and, using the reference coordinate axes in the figures, disposed in the X-Y plane or X-Z plane.

[0060] Figure IB shows a cross section of battery module 150 that includes a heat sink 154, or cooling plate, located on a side (e.g., bottom side) of the module 150, and in thermal communication with the battery' cells 152. . One or more of the battery' cells 152 are shown separated by one or more thermal barriers 160. Although in Figure IB, only selected groups, or subdivisions, of battery cells 152 are separated by thermal barrier 160, the present disclosure is not so limited. In other aspects, every battery' cell 152 is bounded by thermal barriers 160. Side in X-Z plane, bottom or top surfaces in X-Y plane of the battery' module 150 may also include thermal barriers 160. Aspects of thermal barriers 110. 160 are shown in more detail in discussion of Figures below.

[0061] In Figures 1A and IB, the thermal barriers 110, 160 are shown with a lateral footprint that matches a lateral footprint of the battery' cells 102. Put another way, a lateral surface area of the thermal barriers 110, 160 is similar or identical to the lateral surface area of the battery cells themselves. The thermal barriers 110. 160 do not extend beyond lateral dimensions of the battery cells 102 in Y-Z plane. The term “footprint” is used to illustrate how different battery cells not illustrated in the example of Figures 1 A and IB may' include different lateral geometries apart from rectangular or square. For example, pouch battery' cells may be generally rectangular, but may have a less defined outline. A less defined outline of a pouch battery cell will still define a lateral footprint, such as defined by a length times a width as witha rectangular battery cell. Alternatively, the lateral footprint of a pouch battery cell may be defined as the length times a width of the electrodes inside the pouch batery cell.

[0062] Figure 2A shows one aspect of a batery module 200 according to the present disclosure. The batery module 200 of Figure 2A includes a number of battery cells 202 within a module housing 201, at least one battery cell of the batery' cells 202 including a cell vent 204. In the example of Figure 2A, the module housing 201 further includes a lid 203 that encloses the batery cells 202. At least one spacer 210 is shown between batery' cells 202 in the number of batery cells. The battery module 200 further includes a tab 220 that is locally adjacent to the cell vent 204 on an edge of a batery cell 202.

[0063] In some aspects, a cell vent is a specific structure, such as a flap or valve. In some aspects, a cell venting area is a less specific structure. For example, a cell venting area may include a region of a cell that is intentionally weakened such that in a runaway event, the battery- cell will rupture at the knoyvn yveakened region. In one example, a cell venting area is not necessarily intentionally weakened, but is merely a knoyvn or unknown rupture location of a batery cell. A cell venting area as described will be present in several batery’ cell configurations, such as prismatic cells, pouch cells, cylindrical cell, or other cell configurations. In various aspects described, a specific cell vent, such as cell vent 204 is shown for ease of illustration, however, a broader cell venting area as described can be included in place of the cell vent shown in any of the Figures in the present disclosure.

[0064] The tab 220 extends past the edge of the cell in a region that is only a portion of the edge. Put another way, the tab 220 extends past an edge of a cell footprint as defined above. The length of the tab 220 along Y direction is less than the length of the spacer 210. In the aspect of Figure 2A, the tab 220 is located in a middle portion of a top edge (along Y direction) of the batery cells 202, although other configurations are possible. In some configurations, the tab 220 is located on a side edge (along Z direction) of the batery cells 202, or a botom edge (along Y direction opposite to top edge) of the battery cells 202. By only locating the tab 220 in a portion of an edge of the battery cell 202 adjacent to the vent 204, a most critical region of the batery cell 202 adjacent to the vent 204 is protected in the event of a thermal runaway of a given batery cell 202. Other locations along the edge of the batery cell 202, further away from the vent 204, require less protection.

[0065] In some aspects, the top edge and the side edge of the battery cell 202 are aligned with or parallel to the top edge or the side edge of the spacer 210 respectively. The tab 220 is correspondingly located on the top edge (along Y direction), side edge (along Z direction), or botom edge (along Y direction opposite to top edge) of the spacer 210, depending on yvhichcorresponding battery edge the vent 204 is located. For example, if the vent 204 is located on the top edge, the tab 220 is located on the corresponding top edge of the spacer 210 adjacent to the vent 204. In some aspects, the vent 204 is in a middle portion of the battery edges (top, side, or bottom edges) while the tab 220 is in the middle portion of the corresponding edges (top, side, or bottom edges) of the spacer 210. As such the tab 220 helps redirect the thermal runaway ejecta and protect the area of the battery cells 202 close to the vent 204 in a thermal runaway event.

[0066] In the event of a thermal runaway, the thermal runaway ejecta tends to escape through the venting area, such as the vent 204. By only locating the tab 220 in a fraction of an edge of the battery cell 202, the tab 220 protects a very local region adjacent to the vent 204 from the hottest gasses, and the highest concentration of particulate ejecta. This configuration also allows a more diffuse region where the tab 220 is not present to permit the ejecta into a region above the battery cells 202. In the example of Figure 2A, a region 205 between the lid 203 and the battery cells 202 allows less constricted expansion of the ejecta. Region 205 serves as a buffer area to cool down the thermal runaway ejecta, therefore preventing thermal propagation in battery module 200.

[0067] Compared to using a tab that extends the entire length of the edge (e g., alongY direction in Figure. 2A), locating the tab 220 in a fraction of an edge of the battery cell 202 is also cost effective and weight efficient. The improved weight efficiency of the battery module 200 results in a desirable energy density.

[0068] In one example, only a portion (or alternatively referred to as a fraction) of the edge includes a region between battery cell electrodes 206. In one example, only a fraction of the edge includes a middle third of an edge. In one example, only a fraction of the edge includes only a region directly adjacent to the vent 204. In one example, only a fraction of the edge includes a fraction less than 100 percent of the edge. In other words, a length of the tab 220 inY direction is less than 100 percent of a length of the spacer 210. Similarly, in one example, only a fraction of the edge includes a fraction less than 80 percent of the edge. In one example, only a fraction of the edge includes a fraction less than 60 percent of the edge. In one example, only a fraction of the edge includes a fraction less than 50 percent of the edge. In one example, only a fraction of the edge includes a fraction less than 40 percent of the edge. In one example, only a fraction of the edge includes a fraction less than 24 percent of the edge.

[0069] Figures 2B and 2C show an assembled and an exploded views of a more detailed arrangement of one of the spacers 210 from Figure 2A, respectively. In the example of Figure 2B, the spacer 210 includes multiple laminations, although configurations with a single layerare also possible. In Figure 2B, the spacer 210 includes a first side layer 212 and a second side layer 214. An insulator layer 216 is located between the first side layer 212 and the second side layer 214.

[0070] In one example, the insulator layer 216 includes an aerogel. Examples of an aerogel in insulator layer 216 include, but are not limited to, a monolithic aerogel, or a reinforced aerogel composite with monolithic aerogel surrounding a fiber or other reinforcing material in an aerogel matrix as described above. Another example includes aerogel particles encased in a binder or other matrix surrounding the aerogel particles. In one example, the side layers 212, 214 function as dielectric reinforcing layers or conductive layers. The dielectric reinforcing layers and the conductive layers are discussed in detail above. Aerogel materials can be fragile and / or dusty. An inclusion of one or more dielectric reinforcing layers or conductive layers can aid in reducing dust and preventing fracture of an aerogel insulator layer 216.

[0071] In some aspects, the spacer 210 may be a composite of multiple layers. For example, the spacer 210 can include insulation layers 216 and layers of other materials such as structural layers, conductive layers, compressible layers, resilient layers, dielectric layers, adhesive layers, intumescent layers, heat absorbing layers, heat releasing layers, other suitable layers, or combinations thereof. In one example, the insulator layer 216 can include a structural core layer and insulation layers disposed on both surfaces of the structural core layer. In one aspect, the insulator layer can include a structural core layer and insulation layers disposed on one major surface of the structural core layer. The structural core layer mechanically supports other layers in the spacer. The structural core layer comprises materials having stronger mechanical properties than the insulator layer 216, such as a mica layer, a metal or metal alloy layer, a polymer layer, a graphite layer, other suitable layers, and combinations thereof.

[0072] In one example one or more side layers 212, 214 may be selected from polyvinylchloride (PVC), PVC elastomeric materials, PVC rigid materials, rubber, other dielectric materials, and combinations thereof. In one aspect, the side layers 212 may be selected from the conductive layer or dielectric reinforcement layer as described above.

[0073] In one aspect, one or more side layers 212. 214 include mica. The advantage of using mica as the side layers includes the low thermal conductivity and abundant availability of such materials at a low cost. Mica also occurs naturally in sheets or sheet-like forms that provide good structural properties at a low cost. In contrast to powdered dielectric materials, sheets of mica are mechanically strong, and provide the desired reinforcement and encapsulation for the insulator layer 216. In one aspect, the one or more side layers 212, 214include mica particles bound together with binders (e.g., a polymer binder) to form a structural sheet. In one aspect, one or more side layers 212, 214 are flexible. The flexible side layers 212, 214 may bent to form a channel for thermal runaway ejecta during a thermal runaway event. In one aspect, the binders may include a silicone-based polymer, although the disclosure is not so limited. Silicone polymers have an advantage of high heat resistance, and low thermal conductivity.

[0074] In the example of Figures 2A to 2C, a first tab 220 and a second tab 222 are shown. In alternate examples, only one tab 222 is included in a given spacer 210. Spacer 210 with only one tab 222 is used adjacent to battery' cell 212 at the end of the battery' stack next to battery housing 201 (see the rightmost tab 222 in Figure 2A). The only one tab 222 is positioned to the surface (in Y-Z plane) of the battery cell 210 away from the walls of the battery module housing 201. No tab is needed on the other side (in Y-Z plane) of the battery cell 202 adjacent to the wall of the battery module housing 201.

[0075] In the aspects of Figures 2A to 2C, the tabs 220, 222 are integral w ith the one or more side layers 212, 214. In other words, the tabs 220, 222 are portions of the side layers 212, 214 and share the same compositions thereof. In aspects where the tabs 220, 222 are integral with the one or more side layers 212, 214 the material of the tabs 220, 222 is the same as the one or more side layers 212, 214. Example materials are listed in the discussion above. In other examples discussed in more detail below, the tabs 220, 222 are of a different material than the one or more side layers 212. 214, and may be merely located adjacent to the one or more side layers 212, 214, or attached to the spacer 210 using an adhesive, stitching, or other fastening methods.

[0076] Figure 2D shows one aspect of a battery module 200. The battery' module 200 comprises a number of battery cells 202, at least one battery’ cell of the battery cells 202 including a cell vent 204. At least one spacer 225 is shown between battery' cells 202 in the number of battery cells 202. The spacer 225 comprises an insulator layer 216, a side layer 212 laminated with the insulator layer 216, and a tab 220 adjacent to the side layer 212. The tab 220 is adjacent to the cell vent 204 on an edge of a battery’ cell 202.

[0077] Figure 2E shows an exploded view of a portion of battery module 200 of Figure 2D, including a spacer 225 and a battery cell 202. The spacer 225 comprises only one side layer 212 and only one insulator layer 216 adjacent to the only one side layer 212. The insulator layer 216 has a footprint overlaps w ith the footprint of the adjacent battery cell 202 in Y-Z plane. The side layer 212 has a footprint greater than the footprint of the insulator layer 216. The side layer 212 has three edges AB, BC, and CD extending away from the corresponding edges A’B’,B’C’, and C’D’ of the insulator layer 216, while the fourth edge AD of the side layer 212 aligns with the fourth edge A'D’ of the insulator layer 216. This is different from the spacer 210 in Figure 2B where the footprint of the side layer 212 fully overlaps with the footprint of the insulator layer 216, leaving the tab 220 extending away from the footprint of the insulator layer 216.

[0078] As shown in Figure 2E, the tab 220 is an integrated part of the side layer 212 and extends away from the edge AD of the side layer 212 in Y-Z plane. In one aspect, the tab 220 is centered in the middle of the space 225, such as in the middle of the edge AD of the side layer 212, corresponding to the cell vent 204 positioned in the middle of edge of the battery cell 204.

[0079] Figure 2F shows a perspective view of a spacer 225 of Figures 2D and 2E, where the side layer 212 and the insulator layer 216 are assembled together. The edge AD of the side layer 212 aligns with the edge A’D’ of the insulator layer 216, whereas other edges of the side layer 212 extend away from the corresponding edges of the insulator layer 216. As such, the side layer 212 has a width in Z direction and a length in Y direction greater than the corresponding width and length of the insulator layer 216. Correspondingly, a major surface area of the side layer 212 in Y-Z plane is greater than a major surface area of the insulator layer 216 in Y-Z plane. The tab 220 has a length in Y direction smaller than the length of the side layer 212 and / or the length of the insulator layer 216 in Y direction. The tab 220 is centered in the middle of the spacer 225, the middle of the side layer 212, and the middle of the insulator layer 216.

[0080] Figure 2G shows a cross-sectional view of the spacer 225 cutting along plane CC’. The tab 220 has a thickness equal to the thickness of the side layer 212. The tab 220 is coplanar and extending away from the side layer 212, while the insulator layer 216 is positioned over a major surface of the side layer 212. The tab 220 extends away from the side layer 212 and the insulator layer 216 in positive Y direction. In some cases, tab 220 and side layer 212 are made of the same materials.

[0081] Figure 2H shows a perspective view of a battery module 250 accommodated with spacer 210 illustrated in Figures 2D-2G. The module housing 201 includes slots 207 configured to match the edge of the side layer 212. The edge AB of the spacer 210 is positioned in the slot 207 of the module housing 201 to separate the module housing 201 into multiple compartment, where the battery cells are placed therein. The battery module 250 configuration separates the battery cells into multiple compartment to keep the battery cells in place during module assembly and operation.

[0082] Figure 21 shows an alternative configuration of spacer 210. The tab 220 of the spacer 210 has the same length as the side layer 212 in Y direction. The side layer 212 and the tab 220 form an integrated side layer with a rectangular shape. The length (Y direction) and width (Z direction) of the integrated side layer are greater than the length (Y direction) and width (Z direction) of insulator layer 216. The four edges of the integrated side layer extend outwards away from the footprint of the insulator layer 216. This is different from the spacer 210 illustrated in Figure 2E. where three edges of the side layer extend outwards away from the footprint of the insulator layer 216.

[0083] Similar to the spacer 210 illustrated in Figure 2E, each of the side layers 212, 214 has one edge aligned with an edge of the insulator layer 216, while all other edges of side layers 212. 214 extend away outwards from the insulator layer 216. The tab 220, 222 are disposed adjacent to the edges of the side layer 212, 214 that are aligned with the corresponding edges of the insulator layer 216. The tabs 220, 222 forms a gap 221 therebetween. As such, the portions of the side layers 212, 214 and minor surfaces of the insulator layer 216 extending away from the 216 forms a slot 217. The slot 217 is around three edges of the isolation layer 216 where the edges of the side layers 212, 214 extends away from the isolation layer 216. In one aspect, the layers 212, 214 are configured to couple with the slots 207 (not shown in Figure 21) as shown in Figure 2H.

[0084] Figure 2J shows a spacer 210 the same as the spacer 210 illustrated in Figure 21, except the spacer 210 in Figure 2J further comprises an edge seal 219 disposed in the slots 217. In some aspect, the edge seal 219 is placed entirely within the slot 217 between the side layers 212, 214 without extending away from the edges of the side layers 212, 214 in Y or Z directions. A liquid precursor of the edge seal 219 may be disposed in the slot 217 and subsequently dried to form the edge seal 219. Alternatively, the edge seal 219 may be pre-formed (e.g., by molding) and fit into the slot 217 thereafter.

[0085] Figure 2K shows a spacer 210 the same as the spacer 210 illustrated in Figure 2J, except the gap 221 betw een the tabs 220, 220 is filled with an edge seal 223. The edge seal 223 may be the same material as the edge seal 219 for manufacturing convenience. Alternatively, the edge seal 223 may include a material mechanically stronger than that of the edge seal 219 around the edge of the isolation layer 216. Stronger edge seal 223 can better endure the bombardments of the particles generated during a thermal runaway event.

[0086] Figure 2L shows an exploded view of an alternative configuration of spacer 210. The tab 220 of the spacer 210 has the same length as the side layer 212 in Y direction. The side layer 212 and the tab 220 form an integrated side layer with a rectangular shape. The length (Ydirection) and width (Z direction) of the integrated side layer are greater than the length (Y direction) and width (Z direction) of insulator layer 216. The four edges of the integrated side layer extend outwards away from the footprint of the insulator layer 216. This is different from the spacer 210 illustrated in Figure 2E, where three edges of the side layer extend outwards away from the footprint of the insulator layer 216.

[0087] Figure 2M illustrates a cross-sectional view of the spacer 210 in Figure 2L assembled together. The insulator layer 216 of the spacer 210 in Figure 2L has a footprint smaller than the footprint of the integrated side layer 212, 214. The portions of the integrated side layer 212, 214 extending away from the insulator layer 216 forms a gap 217. The gap 217 surround all four edges of the side layer 212, 214. In some embodiments, the gap 217 is filled with the edge seal 219. The edge seal 219 serves as a glue to bond the side layer 212. 214, and the insulator layer prevents or mitigates dust from the insulator layer 216.

[0088] Figure 2N shows an exploded view of a spacer 210. The spacer 210 is the same as any of the spacer 210 illustrated in Figures 2A-2M, except that the spacer 210 in Figure 2N further includes at least one encapsulation layer 213 configured to wrap around at least one of the side layers 212, 214, and insulator layer 216. The spacer 210 may further comprises a second encapsulation layer 215 wrapping around at least one of the side layers 212, 214, and insulator layer 216. In one aspect, the encapsulation layer 213 has flips 218 extending away from the encapsulation layer 213. The flips 218 folds over to enclose the minor surfaces of the at least one of the side layers 212, 214, and insulator layer 216. The flips 218 may additionally comprise glue to attach to the side layers 212, 214, and insulator layer 216 when fold thereover. The encapsulation layers 213 and 215 prevent or reduce dust from the side layers 212, 214, and insulator layer 216. An additional function for the encapsulation layers 213 and 215 is to bind the side layers 212, 214, and insulator layer 216 together. The spacer may further comprise at least one adhesive layer 211 over the encapsulation layers 213 and 215. The adhesive layer 211 is disposed over the exterior surface of the spacer 210 in order to attach the spacer 210 to adjacent battery module components, such as an adjacent battery cell (not shown) or an adjacent battery’ module wall (not shown). The spacer 210 may further includes a release layer 209 to protect the adhesive layer 211. The release layer 209 may be removed prior to applying the spacer 210 to adjacent battery module components.

[0089] Figures 20 and 2P shows a spacer 210 with and without edge seal, respectively. The spacer 210 is the same as the spacer 210 illustrated in Figure 21 except all edges of the side layers 212. 214 extends away from the insulator layer 216. The slot 217 between the extended portions of the side layers 212, 214 surrounds all four edges of the insulator layer 216. The gap221 between the tabs 220 and 222 is connected to the slot 217. Such configuration provides convenience for a continuous process to fill the slot 217 and the gap 221 with edge seal 219.

[0090] Figure 2Q shows a cross-sectional view of the spacer 210 in Figure 2P cutting along plane CC’. The edge seal 223 and 219 are disposed between the side layers 212, 214 entirely, without any portion of the edge seal 223 and 219 disposed beyond the footprint of the side layers 212, 214. Such configuration provides a cuboid shape (e.g., a flat plate) for easier installation into the battery module and even pressure over the major surfaces of the spacer 210 during operation. In some aspect, the edge seal 223, 229 may serve as adhesive to bind the side layer 212, 214, and the insulator layer 216 together.

[0091] Figure 2R shows a prospective view of a spacer 210. The spacer 210 may be any of the spacers illustrated in Figures 2A-2Q. except the spacer 210 comprises an edge seal 219 folding around the edges of the spacer 210. A portion of the edge seal 219 may fold over to contact major surfaces of the spacer 210. In one aspect, the edge seal 219 encloses the edges of the spacer 210, such as the edges of the side layer 212, 214, and the insulator layer 216 (not shown).

[0092] Figures 2S. 2T, 2U show cross sectional views of different aspects of spacer 210 in Figure 2R cutting along planes CC’. The edge seal 219 has a U-shape cross section in X-Z plane. The spacer 219 wraps around and seal the edges of the spacer 210 to prevent any dust from leaking from the edges of the spacer 210, such as from the insulator layer 216 of the spacer 210. A portion of the edge seal may fold over to cover a portion of the major surfaces of the spacer 210. The edge seal 219 may be pre-formed into a frame shape before assembly with the spacer 210. The edge seal 219 in this case can have a 90 angle at the comer of the spacer 210 as shown in Figure 2S. The edge seal 219 may be applied to the edges of the spacer 210 as a liquid precursor followed by a drying process. The edge seal 219 may alternatively be formed by dipping the edge of the spacer 210 into a liquid edge seal precursor followed by a subsequent drying process. The liquid precursor forms round comers at the edge of the spacer 210. The round comers in some aspects maintain their round shape after drying, as shown in Figure 2T.

[0093] Figures 2V. 2W, 2X show views of different aspects of spacer 210. Figure 2V shows an aspect of spacer 210 comprising only one insulator layer 216 and only one side layer 212. Tab 220 extends away from the edge of the side layer 212 outwards. In the some Examples, the edge seal 219 contours the edges of tab 220 and the insulator layer 216. The edge seal 219 has a stepwise profile stepping from the edge of tab 220 to the edge of the insulator layer 216.

[0094] Figure 3A shows another example of a batery module 300 according to the present disclosure. The batery module 300 of Figure 3A includes a number of batery cells 302, at least one of the baten’ cells 302 including a cell vent 304. At least one spacer 310 is show n between batery cells 302 in the number of batery cells. The batery module 300 further includes a tab 320 that is locally adjacent to the cell vent 304 on an edge of a batery cell 302. In the example, of Figure 3A, the tab 320 includes an arced edge. In one example, an arced edge is smoother than an edge with comers, such as the tab 220 from Figures 2A-2B. A smoother edge is less likely to poke or scratch adjacent components (e.g., pouch batery cells) during assembly.

[0095] The tab 320 extends past the edge of the cell in a region that is only a fraction (also referred to as a portion) of the edge. Put another way, the tab 320 extends past an edge of a cell footprint as defined above. In the example of Figure 3 A, the tab 320 is in a middle portion of a top edge (along Y direction) of the batery cells 302, although other configurations are possible. In some configurations, the tab 320 is located on a side edge (along Z direction) of the batery cells 302. or a botom edge (along Y direction and opposite to the top edge) of the batery cells 302.

[0096] Figures 3B and 3C show an assembled view and an exploded view of a more detailed arrangement of one of the spacers 310 from Figure 3 A, respectively. The spacer 310 includes multiple laminations, although configurations with a single lamination are also possible. In Figures 3B and 3C,the spacer 310 includes a first side layer 312 and a second side layer 314. An insulator layer 316 is located between the first side layer 312 and the second side layer 314. In some aspects, the footprint of the side layer 312 is the same as the footprint of the insulator layer 316 for easier manufacturing. In one aspect, the footprint of the side layer 312 completely overlaps with the footprint of the insulator layer 316. Materials and optional arrangements of the spacer 310 are similar to the materials and arrangements discussed above with regard to Figures 2A to 2C.

[0097] In the example of Figures 3B and 3C, a first tab 320 and a second tab 322 are shown. In alternate examples, only one tab is included in a given spacer 310. In the example of Figures 3B and 3C, the tabs 320. 322 are integral with the one or more side layers 312. 314. In some aspects, the tabs 320, 322 are centered in a middle portion of an edge of the side layers 312, 314, respectively. In one aspect, the footprints of the tabs 320, 322 extend aw ay from the footprints of the side layers 312, 314 without overlapping. In some aspects, the tabs 320, 322 have the same thicknesses as the first and second side layers 312, 314. correspondingly. In some aspect, the tabs 320, 322 are coplanar with the first and second side layers 312, 314,correspondingly. The same thickness and coplanar design help prevent sharp edges at the joints of the tabs 320, 322 and the first and second side layers 312, 314. The sharp edges may inadvertently damage adjacent components, such as the battery cells 302.

[0098] Figure 4 shows another example of a battery module 400 according to the present disclosure. The battery module 400 of Figure 4 includes a number of battery cells 402, at least one of the battery cells 402 including a cell vent 404. At least one spacer 410 is shown between battery cells 402 in the number of battery cells. The battery module 400 further includes a tab 420 that is locally adjacent to the cell vent 404 on an edge of a battery cell 402. The tab 420 is also equivalently referred to as the thermal barrier 420. The tab 420 is centered in the middle portion of the edge of the side spacer 410. Similar to the aspect of Figures 3A- 3C. in the aspect of Figure 4, the tab 420 includes an arced edge.

[0099] In the example of Figure 4, the spacer 410 includes multiple laminations, although configurations with a single lamination are also possible. The spacer 410 includes a first side layer 412 and a second side layer 414. An insulator layer 416 is located between the first side layer 412 and the second side layer 414. In some aspects, the footprint of the side layer 412 and / or side layer 414 is smaller than the footprint of the insulator layer 416. Smaller side layers 412, 414 reduces weight and cost while still able to enhance the mechanical strength of the spacer 410, especially around the venting area.

[0100] In one aspect, at least one of the side layers 414 has a length in Y direction that is smaller than a length of the insulator layer 416 in Y direction. A width of at least one of the side layers 412, 414 equals the width of the insulator layer 416 in Z direction. Edges of the side layers 412, 414 along Y direction are alongside edges of the insulator layer 416.

[0101] Materials and optional arrangements of the spacer 410 are similar to the materials and arrangements discussed above with respect to the spacer 310 in Figures 3A-3C and spacer 210 in Figures 2A-2C. A first tab 420 and a second tab 422 are shown in spacer 410 in Figure 4. In alternate examples, only one tab is included in a given spacer 410. In the aspect of Figure 4, the tabs 420, 422 are integral with the one or more side layers 412, 414. Additionally, in the aspect of Figure 4, the one or more side layers 412. 414 are not co-extensive with a lateral footprint (in Y-Z plane) of the insulator layer 416. The side layers 412, 414 are limited to a fraction of a lateral (Y direction) area of the insulator layer 416. One advantage of this configuration includes weight savings, and reduction of material cost. The side layers 412, 414 and the tabs 420, 422 are only included in the portions of the battery module 400 where they are most needed, e.g., around the venting 404. At least one of the side layers 412, 414extends the entire width (Z direction) of the insulator layer 416 for easier manufacturing and installation between two cells.

[0102] Figure 5 shows another example of a batery module 500 according to the present disclosure. The batery module 500 of Figure 5 includes a number of batery cells 502, at least one of the batery' cells 502 including a cell vent 504. At least one spacer 510 is shown between batery cells 502 in the number of batery cells. The batery module 500 further includes a tab 520 that is locally adjacent to the cell vent 504 on an edge of a batery cell 502.

[0103] In the example of Figure 5, the spacer 510 includes multiple laminations, although configurations with a single lamination are also possible. The spacer 510 includes a first side layer 512 and a second side layer 514. An insulator layer 516 is located between the first side layer 512 and the second side layer 514. Materials and optional arrangements of the spacer 510 are similar to the materials and arrangements discussed above with respect to the spacer 210, 310 and 410 in Figures 2A-2C, 3A-3C and 4. A first tab 520 and a second tab 522 are shown. In alternate examples, only one tab is included in a given spacer 510.

[0104] Similar to the example of Figure 4. in the example of Figure 5, the one or more side layers 512, 514 are not co-extensive with a lateral footprint of the insulator layer 516. The side layers 512, 514 are limited to a fraction of a lateral (Y direction) area of the insulator layer 516. In one aspect, the side layers 512, 514 extends to a fraction of the w idth (in Z direction) of the insulator layer 516. In other words, there is a portion of the idth (in Z direction) of the insulator layer 516 that is not covered by the side layers 512, 514. In the example of Figure 5, the tab 520 includes a rectangular configuration having the same width as the side layers 512, 514 in Y direction.

[0105] Figure 6A shows another example of a batery module 600 according to the present disclosure. The batery module 600 of Figure 6A includes a number of batery cells 602, at least one of the batery cells 602 including a cell vent 604. At least one spacer 610 is show n between batery7cells 602 in the number of batery cells. The batery module 600 further includes a tab 620 that is locally adjacent to the cell vent 604 on an edge of a batery cell 602. In the example of Figure 6A, the spacer 610 includes multiple laminations, although configurations with a single lamination are also possible. The spacer 610 includes a first side layer 612 and a second side layer 614. An insulator layer 616 is located between the first side layer 612 and the second side layer 614. Materials and optional arrangements of the spacer 610 are similar to the materials and arrangements discussed above with respect to the spacer 210, 310, 410 and 510 in Figures 2A-2C. 3A-3C. 4, and 5. A first tab 620 and a second tab 622 are shown. In alternate examples, only one tab is included in a given spacer 610.

[0106] Similar to the examples of Figures 4 and 5, in the example of Figure 6A, the one or more side layers 612. 614 are not co-extensive with a lateral footprint of the insulator layer 616. The side layers 612, 614 are limited to a fraction of a lateral (Y direction) area and a vertical (Z direction) area of the insulator layer 616. In the example of Figure 6A, the tab 620 includes an arced edge.

[0107] In the example of Figures 6A and 6B, one or both of the tabs 620, 622 are recessed in the spacer 610. such that major surfaces of one or both of the tabs 620, 622 and the spacer 610 being coplanar. In other words, the spacer 610 has a uniform thickness (X direction). A recess 618 is shown in Figure 6B where the second side layer 614 fits into. In one aspect, recess 618 is preformed prior to attaching the side layers 612, 614 therein. One advantage of this configuration includes a reduction in overall thickness of the spacer 610, which allows for lower volume in the battery module 600 and more space for battery cells 602. Additionally, by eliminating a protrusion of the side layers 612, 614 from the insulator layer 616, stress concentration points are reduced or eliminated with respect to the batten' cells 602. Thus, when the battery cells 602 are compressed in a stack, without protrusions within a lateral battery cell footprint (Y-Z plane), potential damage to sides of the battery cells 602 is reduced.

[0108] Figures 7A and 7B show another example of a battery module 700 according to the present disclosure. The battery' module 700 includes a number of battery' cells 702, at least one of the battery cells 702 including a cell vent 704. At least one spacer 710 is shown between battery cells 702 in the number of battery cells 702. The battery module 700 further includes a number of flexible tabs 706. A first flexible tab 720 and a second flexible tab 730 are included in the number of flexible tabs 706. As shown in Figure 7B, at least two flexible tabs are located adjacent to a cell vent 704 on an edge of a cell 702.

[0109] The first flexible tab 720 includes a first fold 723, and the second flexible tab 730 includes a second fold 733. In Figures 7A and 7B, all of the number of flexible tabs 706 are folded similarly to form a cascade of folds across a surface of the battery module 700. In this example, the surface includes a top (X-Y plane) of the battery' module 700, however other surfaces such as a side (X-Z plane) or bottom (X-Y plane and opposite to the top) are also within the scope of the present disclosure.

[0110] In the Figures 7A, 7B the first flexible tab 720 is folded with an end 721 of the first flexible tab 720 configured to contact the second flexible tab 730 in normal battery module operating conditions. An enclosed space 708 is formed by the folds 723, 733 and by the ends such as end 721 contacting adjacent flexible tabs 706.

[0111] In the example of Figures 7A, 7B, the spacer 710 includes multiple laminations, although configurations with a single lamination are also possible. The spacer 710 includes a first side layer 712 and a second side layer 714. An insulator layer 716 is located between the first side layer 712 and the second side layer 714. Materials and optional arrangements of the spacer 710 are similar to the materials and arrangements discussed above with respect to the spacer 210. 310, 410. 510, 610 in Figures 2A-2C, 3A-3C, 4, 5, 5A-6B. In the example of Figure 7A. 7B, only one flexible tab is included in a given spacer 710, although two flexible tabs formed from each side layer 712, 714 are also possible.

[0112] As shown in more detail in Figure 7B, the configuration of flexible tabs 706 provides an improved level of containment and re-direction of hot gasses and ejecta in the event of a thermal runaway of a given cell. Because of the flexibility of the flexible tabs 706, venting of a cell in thermal runaway is facilitated, while other adjacent cells are protected by adjacent portions of the flexible tabs 706 contacting one another. In the example of Figure 7A and 7B, the number of flexible tabs 706 extend across an entire edge (along Y direction) of the cells 702. In this configuration, an entire surface of a side (in X-Y plane) of the batten- module 700 is protected by the cascading and contacting tabs 706, while still allowing venting on a given cell in thermal runaway.

[0113] Figure 8 shows another example of a battery module 800 according to the present disclosure. The battery module 800 includes a number of battery cells 802, at least one of the battery cells 802 including a cell vent 804. At least one spacer 810 is shown between battery cells 802 in the number of battery cells. The battery module 800 further includes a number of flexible tabs 806. A first flexible tab 820 and a second flexible tab 830 are included in the number of flexible tabs 806. As shown in Figure 8, at least two flexible tabs are located adjacent to a cell vent 804 on an edge of a cell 802.

[0114] The first flexible tab 820 includes a first fold 823, and the second flexible tab 830 includes a second fold 833. In the example of Figure 8, all of the number of flexible tabs 806 are folded similarly to form a cascade of folds across a surface of the battery module 800. In this example, the surface includes a top of the battery module 800, however other surfaces such as a side or bottom are also within the scope of the present disclosure.

[0115] Similar to the example of Figures 7A and 7B, the configuration of flexible tabs 806 provides an improved level of containment and re-direction of hot gasses and ejecta in the event of a thermal runaway of a given cell. Because of the flexibility of the flexible tabs 806, venting of a cell in thermal runaway is facilitated, while other adjacent cells are protected by adjacent portions of the flexible tabs 806 contacting one another.

[0116] In the example of Figure 8, the number of flexible tabs 806 extends across only a portion of the edge (along Y direction) of the cells 802. In this configuration, only a portion of cells 802 that is in close proximity to the vent 804 is protected by the cascading and contacting tabs 806, while still allowing venting on a given cell in thermal runaway. This configuration provides a good level of protection for structures closest to the vent 804 that are most likely to incur damage during a thermal runaway event. This configuration further allows escaping hot gasses and ejecta more room to expand around the side of the battery module 800. which can help dissipate the energy involved in the thermal runaway.

[0117] Figure 9A shows another example of a battery7module 900 according to the present disclosure. Figure 9B is a cross-sectional view of the battery module 900 along line 9B. The battery module 900 includes a number of battery cells 902, at least one of the battery cells 902 including a cell vent 904. At least one spacer 910 is shown between battery' cells 902 in the number of battery cells. The battery module 900 further includes a number of flexible tabs 906. A first flexible tab 920 and a second flexible tab 930 are included in the number of flexible tabs 906. As shown in Figures 9A and 9B, at least two flexible tabs are located adjacent to a cell vent 904 on an edge of a cell.

[0118] The first flexible tab 920 includes a first fold 923, and the second flexible tab 930 includes a second fold 933. In the example of Figures 9A and 9B, all of the number of flexible tabs 906 are folded similarly to form a cascade of folds across a surface of the battery module 900. In this example, the surface includes a top of the battery module 900. however other surfaces such as a side or bottom are also within the scope of the present disclosure.

[0119] The first flexible tab 920 includes a first fold 923, and the second flexible tab 930 includes a second fold 933. In the example of Figure 9B, all of the number of flexible tabs 906 are folded similarly to form a cascade of folds across a surface of the battery module 900. In this example, the surface includes a top of the battery module 900, however other surfaces such as a side or bottom are also within the scope of the present disclosure.

[0120] In the example of Figures 9A and 9B, a channel 940 is further included. The channel 940 encloses the first flexible tab 920 and the second flexible tab 930. In one example, electrode terminals 901 of cells 902 are further enclosed with electrode channels 942 different from channel 940. Enclosing electrodes provides additional protection of the electrodes from damage in the event of a thermal runaway event.

[0121] Figure 9B further illustrates a housing 950 for the battery module 900. The housing 950 is shown with a housing lid 952. A housing vent 954 is included, and aligned with an end of the channel 940, and one side of the cascading number of flexible tabs 906. In theevent of a thermal runaway of a cell in any of the number of cells 902, the thermal runaway ejecta from the runaway cell flaps the flexible tab 920 there above upwards away from the battery cells 902. At the same time, the thermal runaway ejecta bends other flexible tabs (e.g., tab 930) further downw ards tow ards the battery cells 902. An enclosed space 908 is formed as a result where the ejecta is redirected by the flexible tab 920 flapping up and the flexible tabs 930 bending down further. The flexible tabs 930 bending down protects other healthy battery cells 902 from the runaway battery cells 902. The gas and / or ejecta will exit the vent 904 of the runaway battery cell 902 and enter an enclosed space 908 formed by the folds 923, 933. and by the ends such as end 921 normally contacting adjacent flexible tabs 906. Pressure from the escaping gas and / or ejecta will force the end 921 upwards and the flexible tab 930 downwards to expand the space 908. The gas and / or ejecta will pass into the space 908 and away from runaway cell 903 as indicated by arrows 905. In the example of Figure 9B, the gas and / or ejecta is directed towards the housing vent 954 where it is removed from the module 900. Other cells 902 in the module 900 are protected by the cascading number of flexible tabs 906, such as the tab 930.

[0122] In one example of an electric vehicle including a battery module such as battery module 900, the housing vent 954 is oriented below a chassis of the vehicle. In an event of a thermal runaway, hot gasses and / or ejecta are therefore directed away from a passenger compartment. Although beneath a chassis of a vehicle is used as an example, other directions that improve safety are within the scope of the present disclosure, such as behind a vehicle, and / or a side of a vehicle.

[0123] Although a channel 940 and housing vent 954 are included in selected examples, the disclosure is not so limited. Other examples may include a housing vent 954, without a channel 940 to guide gas and / or ejecta to the housing vent 954. Gas and / or ejecta may be sufficiently removed from a battery module in selected examples without the guiding function of a channel. Further, in selected examples, a housing vent 954 may not be required. Dissipation of gas and / or ejecta within a housing 950 may be enough dissipation of energy' without the need to vent outside the housing 950.

[0124] Figures 10A and 10B show another example of a battery module 1000 according to the present disclosure. The battery module 1000 includes a number of battery cells 1002, at least one of the battery cells 1002 including a cell vent. At least one spacer 1010 is shown between battery cells 1002 in the number of battery cells. The battery' module 1000 further includes a number of flexible tabs 1006. Figure 10A illustrates the battery module 1000 undernormal operating conditions, while Figure 10B illustrates the battery module 1000 with cells 1003 and 1005 undergoing thermal runaway.

[0125] Similar to the example in Figures 9A and 9B, the example of Figure 10A and 10B includes a housing 1050 for the battery module 1000. The housing 1050 is shown with a housing lid 1052. A first housing vent 1054 is included, on a first side of the housing 1050, and a second housing vent 1056 is included on a second side of the housing 1050. In one example, the second housing vent 1056 is on a side opposite the first housing vent 1054. although the disclosure is not so limited.

[0126] The example of Figures 10A and 10B illustrate an arrangement where the number of flexible tabs 1006 are arranged in two-fold patterns extending in opposite directions. One advantage of this configuration includes a closer proximity of cells to an available vent 1054, 1056. As shown in Figure 10B, thermal runaway cell 1003 vents and is directed towards first housing vent 1054, while the thermal runaway cell 1005 vents and is directed towards second housing vent 1056. The configurations in Figures 10A and 10B provides shorter travel passes for thermal runaway ejecta compared to the configurations illustrated in Figures 9A and 9B.

[0127] Battery modules and / or battery packs with thermal barriers as described above are used in a number of electronic devices. Figure 11 illustrates an example electronic device 1100 that includes a battery module 1110. The battery module 1110 is coupled to functional electronics 1120 by circuitry 1112. In the example shown, the battery module 1110 and circuitry 1112 are contained in a housing 1 102. A charge port 1 114 is shown coupled to the battery module 1110 to facilitate recharging of the battery' module 1110 w hen needed.

[0128] In one example, the functional electronics 1120 include devices such as semiconductor devices with transistors and storage circuits. Examples include, but are not limited to, telephones, computers, display screens, or navigation systems.

[0129] 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 example 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.

[0130] Examples of electric vehicle 1200 include, but are not limited to, consumer vehicles such as cars, trucks, etc. 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 isnot so limited. For example, two wheeled vehicles such as motorcycles and scooters are also within the scope of the invention.

[0131] Figures 13A and 13B show another example of a battery module 1300 according to the present disclosure tabs 1320 aligned with electrical terminals 1306. Figure 13A shows the tab 1320 before bending in the process of assembly of the battery module 1300. Figure 13B shows battery module 1300 with the tab 1320 bends over to cover the electrical terminals 1306.

[0132] The battery module 1300 includes a number of battery cells 1302, at least one of the battery cells 1302 including a cell vent 1304. At least one spacer 1310 is shown between battery cells 1302 in the number of battery cells. The battery module 1300 further includes a number of flexible tabs 1320. Tab 1320 extends away from an edge of the insulator layer 1316. Tab 1320 is aligned with the electrical terminals 1306 and the busbar 1308 connecting the electrical terminals 1306. The tab 1320 folds over to cover the electrical terminals 1306 and the busbar 1308 when assembled in the battery' module. The tab may extend away from the side layer 1312 long enough to cover two battery' cells 1302 that are connected by a busbar 1308. The tab 1320 may be long enough to cover the electrical terminal 1306 on a single battery cell 1302 in the case w here 1302 is at the end of the battery module 1300. There may be only a side layer 1312 without insulator layer 1316 at the end of the battery module where the end battery' is adjacent to a wall (not shown) of the battery' cell. The tab 1320 protects the electrical terminal 1306 and busbar 1308 during a thermal runaway event from released heat and particles.

[0133] Figures 13 A and 13B show another example of a battery module 1300 according to the present disclosure with tab 1320 aligned with electrical terminals 1306. Figure 13A shows the tab 1320 before bending in the process of assembly of the battery' module 1300. Figure 13B shows battery module 1300 with the tab 1320 bends over to cover the electrical terminals 1306.

[0134] The battery module 1300 includes a number of battery cells 1302, at least one of the battery' cells 1302 including a cell vent 1304. At least one spacer 1310 is shown between battery cells 1302 in the number of battery' cells. The battery module 1300 further includes a number of flexible tabs 1320. Tab 1320 extends away from an edge of the insulator layer 1316. Tab 1320 is aligned with the electrical terminals 1306 and the busbar 1308 connecting the electrical terminals 1306. The tab 1320 folds over to cover the electrical terminals 1306 and the busbar 1308 when assembled in the battery' module. The tab may extend away from the side layer 1312 long enough to cover two battery' cells 1302 that are connected by a busbar 1308. The tab 1320 may be long enough to cover the electrical terminal 1306 on a single battery cell 1302 in the case w here 1302 is at the end of the battery’ module 1300. There may be only na side layer 1312 without insulator layer 1316 at the end of the battery module where the end battery is adjacent to a wall (not shown) of the battery cell. The tab 1320 protects the electrical terminal 1306 and busbar 1308 during a thermal runaway event from released heat and particles.

[0135] Figures 14A, 14B, and 14C show another example of a battery module 1400 according to the present disclosure. Battery module 1400 is similar to battery' module 1300 illustrated in Figure 13 except battery’ module 1400 further comprises a second tab 1440 in addition to a first tab 1420. Figure 14A shows the tab 1420 before bending in the process of assembly of the battery module 1400. Figure 14B shows an exploded view of battery module 1400 to better illustrate the relative positions of the components of the battery' module 1400. Figure 14C shows with the tab 1420 bends over to cover the electrical terminals 1406 and the cell vent 1404.

[0136] The battery module 1400 comprises a number of battery cells 1102, at least one of the battery' cells 1402 including a cell vent 1404 and electrical terminals 1406. At least one spacer 1410 is shown between battery' cells 1402 in the number of battery' cells. The batterymodule 1400 further a first tabs 1420 aligned with the electrical terminals 1406 and the busbar 1408 connecting the electrical terminals 1406. The first tab 1420 folds over to cover the electrical terminals 1406 and the busbar 1408 when assembled in the battery module.

[0137] The battery’ module 1400 further comprises a second tab 1440 aligned with cell vent 1404. The second tab 1440 may be connected to the first tab 1420 for easier manufacturing and installation. The second tab 1440 folds over to cover the cell vent 1404 during an extreme situation such as thermal runaway. The second tab 1440 extends away from an edge of the side layer 1414 at a length sufficient to cover the cell vent 1404. In one aspect, the extended length of the tab 1440 equals a thickness of the adjacent battery cell 1402 over whose cell vent 1404 the second tab 1440 bends over. The second tab 1440 may be integrated with the first tab 1420 and / or the side layer 1414. The second tab 1440 may include a material different from the material of the first tab 1420 to withstand the particle bombardments, although the disclosure is not so limited. In one aspect, the second tab has a width in Z direction equals half of the width of the first tab 1420, such that each battery cell 1420 has its own tab for potential thermal runaway event.

[0138] As shown in Figure 14C, the terminals 1406 and / or the busbar 1408 are covered by the tab 1420 when assembled in the battery module. The cell vent 1404 is covered by the second tab 1440. During an extreme event, such as thermal runaway, the venting gas from the cell vent 1404 push open the second tab 1404 to escape in the space above the battery folded first tabs 1420 and second tab 1440. The folded first tab 1420 and second tabs 1440 werepushed downward towards the battery cells 1402 and separated the venting gas from the battery cells 1402 thereunder.

[0139] To better illustrate the method and apparatuses disclosed herein, a non-limiting list of embodiments is provided here:

[0140] Aspect 1. A battery module, comprising: a number of battery cells within a module housing, at least one of the battery cells including a cell venting area; at least one spacer between battery cells in the number of battery cells; and atab locally adjacent to the cell venting area on an edge of a cell, the tab extending past the edge of the cell in a region that is only a fraction of the edge.

[0141] Aspect 2. The battery module of aspect 1, wherein the tab includes a dielectric material.

[0142] Aspect 3. The battery module of aspect 2, wherein the dielectric material includes mica.

[0143] Aspect 4. The battery module of aspect 1, wherein the tab includes a metal.

[0144] Aspect 5. The battery module of aspect 4, wherein the metal includes stainless steel.

[0145] Aspect 6. The battery' module of aspect 1, wherein the spacer includes aerogel.

[0146] Aspect 7. The battery' module of aspect 1, wherein the fraction of the edge is a middle fraction of the edge.

[0147] Aspect 8. The battery module of aspect 1, wherein the cell venting area is on an edge of the cell between a first electrode and a second electrode.

[0148] Aspect 9. The battery module of aspect 8, wherein the fraction of the edge is between the first electrode and the second electrode.

[0149] Aspect 10. The battery module of aspect 1. wherein the cell venting area is on a side of the cell.

[0150] Aspect 11. The battery module of aspect 1 , wherein the tab is integral with the spacer.

[0151] Aspect 12. The battery module of aspect 1, wherein the tab is laminated with the spacer.

[0152] Aspect 13. The battery module of aspect 12, wherein the tab is only laminated in a middle portion of the spacer.

[0153] Aspect 14. The battery module of aspect 13. wherein the tab is recessed in the spacer with major surfaces of the tab and the spacer being coplanar.

[0154] Aspect 15. A battery module, comprising: a number of battery cells within a module housing, at least one of the battery cells including a cell venting area; at least one spacer layer between battery cells in the number of battery cells; and a first flexible tab and a second flexible tab both located adjacent to the cell venting area on an edge of a cell, wherein the first flexible tab is folded with an end of the first flexible tab configured to contact the second flexible tab in normal battery’ module operating conditions.

[0155] Aspect 16. The battery module of aspect 15, wherein the first flexible tab and the second flexible tab include mica.

[0156] Aspect 17. The battery’ module of aspect 15, wherein the first flexible tab and the second flexible tab include a metal.

[0157] Aspect 18. The battery module of aspect 15. wherein the spacer includes aerogel.

[0158] Aspect 19. The battery’ module of aspect 15, wherein the first flexible tab and the second flexible tab both extend across an entire edge of the cell.

[0159] Aspect 20. The battery module of aspect 15, wherein the first flexible tab and the second flexible tab extend across only a portion of the edge of the cell.

[0160] Aspect 21. The battery module of aspect 15, further including a channel enclosing the first flexible tab and the second flexible tab.

[0161] Aspect 22. The battery module of aspect 15, further including a housing vent.

[0162] Aspect 23. The battery module of aspect 21, further including a housing vent aligned with an end of the channel.

[0163] Aspect 24. The battery’ module of aspect 21, wherein the first flexible tab and the second flexible tab are included in a number of flexible tabs, the number of flexible tabs arranged in two-fold patterns extending in opposite directions.

[0164] Aspect 25. An electric vehicle, comprising: a number of wheels attached to a vehicle chassis; at least one electric motor on the chassis, the at least one electric motor coupled to drive the number of wheels; a battery module coupled to the at least one electric motor, the battery module including; a number of battery cells within a module housing, at least one of the battery cells including a cell venting area; at least one spacer layer between battery cells in the number of battery cells; and a first flexible tab and a second flexible tab both located adjacent to the cell venting area on an edge of a cell, wherein the first flexible tab is folded with an end of the first flexible tab configured to contact the second flexible tab in normal battery module operating conditions.

[0165] Aspect 26. The electric vehicle of aspect 25, wherein the module housing includes a housing vent configured to re-direct venting material away from the chassis.

[0166] Aspect 27. The electric vehicle of aspect 26, wherein the housing vent is orthogonal to the cell venting area.

[0167] Aspect 28. The electric vehicle of aspect 25, wherein the housing vent is oriented downward below the chassis.

[0168] Aspect 29. A spacer for insulating a battery cell, comprising: an insulator layer having an insulator layer edge; and a tab configured to extend past an edge of a battery cell when the spacer is included in a battery' module, the tab located in a region that is only a fraction of the insulator layer edge.

[0169] Aspect 30. The spacer of aspect 29. wherein the tab is integral with the insulator layer.

[0170] Aspect 31. The spacer of aspect 29, wherein the tab is part of a dielectric layer laminated with the insulator layer.

[0171] Aspect 32. The spacer of aspect 31, wherein a lateral footprint of the insulator layer overlaps with a lateral footprint of the dielectric layer, and wherein the tab extends past an edge of the lateral footprint of the insulator layer.

[0172] Aspect 33. The spacer of aspect 32, wherein the lateral footprint of the dielectric layer is smaller in area than the lateral footprint of the insulator layer.

[0173] Aspect 34. The spacer of aspect 31. wherein a major surface of the dielectric layer is coplanar with a major surface of the insulator layer.

[0174] Aspect 35. The spacer of aspect 31, wherein the dielectric layer is a first dielectric layer, and further including a second tab that is part of a second dielectric layer wherein the first dielectric layer and the second dielectric layer are on opposing surfaces of the insulator layer.

[0175] Aspect 36. The spacer of aspect 29, wherein the tab is configured to be located adjacent to a venting area on a battery cell when the spacer is included in a battery module.

[0176] Aspect 37. The spacer of aspect 29, wherein the tab is located in a middle portion of the insulator layer edge.

[0177] Aspect 38. The spacer of aspect 29, wherein the tab has a semicircle shape.

[0178] Aspect 39. The spacer of aspect 29, wherein the tab is flexible with respect to the insulator layer.

[0179] The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used incombination with each other. Other embodiments can be used, such as by one of ordinary' skill in the art upon reviewing the above description. The Abstract is provided to comply with 37 C.F.R. §1.72(b), to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be 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 embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or 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.

[0180] Although an overview of the inventive subject matter has been described with reference to specific example embodiments, various modifications and changes may be made to these embodiments without departing from the broader scope of embodiments of the present disclosure. Such embodiments 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.

[0181] The embodiments illustrated herein are described in sufficient detail to enable those skilled in the art to practice the teachings disclosed. Other embodiments may be 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 embodiments is defined only by the appended claims, along with the full range of equivalents to which such claims are entitled.

[0182] 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 embodiments of the present disclosure. In general, structures and functionality presented as separate resources in the example 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 embodiments 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.

[0183] The foregoing description, for the purpose of explanation, has been described with reference to specific example embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the possible example embodiments to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. The example embodiments were chosen and described in order to best explain the principals involved and their practical applications, to thereby enable others skilled in the art to best utilize the various example embodiments with various modifications as are suited to the particular use contemplated.

[0184] 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. For example, 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 example embodiments. The first contact and the second contact are both contacts, but they are not the same contact.

[0185] The terminology used in the description of the example embodiments herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used in the description of the example embodiments and the appended examples, 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 wall 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.

[0186] 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 statedcondition 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 03 September 2025 (03.09.2025)What is claimed is:

1. A spacer for insulating a battery cell, comprising: an insulator layer having an insulator layer edge; a side layer laminated with the insulator layer, wherein a major surface of the side layer is coplanar with a major surface of the insulator layer; and a tab adjacent to the insulator layer edge, wherein at least a portion of the tab is configured to extend past the insulator layer edge, wherein the tab is recessed in the spacer with major surfaces of the tab and the spacer being coplanar.

2. The spacer of claim 1 , wherein the tab is integral with the side layer.

3. The spacer of claim 1, wherein the lateral footprint of the side layer is greater in area than the lateral footprint of the insulator layer.

4. The spacer of claim 1, wherein a lateral footprint of the insulator layer overlaps with a lateral footprint of the side layer, and wherein the tab extends past an edge of the lateral footprint of the insulator layer.

5. The spacer of any of the claims 1-4, wherein the tab is located in a middle portion of the insulator layer edge.

6. The spacer of any of the claims 1-5, wherein the tab is located in an end portion of the insulator layer edge.

7. The spacer of any of the claims 1-7, wherein the tab has a semicircle shape or a rectangular shape.

8. The spacer of claim 1-8, wherein the tab is a first tab, wherein the spacer further comprises a second tab coplanar with the first tab.

9. The spacer of claim 8, wherein the first tab extends away from the spacer further than the second tab.

10. The spacer of any of the claims 1-9, wherein the tab is a first tab disposed on a first side of the spacer, and wherein the spacer further comprises a second tab disposed on a second side of the spacer opposite to the first side.

11. The spacer of any of the claims 1 -9, wherein the side layer is a first side layer and the tab is a first tab, wherein the spacer further comprises a second side layer, wherein the second side layer comprises a second tab that is part of a second side layer, wherein the first side layer and the second side layer are disposed on opposite surfaces of the insulator layer.

12. The spacer of claims 10 or 11, wherein the first tab and the second tab form a gap, and wherein the spacer further comprises an edge seal that fills the gap.

13. The spacer of claim 12, wherein the first side layer and the second side layer each comprises extended portions that extend away from the insulator layer, and wherein extended portions form a slot.

14. The spacer of claim 13, wherein the slot is filled by an edge seal.

15. The spacer of any of the claims 1-14, wherein the tab is flexible with respect to the insulator layer.

16. A batery module, comprising: a plurality of batery cells within a module housing, at least one battery cell of the plurality of battery cells including a cell edge, a cell venting area on the cell edge, and an electrical terminal on the cell edge apart from the cell venting area; at least one spacer adjacent to the at least one battery cell between the plurality of batery cells, the at least one spacer has a spacer edge aligned with the cell edge; and a tab positioned on the spacer edge, the tab extending past the edge of the batery cell, wherein the tab is aligned with the cell venting area.

17. The batery module of claim 16, wherein the tab is a first tab, and wherein the battery module further comprises a second tab coplanar with the first tab, and wherein the second tab is aligned with the electrode terminal.

18. The battery module of claims 16 or 17, wherein the tab is a first tab positioned on a first side of the insulator layer, and wherein the battery module further comprises a second tab positioned on a second side of the insulator layer opposite to the first side of the insulator layer.

19. The battery module of claim 18, wherein the first tab is folded with the end configured to contact the second flexible tab in normal batery module operating conditions.

20. The battery module of claims 18 or 19, wherein the first flexible tab and the second flexible tab both extend across an entire edge of the cell.

21. The batery module of any of the claims 18-20, further comprising a channel enclosing the first flexible tab and the second flexible tab.

22. The batery module of claim 21, further including a housing vent aligned with an end of the channel.

23. The battery module of any of the claim 18-22, wherein the first flexible tab and the second flexible tab fold to a first direction, wherein the battery module further includes a third flexible tab folding to a second direction opposite to the first direction.[0001][0002]STATEMENT UNDER ARTICLE 19(1)[0003]This statement is being submitted as supportive information and not as informal comments. Claims 1-23 are pending, claims 1 and 5-23 are amended. Amended claim 1 now recites that a major surface of the side layer is coplanar with a major surface of the insulator layer and the tab is recessed in the spacer with major surfaces of the tab and the spacer being coplanar. Amended claim 16 (original laim 18) now recites wherein the tab is aligned with the cell venting area.[0004]Applicant submits that no new matter has been added by way of these amendments.[0005]Further, Applicant respectfully submits that it is not obvious for a person skilled in the art to arrive at the invention by combining the teachings of D1-D3. In particular, D1- D3 do not disclose the coplanar side layer structure and coplanar recessed tab structure, as recited in claim 1. Neither do D1-D3 disclose the tab aligned with the cell venting area of claim 16 (original calim 18). Moreover, it is believed that D1-D3 do not disclose the edge seal technology of claim 12 (original claim 14) or the channel-venting system of claims 21-22 (original claims 24-25). Therefore, the instant claims are inventive over the disclosures of D1-D3, either alone or in combination, and should be found allowable.

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