Thermal insulating separator assembly for battery modules

Abstract

A thermal insulating separator assembly (102) for a battery module (100) is disclosed. The thermal insulating separator assembly (102) includes a support structure (106) having a first surface and a second surface, shaped to correspond to a battery module (100) and configured to extend over a venting surface of the battery module (100). An insulating layer (108) is bonded to at least one of the first surface or the second surface of the support structure (106). The support structure (106) and the insulating layer (108) are arranged in a layered configuration to absorb an impact of venting gases released from a cell vent during a thermal runaway event. The insulating layer (108) further functions as a diffuser to diffuse the venting gases.

Description

THERMAL INSULATING SEPARATOR ASSEMBLY FOR BATTERY MODULESTECHNICAL FIELD

[0001] The present subject matter relates, in general, to battery modules and, particularly, to a thermal insulating separator assembly for battery modules in a battery pack.BACKGROUND

[0002] A battery pack that powers electric vehicles consists of individual battery cells and modules organized in series and parallel. A battery cell is the smallest unit of a battery pack. The characteristics of a battery cell play a pivotal role in overall performance of the electric vehicles. A module consists of multiple cells connected in series and / or parallel, encased in a mechanical structure. A battery pack is assembled by connecting multiple modules together in series or parallel with sensors and controllers and then encased in a casing as a final battery pack.

[0003] The process of charging and discharging the battery cells normally causes a small amount of heat generation. Also, a significant amount of heat is generated during power generation by the battery cells. In ideal conditions, the heat dissipates from the cells. However, in thermal runaway, the cells may generate heat at a rate several times higher than the rate at which heat dissipates from the cells. The sequential occurrence of thermal runaway within a battery pack triggered by the thermal runaway of a cell in the battery pack is known as thermal propagation.

[0004] Regulatory requirements AUTOMOTIVE INDUSTRY STANDARD (AIS) 156 (Amendment 2) mandate that the Rechargeable Electrical Energy Storage System (REESS) should withstand thermal propagation which is triggered by an internal short circuit, leading to a single cell thermal runaway and subsequent thermal propagation and shall not result in fire and explosion.

[0005] The heat generated during a single cell thermal runaway in the battery module of the battery pack needs to be contained so that it does not adversely impact other cells of the battery pack. It is necessary to quickly vent out the high-temperature gases to the outside of the battery pack and also quench flames, if any, to maintain the temperature of the battery modules under control during operation.SUMMARY OF T HE INVENTION

[0006] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0007] In accordance with embodiments of the present invention, there is provided a thermal insulating separator assembly for a battery. The assembly comprises at least one support structure having a first surface and a second surface and configured to extend to cover a venting surface of at least one battery module of the battery. The shape of the at least one support structure corresponds to the shape of the at least one battery module. The assembly further comprises at least one insulating layer bonded to at least one of the first surface and the second surface of at least one of the support structure. Further, the at least one of the support structure and the at least one insulating layer are arranged in a layered configuration to absorb an impact of gases vented from a cell of the at least one battery module in an event of a thermal runaway and the at least one insulating layer acts as a diffuser to diffuse the vented gases.

[0008] In accordance with example embodiments of the present invention, the at least one battery module comprise a first battery module and a secondbattery module, where each of the first battery module and the second battery module comprises cells arranged such that the cell vents of the cells in the first battery module face the cell vents of the cells in the second battery module. A common venting channel is provided in battery configurations where the cell vents of different modules face each other. According to the example embodiments of the present subject matter, in such configurations, the thermal insulating separator assembly may be provided along the common venting channel, wherein the thermal insulating separator assembly comprises a first insulating layer and a second insulating layer bonded on either side of at least one of the support structures and positioned between the first battery module and the second battery module.

[0009] Positioning the assembly along the common venting channel simplifies integration within compact battery pack designs. Further, this arrangement allows the assembly to simultaneously intercept venting gases from both the battery modules, enhancing the efficiency of thermal management during the thermal runaway event.

[0010] The foregoing general description of the illustrative embodiments and the following detailed description thereof are merely exemplary aspects of the teachings of this disclosure and are not restrictive.BRIEF DESCRIPTION OF DRAWINGS

[0011] The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawings to reference like features and components.

[0012] Figure 1 illustrates a cross-sectional view of a battery module comprising a thermal insulating separator assembly, in accordance with an implementation of the present subject matter.

[0013] Figure 2A and 2B each illustrate a cross-sectional view of a battery module comprising the thermal insulating separator assembly, in accordance with an implementation of the present subject matter.

[0014] Figure 3A illustrates an exploded view of the first and the second battery modules having the thermal insulating separator assembly, in accordance with an implementation of the present subject matter.

[0015] Figure 3B and 3C illustrate an exploded side view and assembled front view of the thermal insulating separator assembly, respectively, in accordance with an implementation of the present subject matter.

[0016] Figure 3D illustrates an exploded side view of the thermal insulating separator assembly, in accordance with an implementation of the present subject matter.

[0017] Figure 4A and 4B each illustrate an exploded side view of the thermal insulating separator assembly, in accordance with an implementation of the present subject matter.

[0018] Figure 4C illustrates the assembled front view of the thermal insulating separator assembly, in accordance with an implementation of the present subject matter.DESCRIPTION OF EMBODIMENTS

[0019] The present subject matter relates to a thermal insulating separator for battery modules in a battery pack.

[0020] In an event of a thermal runaway, a battery cell, such as a lithium- ion cell, generates heat at a rate several times higher than the rate at which the heat can be dissipated and vents out gases at a very high pressure. The thermal runaway of the battery cell may cause thermal propagation in a batterymodule in which the battery cell is located and may cause thermal runaway to occur in one or more of the remaining cells within the battery module. The thermal propagation caused due to the continuous thermal runaway within the battery module may further lead to fire and explosion in the battery module.

[0021] Batteries, such as Lithium-ion batteries, have various uses due to their utility and advantages over other types of batteries. In an example, Lithium-ion batteries may be used in the Electric Vehicles (EVs). As the demand for batteries for EVs is increasing, there is also a growing need to make the EVs safer. An event such as the thermal propagation can be severely detrimental to the safety of a user of the electric vehicle. The battery modules used in the EVs are susceptible to thermal runaway, during which a malfunctioning cell emits high-temperature, high-pressure gases and flames.

[0022] In the existing battery pack designs, irrespective of whether the cell modules are arranged so that the cell vents face each other or are away from each other, one of the major issues is the risk of thermal propagation. During the thermal runaway, the heat and gases emitted from one cell in a module can directly impact one or more proximal cells of another module facing the cell vent of the cell experiencing a runaway event. As the cell vents can release gases with high force, it may cause a direct impact or damage to the proximal cells. The hot gases released from a cell during thermal runaway can exert significant pressure, which may lead to the rupture or damage of other components within the battery module due to the high-pressure venting. This can lead to the failure of the entire battery pack in some cases.

[0023] Depending on their configuration, the cells of the battery module could be bottom vented or top vented. When a cell is bottom vented, i.e. , the cell comprises a pressure release valve at the bottom of a cell which allows to vent out the hot gases from the bottom end of the cell in the event of thermal runaway. In the event of thermal runaway, the bottom of the cell can of thebottom vented cell ruptures, releasing the heat and the hot gases, and not the entire cell can.

[0024] Each battery module assembled in the battery pack comprises its separate passage for venting out hot gases dissipated from any of the cells in the respective battery module in the event of thermal runaway. However, before reaching the passage for venting out of hot gases, the hot gases released from the cell under pressure have the potential to damage the proximal cells facing the cell that released the hot gases. During thermal runaway, a malfunctioning battery cell can rapidly emit high-temperature, high- pressure gases, accompanied by visible flames. These high-energy discharges may inflict damage on proximate components, provoke cascading failures in neighbouring cells, or violate regulatory safety standards by permitting visible flames to escape a battery housing. The existing battery pack designs often fail to provide adequate measures for thermal insulation of such proximal cells as well as for protection of these cells from the impact that may be caused due to the hot gases. Further, even though current solutions have passive barriers to delay propagation, they frequently lack structural durability, volumetric efficiency, and multi-functionality.

[0025] Moreover, conventional systems need more flame arrestors, which increase their complexity and expense. Design restrictions are further tightened by government safety regulations that forbid visible flames outside battery casings. Thus, the existing battery pack designs are oftentimes not up to the required safety standards, and there is still a need for a compact, cost- effective, and simple venting solution that passively diffuses heat, suppresses flames, and withstands venting impact.

[0026] The present subject matter is related to a thermal insulating separator assembly for a battery. The assembly comprises at least one support structure having a first surface and a second surface and configured to extendto cover a venting surface of at least one battery module of the battery. The shape of the at least one support structure corresponds to the shape of the at least one battery module. The assembly further comprises at least one insulating layer bonded to at least one of the first surface and the second surface of at least one of the support structure. Further, the at least one of the support structure and the at least one insulating layer are arranged in a layered configuration to absorb an impact of venting gases from a cell vent of a cell of the at least one battery module in an event of a thermal runaway and the at least one insulating layer acts as a diffuser to diffuse the venting gases.

[0027] The claimed subject matter addresses the above-described technical problems by providing the thermal insulating separator assembly to prevent the transfer of heat and gases between cell modules during thermal runaway, while also offering impact resistance. The support structure absorbs the impact from a cell undergoing thermal runaway, and the insulating layer dampens the pressure exerted on the proximal cells. Additionally, the thermal insulating layers act not only as heat barriers but also as impermeable membranes that prevent hot gases from reaching cells in neighboring modules, thereby protecting them from both thermal and chemical damage.

[0028] The insulating layer, together with the support structure, creates a strong and durable thermal barrier. The support structure provides mechanical strength to withstand high-pressure impacts and heat released from cells in the event of thermal runaway. The assembly is flexible and adaptable to different battery pack sizes and shapes, and it also creates isolated compartments for each module. To simplify assembly and reduce subassembly complexity, the separator includes dedicated mountings such as fasteners and snap-fit connections.

[0029] The present subject matter is further described with reference to the accompanying figures. It should be noted that the description and figuresmerely illustrate the principles of the present subject matter. It is thus understood that various arrangements may be devised that, although not explicitly described or shown herein, encompass the principles of the present subject matter. Moreover, all statements herein reciting principles, aspects, and examples of the present subject matter, as well as specific examples thereof, are intended to encompass equivalents thereof.

[0030] Although embodiments for methods and systems for the present subject matter have been described in a language specific to structural features and / or methods, it is to be understood that the present subject matter is not necessarily limited to the specific features or methods described. Rather, the specific features and methods are disclosed as exemplary embodiments for the present subject matter.

[0031] In accordance with an example implementation of the present invention, Figure 1 illustrates a cross-sectional view of a battery module 100 comprising a thermal insulating separator assembly 102.

[0032] While this figure depicts a specific shape of the thermal insulating separator assembly 102, it will be clear to a person skilled in the art that the shape shown in the figure is not a limitation. Rather, the shape of the thermal insulating separator assembly 102 of the present invention is flexible with respect to the arrangement of the cells 104 in the battery module 100 and can be configured to be used in the battery pack of different shapes and sizes. In an example implementation, the thermal insulating separator 102 assembly for battery modules 100 may be used in a battery pack of electric vehicles.

[0033] While the embodiment depicted in Fig. 1 depicts a single battery module 100 with cells 104 arranged such that the cell vents are oriented perpendicular to the thermal insulating separator assembly 102, it will be appreciated that the thermal insulating separator assembly 102 may also be implemented in battery packs comprising two or more battery modules 100. Insuch implementations, each battery module 100 may be provided with a dedicated thermal insulating separator assembly 102, or a common thermal insulating separator assembly 102 may be implemented for two battery modules 100. Such example implementations are elaborated subsequently.

[0034] The thermal insulating separator assembly 102 comprises a support structure 106 having a surface and configured to extend over a venting surface of the battery module 100. The shape of the support structure 106 corresponds to the shape of the battery module 100, ensuring full coverage and compatibility. An insulating layer 108 is bonded to the surface of the support structure 106. The support structure 106 and the insulating layer 108 are arranged in a layered configuration to absorb the impact of venting gases released from a cell vent during a thermal runaway event. The insulating layer 108 also functions as a diffuser to diffuse the venting gases.

[0035] The support structure 106 is made of a thermally stable and corrosion-resistant metal. In an example, the metal is selected from a group consisting of aluminium alloys, stainless steel, titanium, copper alloys, and coated low-carbon steels. In various other example embodiments, it is also possible that the support structure is made of heat-resistant plastic, fiber material or composite material. The material used may be determined by the thermal performance of the application, weight limits, environmental exposure, and economic concerns. Aluminium alloys provide lightweight thermal resistance, stainless steel offers corrosion durability, and coated steels deliver cost-effective impact shielding.

[0036] The support structure 106 may include functional features such as perforations, corrugations, embossing, surface textures, or flow-directing structures to improve gas dispersion, energy absorption, and mechanical engagement with the insulating layer 108.

[0037] The insulating layer 108 is made of wool, and in other examples, may be made of any insulating material selected from a group consisting of mica, porcelain, PVC, paper, cardboard, and Teflon. In an embodiment, the wool may be high-temperature-resistant, porous fibrous materials such as ceramic wool, glass wool, mineral wool, basalt wool, or silica fibre mat, which can endure temperatures of 800°C to 1200°C. The wool acts as a first line of thermal defense, diffusing high-velocity vent gases while absorbing heat energy. This action efficiently reduces the temperature and pressure of the gases released during the thermal runaway before they reach the surrounding components. The porosity and fibre orientation of wool facilitate multidirectional expansion and improve the efficient dissipation of the gases.

[0038] The support structure 106 and the insulating layer 108 are stacked to form the thermal insulating separator assembly 102.

[0039] During the thermal runaway event, gases released from the cell vent of the cells 104 are captured by the insulating wool, which absorbs heat and facilitates gas diffusion to dissipate energy. This process reduces the temperature and velocity of the gases before they reach the lower structure of the battery module. The support structure 106 is placed behind the wool with respect to the direction of release of the gases and acts as a mechanical and thermal barrier, protecting the housing of the battery pack, vehicle chassis, and adjacent modules from damage. This layered configuration effectively achieves flame arrest, gas redirection, and impact energy absorption through a compact, passive, and manufacturable design.

[0040] In the embodiment shown in Figure 1 , the battery module 100 has bottom-vented cells 104, which release gases through the bottom vents during the thermal runaway event. In this configuration, the thermal insulating separator assembly 102 is positioned such that the insulating wool is positioned directly beneath the cell vents, such that it is the first point of contact for thegas vented out of the cells 104 during the thermal runaway event. The support structure 106 is located beneath the insulating layer 108 made of wool, functioning as both a structural and thermal barrier.

[0041] In general, the battery pack that powers electric vehicles consists of individual battery cells and the battery modules 100 organized in series and parallel. The battery module 100 consists of a plurality of cells 104 connected in series and / or parallel, encased in a mechanical structure. Examples of the cells used in the battery modules include but are not limited to the lithium-ion cell, the battery module 100 may use a Nickel-Cadmium cell, Nickel-metal hydride cell, dry cell, etc. The battery pack is assembled by connecting multiple battery modules 100 together in series or parallel. A thermal propagation caused due to the continuous thermal runaway within the battery module 100 may further lead to fire and explosion in the battery module 100. The thermal insulating separator assembly 102 serves to prevent such an eventuality, as elaborated later.

[0042] In an example embodiment, the support structure 106 may be integrated into a cell holder or a lower casing of the battery pack comprising the battery modules 100. In embodiments, the thermal insulating separator assembly 102, may be configured as a continuous panel, a cell-specific insert, or a modular diffuser assembly, depending on the layout and thermal zoning specifications of the battery module. Additionally, in an example embodiment, the thermal insulating separator assembly 102 may be integrated with the structural components of the battery module 100, including a top cell holder.

[0043] In accordance with an example implementation of the present invention, Figure 2A and 2B each illustrate a cross-sectional view of a battery module 100 comprising the thermal insulating separator assembly 102. These figures depict a first battery module 100-1 and a second battery module 100-2, collectively referred to as battery modules 100, positioned with their cell vents(not shown) facing each other. The thermal insulating separator assembly 102 is positioned between the first battery module 100-1 and the second battery module 100-2. The thermal separator assembly 102 uses fasteners to secure the thermal insulating separator assembly 102 onto the battery module 100. The thermal separator assembly 102 is sandwiched between two battery modules 100-1 and 100-2, with their cell vents facing each other. The insulating separator assembly 102 is positioned in such a way that it compartmentalizes each battery module and isolates them from the opposite or adjacent battery modules 100.

[0044] In accordance with embodiments of the present subject matter, each of the first battery module 100-1 and the second battery module 100-2 comprises an outlet port (not shown) which is in fluid communication with an integrated venting channel 202 of the battery modules 100. The integrated venting channel 202 plays a crucial role in guiding and venting out the hot gases from the battery modules 100 and also prevents thermal propagation. The venting channel 202 vents out the hot gases released from the cells 104 of the battery modules 100 via the outlet port, in the event of a thermal runaway.

[0045] In accordance with embodiments of the present subject matter, the placement of the insulating separator assembly 102 is such that it acts as a thermal barrier between two battery modules having cell vents facing each other. The insulating layer 108 is bonded on either side of the support structure 106 faces the cell vents and acts as a barrier, and prevents the venting gases released from any cell of the battery module 100 from entering the other cells 104 placed on the opposite side of the battery module 100. During an event of the thermal runaway, the high-pressure hot venting gases from the cell hit the insulating layer 108 of wool, which is positioned directly in the gas flow path to intercept the high-pressure gases. The support structure 106 is positioned behind the insulating layer 108 and can be flat, contoured, or modular to alignwith the enclosure design. The insulating layer 108 is present on either side of the support structure 106 to absorb the impact of high-pressure gases from the cells 104 of both battery modules 100. The high-pressure gases lose their energy after hitting the insulating layer 108 of the thermal insulating separator assembly 102 and are unable to further pierce the cell module placed on the opposite side. Further, the insulating separator assembly 102 deflects the high- pressure hot venting gases into the venting channel 202, which is then discarded into the outer environment through the outlet ports of the battery module 100, as depicted by arrows in Figure 2B.

[0046] As described previously, the support structure 106 may be integrated into the cell holder or the lower casing of the battery pack, comprising the battery modules 100. In an example, the thermal insulating separator assembly 102 can be mounted on the battery module 100 using conventional methods such as fasteners or snap-fit connections. Figures 2A and 2B depict the thermal insulating separator assembly 102 mounted on the cell holder of the battery modules 100.

[0047] In accordance with example embodiments described in the context of Figures 1 , 2A, 2B, 3A, 3B, 3C, and 3D, the support structure 106 is made of metal, such as stainless steel, and the insulating layer 108 is made of wool. In such embodiments, the metal plate may be electrically grounded to enhance EMI shielding or grounding capabilities. A perforated screen, mesh layer, or gas guide structure may be inserted between the wool and the plate to manage gas flow patterns, reduce backpressure, and enhance flame suppression performance. Further, the battery modules 100 comprise one or more busbars (not shown) to electrically interconnect the cells and are located near the top surface, potentially positioned adjacent to or above the metal plate, contingent upon the design of the battery module 100.

[0048] In accordance with an example implementation of the present invention, Figure 3A illustrates an exploded view of a battery pack comprising the first battery module 100-1 , the second battery module 100-2, and the thermal insulating separator assembly 102 sandwiched therebetween. This figure depicts a comprehensive layout of the battery modules 100, the thermal insulating separator assembly 102, and the associated structural components.

[0049] The housing 302 of the battery pack, as shown in the figure, encapsulates the battery modules 100 and serves as a protective enclosure against environmental exposure and external mechanical impact. Within the housing 302, a foam 304 element is provided, which corresponds to the shape of the housing 302 of the battery pack and provides cushioning support to the cell holder 306 of each battery module 100-1 and 100-2. Each battery module includes a dedicated cell holder 306-1 and 306-2 designed to secure the arrangement of cells. The cell holders 306 comprise mounting structures 308 that facilitate the installation of the thermal insulating separator assembly 102 within the battery modules 100.

[0050] As shown in the figure, the thermal insulating separator assembly 102 is positioned between the first battery module 100-1 and the second battery module 100-2. The cells 104 of the first battery module 100-1 are arranged such that their cell vents face the cell vents of the cells 104 of the second battery module 100-2. To cater to this orientation, the thermal insulating separator assembly 102 is positioned between the battery modules 100-1 and 100-2 to intercept and manage the venting gases released from either or both modules during the thermal runaway event.

[0051] The support structure 106 is mounted onto the cell holders 116-1 and 116-2 using fasteners 310, which are also depicted in the figure. The insulating layer 108 is bonded to the support structure 106 and is oriented to face the venting surfaces of both battery modules 100-1 and 100-2. The figurefurther shows the wire bonds 312 connecting the cells 104 within each battery module to create the electrical interconnections necessary for the battery modules 100 to operate.

[0052] In accordance with an example implementation of the present invention, Figure 3B and Figure 3C illustrate an exploded side view and assembled front view of the thermal insulating separator assembly 102, respectively. The thermal insulating separator assembly 102 comprises a support structure 106, which is a metal plate in the depicted embodiment, and two insulating layers 108 made of wool. A first insulating layer 108-1 is bonded to one side of the support structure 106, and a second insulating layer 108-2 is bonded to the opposite side to form a symmetrical layered configuration. This dual-layer arrangement, as shown in the figure, enhances the ability of the thermal insulating separator assembly 102 to absorb the impact of venting gases and diffuse them effectively during a thermal runaway event.

[0053] Further, as shown in the figure, the surface of the support structure may include features such as ridges and protrusions on both sides. These surface features enhance the interlocking between the support structure and the insulating layers. Additionally, the support structure 106 comprises multiple recesses 314 that allow venting gases to fill the space between the first battery module 100-1 and the second battery module 100-2, thereby reducing peak pressure, which eliminates the risk of any structural damage. Further, multiple holes are also present on the support structure 106 that are configured to receive fasteners 310 to enable secure mounting of the thermal insulating separator assembly 102 onto the cell holder 306 of the battery modules 100.

[0054] Figure 3C depicts the assembled front view of the thermal insulating separator assembly 102 and shows the integrated form after the insulatinglayers 108-1 and 108-2 have been bonded and the fasteners 310 have been used to join the insulating layers 108-1 and 108-2 with the support structure.

[0055] In accordance with an example implementation of the present invention, Figure 3D illustrates an exploded side view of the thermal insulating separator assembly 102. This figure shows each layer of the thermal insulating separator assembly 102 comprising the first insulating layer 108-1 and the second insulating layer 108-2, each bonded on either side of the support structure 106.

[0056] In accordance with an example implementation of the present invention, Figures 4A and 4B each illustrate an exploded side view of the thermal insulating separator assembly 102. In an alternative embodiment of the present subject matter, the thermal insulating separator assembly 102 comprises a support structure 106 made of plastic that is flexible and heat resistant. The support structure 106 has a thickness of 2-3 mm in one example. The support structure 106 has a thickness of 2.5 mm in one example. The support structure 106 can be made of any fire retardant (FR) grade plastic material, such as Polypropylene (PP), Polycarbonate acrylonitrile butadiene styrene (PC-ABS), or Polyamide 6 (PA6). The material for the support structure 106 is selected based on its mechanical strength, thermal stability, and compatibility with the thermal insulating sheets, i.e., the first insulating layer 108-1 and the second insulating layer 108-2.

[0057] As described previously, the first insulating layer 108-1 and the second insulating layer 108-2 are bonded on either side of the support structure 106. The first insulating layer 108-1 and the second insulating layer 108-2 are preferably made of any material which has high thermal resistance properties. Examples of the materials that may be used for making the first insulating layer 108-1 and the second insulating layer 108-2 of the thermal insulating separator assembly 102 include but are not limited to the Mica Sheets, and the thermalinsulating layers of any suitable insulating materials, such as porcelain, PVC, paper and cardboard, Teflon, etc. As will be evident, the choice of material to make the insulating layers 108-1 and 108-2, the composition, and the thickness of these sheets depend on design considerations, such as the size of the battery module and rating of the cells in the module, etc.

[0058] In one example, the insulating layers 108-1 and 108-2 can be made of Mica. The Mica used in the thermal insulating sheets has a thickness of 0.5- 1 .5 mm in one example. The Mica used in the insulating layers 108-1 and 108- 2 has a thickness of 1 mm in one example.

[0059] In an example, the first insulating layer 108-1 and the second insulating layer 108-2 are bonded to the support structure 106, using a thermal adhesive, to form a single structure of the thermal insulating separator assembly 102. In an example, the thermal conductive adhesive can be Epoxy adhesives, Silicone adhesives, Polyurethane adhesives, etc.

[0060] The combination of the support structure 106 and the thermal insulating layers 108 has a multipurpose use. The first insulating layer 108-1 and the second insulating layer 108-2 prevent heat and gases from directly transferring between the battery modules 100, and the support structure 106 provides structural rigidity to the thermal insulating separator assembly 102. The support structure 106, being made of a plastic material, is flexible and is able to absorb the impact that can occur due to the release of gases in the event of thermal runaway without substantial deformation in the support structure 106. This enables the support structure 106 to retain its shape and structural integrity to be able to support the remaining cells despite the occurrence of a thermal runaway in one or few cells 104 in the battery module 100.

[0061] In accordance with embodiments of the present subject matter, the thermal insulating separator assembly 102 is adaptable to be used with cellsand battery packs of different shapes and sizes. The structure of the insulating separator assembly 102 is such that it can be configured to accommodate battery packs of different shapes and sizes. The thermal insulating separator assembly 102 can be mounted on the battery module 100 using conventional methods such as fasteners or snap-fit connections 402, as also shown in Figures 4A and 4B.

[0062] In an example, the support structure 106 can be manufactured using various methods, including injection molding, extrusion, blow molding, etc. Details of conventional manufacturing steps / techniques have been skipped for the sake of brevity of the present description.

[0063] In accordance with an example implementation of the present invention, Figure 4C depicts the assembled front view of the thermal insulating separator assembly 102 and shows the final integrated form after the insulating layers 108 of mica sheets have been bonded to the support structure 106 by the snap-fit connection 402. Further, this figure shows multiple mounting features 404 present on the surface of the surface of thermal insulating separator assembly 102 to mount the assembly 102 onto the battery modules 100. These mounting features 404 are present on either side of the thermal insulating separator assembly 102.

[0064] In accordance with embodiments of the present subject matter, the use of the thermal insulating separator assembly 102 for the battery modules 100 is not limited to electric vehicles, the disclosed thermal insulating separator assembly 102 can be used in various applications that implement a battery pack, in high voltage in particular. For instance, apart from their application in the electric vehicles, the disclosed thermal insulating separator assembly 102 for the battery modules 100 can be also used in any electronic equipment. For example, in industrial applications, and a high-capacity power bank that offers uninterruptible power supply (UPS) capabilities.

[0065] In an example, thermal sensors, rupture membranes, or gas detection elements may be embedded within or adjacent to the thermal insulating separator assembly to facilitate the early detection and management of abnormal thermal events.

[0066] Although the subject matter has been described in considerable detail with reference to certain examples and implementations thereof, other implementations are possible. As such, the present disclosure should not be limited to the description of the preferred examples and implementations contained therein.

Claims

I / We Claim:

1. A thermal insulating separator assembly (102) for a battery, said assembly comprising: at least one support structure (106) having a first surface and a second surface and configured to extend to cover a venting surface of at least one battery module (100) of the battery, wherein shape of the at least one support structure (106) corresponds to the shape of the at least one battery module (100); at least one insulating layer (108) bonded to at least one of the first surface and the second surface of at least one of the support structure (106), wherein at least one of the support structure (106) and the at least one insulating layer (108) are arranged in a layered configuration to absorb an impact of venting gases from a cell vent of a cell (104) of the at least one battery module (100) in an event of a thermal runaway, and wherein the at least one insulating layer (108) acts as a diffuser to diffuse the venting gases.

2. The assembly (102) as claimed in claim 1 , wherein the at least one support structure (106) is made of a thermally stable and corrosion-resistant metal and the at least one insulating layer (108) is made of insulating wool.

3. The assembly (102) as claimed in claim 2, wherein the metal is selected from a group consisting of aluminium alloys, stainless steel, titanium, copper alloys, and coated low-carbon steels.

4. The assembly (102) as claimed in claim 1 , wherein the at least one support structure (106) is made of a thermally stable and fire-retardant (FR) grade plastic material and the at least one insulating layer (108) is made of mica.

5. The assembly (102) as claimed in claim 4, wherein the FR grade plastic is selected from a group consisting of Polypropylene (PP), Polycarbonate acrylonitrile butadiene styrene (PC-ABS), and Polyamide 6 (PA6).

6. The assembly (102) as claimed in claim 1 , wherein the at least one insulating layer (108) is made of any insulating material selected from a group consisting of wool, Mica, Porcelain, PVC, paper, cardboard, and Teflon.

7. The assembly (102) as claimed in claim 1 , wherein the at least one battery modules (100) comprise a first battery module (100-1) and a second battery module (100-2), wherein each of the first battery module (100-1) and the second battery module (100-2) comprises cells (104) arranged such that the cell vents of the cells (104) in the first battery module (100-1) face the cell vents of the cells (104) in the second battery module (100-2), and wherein the at least one insulating layer (108) comprises a first insulating layer (108-1 ) and a second insulating layer (108-2) bonded on either sides of at least one of the support structure (106) and positioned between the first battery module (100- 1) and the second battery module (100-2).

8. The assembly (102) as claimed in claim 1 , wherein the at least one battery modules (100) comprise a first battery module (100-1 ) stacked above a second battery module (100-2), each comprising cells (104) arranged such that the cell vents of the cells (104) in the first battery module (100-1) face opposite to the cell vents of the cells (104) in the second battery module (100-2), and wherein the at least one support structure (106) comprises a first support structure for the first battery module (100-1 ) and a second support structure for the second battery module (100-2), each of the support structure (106) having an insulating layer (108) bonded on the side facing the cell vents of the cells (104) of the respective module, wherein the assembly (102) is positioned in a direction of the cell vents of the first battery module (100-1 ) and the second battery module (100-2).

9. The assembly (102) as claimed in claim 1 , wherein the at least one insulating layer (108) is bonded to the support structure (106) using a high- temperature-resistant adhesive selected from the group consisting of epoxy adhesives, silicone adhesives, and polyurethane adhesives.

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