WO2024107321A1 - Structure et procédé d'isolation et de conduction thermique - Google Patents

Structure et procédé d'isolation et de conduction thermique Download PDF

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Publication number
WO2024107321A1
WO2024107321A1 PCT/US2023/036006 US2023036006W WO2024107321A1 WO 2024107321 A1 WO2024107321 A1 WO 2024107321A1 US 2023036006 W US2023036006 W US 2023036006W WO 2024107321 A1 WO2024107321 A1 WO 2024107321A1
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WO
WIPO (PCT)
Prior art keywords
battery module
thermal insulation
insulation layer
central separator
opposing
Prior art date
Application number
PCT/US2023/036006
Other languages
English (en)
Inventor
John Williams
Lixin Wang
Original Assignee
Aspen Aerogels, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Aspen Aerogels, Inc. filed Critical Aspen Aerogels, Inc.
Priority to CN202311540140.3A priority Critical patent/CN118054136A/zh
Publication of WO2024107321A1 publication Critical patent/WO2024107321A1/fr

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/61—Types of temperature control
    • H01M10/613—Cooling or keeping cold
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/65—Means for temperature control structurally associated with the cells
    • H01M10/655—Solid structures for heat exchange or heat conduction
    • H01M10/6551—Surfaces specially adapted for heat dissipation or radiation, e.g. fins or coatings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/65—Means for temperature control structurally associated with the cells
    • H01M10/658—Means for temperature control structurally associated with the cells by thermal insulation or shielding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H01M50/207—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/218—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material
    • H01M50/22—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material of the casings or racks
    • H01M50/222—Inorganic material
    • H01M50/224—Metals
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/289—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs
    • H01M50/291—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs characterised by their shape
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/289—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs
    • H01M50/293—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs characterised by the material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Definitions

  • the present disclosure further relates to a battery module or pack with one or more battery cells that includes the thermal barrier materials, as well as systems including those battery modules or packs. Examples described generally may include aerogel materials.
  • LIBs 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.
  • 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 and high pressure.
  • FIG. 1 shows a battery system in accordance with some example aspects.
  • FIG. 2 shows a side view of a battery module in accordance with some example aspects.
  • FIG. 3 shows another battery module in accordance with some example aspects.
  • FIG. 4 shows another battery module in accordance with some example aspects.
  • FIG. 5A shows a battery module in accordance with some example aspects.
  • FIG. 5B shows a battery module in accordance with some example aspects.
  • FIG. 5C shows a battery module in accordance with some example aspects.
  • FIG. 6 shows another battery module in accordance with some example aspects.
  • FIG. 7A shows another battery module in accordance with some example aspects.
  • FIG. 7B shows another battery module in accordance with some example aspects.
  • FIG. 8 shows another battery module in accordance with some example aspects.
  • FIG. 9 shows a portion of a separator in accordance with some example aspects.
  • FIG. 10 shows another portion of a separator in accordance with some example aspects.
  • FIG. 11 shows an electronic device in accordance with some example aspects. [0018] FIG.
  • FIG. 12 shows an electric vehicle in accordance with some example aspects.
  • Atty. Dkt. No.6089.004WO1 / Client Ref. No.1162-WO01 Description of Aspects [0019] The following description and the drawings sufficiently illustrate specific aspects to enable those skilled in the art to practice them. Other aspects may incorporate structural, logical, electrical, process, and other changes. Portions and features of some aspects may be included in, or substituted for, those of other aspects. Aspects set forth in the claims encompass all available equivalents of those claims. [0020] Insulation materials, as described in examples below, can be used as a single heat resistant 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 safety and prevention of fire propagation for such products in the fields of electronic, industrial and automotive technologies.
  • 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.
  • 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.
  • Thermal Barrier Insulation Materials [0022]
  • One example 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 m 2 /g or higher) and subnanometer scale pore sizes. The pores may be filled with gases such as air. Aerogels can be distinguished from other porous materials by their physical and structural properties. Although an aerogel material is an exemplary insulation material, the invention is not so limited. Other thermal insulation material layers may also be used in examples of the present disclosure. [0023] Selected examples of aerogel formation and properties are described. In several examples, a precursor material is gelled to form a network of pores that are filled with solvent. The solvent is then extracted, leaving Atty. Dkt. No.6089.004WO1 / Client Ref.
  • 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.
  • Inorganic aerogels may be formed from metal oxide or metal alkoxide materials. The metal oxide or metal alkoxide materials may be based on oxides or alkoxides of any metal that can form oxides.
  • Such metals include, but are not limited to silicon, aluminum, titanium, zirconium, hafnium, yttrium, vanadium, cerium, and the like.
  • Inorganic silica aerogels are traditionally made via the hydrolysis and condensation of silica-based alkoxides (such as tetraethoxylsilane), or via gelation of silicic acid or water glass.
  • 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.
  • metal silicates such as sodium silicate or potassium silicate
  • pre-hydrolyzed TEOS such as Silbond H-5 (SBH5, Silbond Corp), which is hydrolyzed with a water/silica ratio of about 1.9-2
  • TEOS such as Silbond H-5 (SBH5, Silbond Corp)
  • Silbond 40 polyethysilicate
  • polymethylsilicate may also be used as commercially available or may be further hydrolyzed prior to incorporation into the gelling process.
  • Inorganic aerogels can also include gel precursors comprising at least one hydrophobic group, such as alkyl metal alkoxides, cycloalkyl metal alkoxides, and aryl metal alkoxides, which can impart or improve certain properties in the gel such as stability and hydrophobicity.
  • Inorganic silica aerogels can specifically include hydrophobic precursors such as alkylsilanes or Atty. Dkt. No.6089.004WO1 / Client Ref. No.1162-WO01 arylsilanes. Hydrophobic gel precursors may be used as primary precursor materials to form the framework of a gel material.
  • hydrophobic gel precursors are more commonly used as co-precursors in combination with simple metal alkoxides in the formation of amalgam aerogels.
  • Hydrophobic inorganic precursor materials for silica based aerogel synthesis include, but are not limited to trimethyl methoxysilane (TMS), dimethyl dimethoxysilane (DMS), methyl trimethoxysilane (MTMS), trimethyl ethoxysilane, dimethyl diethoxysilane (DMDS), methyl triethoxysilane (MTES), ethyl triethoxysilane (ETES), diethyl diethoxysilane, dimethyl diethoxysilane (DMDES), ethyl triethoxysilane, propyl trimethoxysilane, propyl triethoxysilane, phenyl trimethoxysilane, phenyl triethoxysilane (PhTES), hexamethyldisilazane and hexa
  • Organic aerogels are generally formed from carbon-based polymeric precursors.
  • polymeric materials include, but are not limited to resorcinol formaldehydes (RF), polyimide, polyacrylate, polymethyl methacrylate, acrylate oligomers, polyoxyalkylene, polyurethane, polyphenol, polybutadiane, trialkoxysilyl-terminated polydimethylsiloxane, polystyrene, polyacrylonitrile, polyfurfural, melamine-formaldehyde, cresol formaldehyde, phenol-furfural, polyether, polyol, polyisocyanate, polyhydroxybenze, polyvinyl alcohol dialdehyde, polycyanurates, polyacrylamides, various epoxies, agar, agarose, chitosan, and combinations thereof.
  • RF resorcinol formaldehydes
  • polyimide polyacrylate
  • polymethyl methacrylate acrylate oligomers
  • organic RF aerogels are typically made from the sol-gel polymerization of resorcinol or melamine with formaldehyde under alkaline conditions.
  • 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(OX)4.
  • 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, Atty. Dkt. No.6089.004WO1 / Client Ref. No.1162-WO01 vinyl, epoxide, and the like.
  • the organic components in ormosil aerogel may also be dispersed throughout or chemically bonded to the silica network. [0029] Aerogels can be formed from flexible gel precursors.
  • One method of aerogel formation includes batch casting. Batch casting includes catalyzing one entire volume of sol to induce gelation simultaneously throughout that volume. Gel-forming techniques include adjusting the pH and/or temperature of a dilute metal oxide sol to a point where gelation occurs. Suitable materials for forming inorganic aerogels include oxides of most of the metals that can form oxides, such as silicon, aluminum, titanium, zirconium, hafnium, yttrium, vanadium, and the like.
  • an aerogel may be organic, inorganic, or a mixture thereof.
  • the aerogel includes a silica-based aerogel.
  • One or more layers in a thermal barrier may include a reinforcement material.
  • the reinforcing material may be any material that provides resilience, conformability, or structural stability to the aerogel material.
  • 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.
  • the reinforcement material can be selected from organic polymer-based fibers, inorganic fibers, carbon-based fibers or a combination thereof.
  • the inorganic fibers are selected from glass fibers, rock fibers, metal fibers, boron fibers, ceramic fibers, basalt fibers, or combination thereof.
  • the reinforcement material can include a reinforcement including a plurality of layers of material.
  • Atty. Dkt. No.6089.004WO1 / Client Ref. No.1162-WO01 Overview of Carrier Frame Structures [0033]
  • structures described herein provide numerous benefits to the assembly and operation of battery packs.
  • the use of a carrier frame, as described below can provide a dimensionally consistent and durable frame to contain battery cells, particularly pouch cells which have a flexible outer structure that contains the electrochemically active materials. This type of structure enables modern manufacturing techniques and also enables precision in the dimensions of the battery pack and its components.
  • thermal management may include one or more of cooling (e.g., via conductive, convection, forced or passive cooling) and insulation.
  • 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.
  • a thermally conductive layer or layers helps to dissipate heat away from a localized heat load within a battery module or pack.
  • high thermal conductivity materials include carbon fiber, graphite, silicon carbide, metals including but not limited to copper, stainless steel, aluminum, and the like, as well as combinations thereof.
  • 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.
  • 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.
  • at least one thermally conductive layer of the multilayer materials disclosed herein can be in thermal communication with other elements of the Atty. Dkt. No.6089.004WO1 / Client Ref. No.1162-WO01 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.
  • FIG. 1 shows one example of a battery system 100.
  • the system 100 includes one or more battery modules 102.
  • each module includes a carrier frame and two batteries as indicated by the dashed square 106.
  • a heat sink 104 is shown located on a side of the system 100, and in thermal communication with the battery modules 102.
  • FIG. 2 shows a cross section of a portion of a battery module 200 similar to battery module 102 in the dashed square 106 of Figure 1.
  • the battery module 200 includes a carrier frame 202, a central separator 208, a first battery 210, a second battery 212 are shown.
  • the carrier frame 202 in some aspects, provides physical containment for pouch cells, which have a flexible outer surface. The flexible outer surface of the pouch cell, absent a containing structure, presents assembly challenges that overcome by the aspects described herein.
  • the carrier frame 202 may also provide additional benefits, such as managing the thermal conditions within a battery pack.
  • the carrier frame 202 includes a first cavity 204 and a second cavity 206.
  • the first cavity 204 and the second cavity 206 may be disposed on opposite sides of the central separator 208 in some aspects.
  • the first cavity 204 and the second cavity 206 may be configured and dimensioned (e.g., based on the dimensions of the central separator 208 and Atty. Dkt. No.6089.004WO1 / Client Ref. No.1162-WO01 other features of the carrier frame 202) to receive the first battery 210 and the second battery 212.
  • the first battery 210 and the second battery 212 are shown located at least partially within the a first cavity 204 and the second cavity 206.
  • the batteries 210, 210 are lithium ion pouch cells, although the invention is not so limited.
  • W h i l e lithium ion pouch cells are frequently used in electric vehicle battery modules, other examples of batteries that may be held by the carrier frame 202 (e.g., via dimensioning and configuring the structure defining first cavity 204 and the second cavity 206) include prismatic cells, cylindrical cells, among others.
  • Figure 3 shows a battery module 300 similar to similar to battery module 102 from Figure 1.
  • the module 300 includes a carrier frame 302, a first cell 310 in corresponding first cavity, a second cell 312 in a corresponding second cavity, a central separator 320, a thermal insulation layer 322, a first metal plate 324, a second metal plate 326, a first heat sink 330, and a second heat sink 332.
  • the battery module 300 employs conductive materials (e.g., metals, graphite) as the carrier frame 302. Conductive materials may also be used within some components of the central separator 320, and heat sinks 330, 332 to conduct heat away from cells 310, 312 and into the heat sinks 330, 332.
  • thermal insulation layer 322 provides a level of safety in the event of a thermal runaway in one or more of the cells 310, 312 by reducing heat transfer between adjacent cells.
  • thermal conduction from the opposing metal plates 324 and 326 and the carrier frame 302 help to cool the cells 310, 312.
  • the central separator 320 provides both cooling to improve battery performance, and safety from the thermal insulation layer 322.
  • the carrier frame 302 and the central separator 320 are dimensioned and configured to define the first cavity and the second cavity, both of which are occupied by corresponding first and second cells 310, 312 in Figure 3.
  • the description of the carrier frame, the central separator, and the first and second cavities, and other features, presented above are equally applicable to their corresponding features in the module 300.
  • Atty. Dkt. No.6089.004WO1 / Client Ref. No.1162-WO01 [0045]
  • the first cell 310 and the second cell 312 are disposed within the first cavity and the second cavity, respectively, as described above.
  • the central separator 320 functions as a heat sink and a heat transfer barrier, thereby conducting heat away from hot spots within a cell and preventing the undesired transfer of heat from one cell to another. By one or both of these mechanisms, the central separator 320 prevents thermal events from spreading from one cell to another cell.
  • the central separator 320 may have sufficient mechanical integrity to resist (for 30 seconds, for 1 minute, for 5 minutes) the degrading effects of ejecta from a cell (e.g., cell 310, 312) in thermal runaway, thereby preventing the ejecta from damaging and/or igniting an adjacent cell.
  • the central separator 320 of the module 300 is a multi-component structure. Aspects in which a central separator 320 are fabricated from multiple layers may accomplish multiple design goals more efficiently than single-layer configurations.
  • the central separator 320 may prevent the undesired transfer of heat between cells, facilitate the conductive transfer of heat from one or more cells to a heat sink, and provided added protection to cells from the damaging exposure to ejecta from an adjacent cell experiencing thermal runaway.
  • the thermal insulation layer 322 has a low thermal conductivity (e.g., on the order of 40 milliWatts/meter-Kelvin) to prevent undesired heat transfer between adjacent cells.
  • the thermal insulation layer 322 may be fabricated from an aerogel material and/or a reinforced aerogel material.
  • the opposing metal plates 324 and 326 may be fabricated from a known thermal conductor. In some aspects, the opposing metal plates 324, 326 may have a thermal conductivity of at least 50 Watts/meter-Kelvin. In some aspects, the opposing metal plates 324, 326 may be Atty. Dkt. No.6089.004WO1 / Client Ref.
  • the opposing metal plates 324 and 326 may include graphite plates, graphite or carbon coated metal plates, polymer plates filled with metallic or conductive particles and/or metallic or conductive fibers, or other analogous composite materials.
  • one aspect of the metal plates 324, 326 is to conduct heat from the cells.
  • the first heat sink 330 and the second heat sink 332 are shown in thermal contact with the carrier frame 302, and more specifically, metal plates 324, 326 of the central separator 320.
  • Figure 4 shows a battery system 400 similar to battery system 100 of Figure 1 and similar to battery module 300 of Figure 3.
  • the system 400 includes a first cell 410, a second cell 412, a carrier frame 402, and a central separator 420, and a heat sink 430.
  • the system 400 includes a first cavity and a second opposing cavity similar to aspects described above.
  • any of the modules described herein may include a single heat sink, as is illustrated in Figure 4.
  • the single heat sink 430 is in thermal communication with an “L” shaped metal plates 424, 426 that provide a conduction pathway that removes heat generated by cells 410, 412.
  • any of the modules described herein may alter the insulative characteristics of the central separator 420 by including one or more air gaps 428, 429 adjacent to the thermal insulation layer 422, as is shown in Figure 4.
  • the central separator 420 thus includes an insulation layer 422, with opposing major surfaces at least partially exposed by a corresponding air gap 428, 429.
  • the air gaps 428, 429 are at least partially defined by the insulation layer 422 on one side and a portion of the “L-shaped” metal plates 424, 426 on another side.
  • the central separator 420 is part of (i.e., integral with, attached to, mounted on) the carrier frame 402.
  • the carrier frame 402 may be an assembly of the metal plate 424, 426 and optionally the central separator 420.
  • the central separator 420 in Figure 4 includes a thermal insulation layer 422 included between opposing metal plates 424 and 426. The preceding descriptions of the materials used to fabricate the thermal insulation layer and the metal plates are equally applicable to the analogous elements in Figure 4.
  • the central separator 420 further includes one or more air gaps 428, 429 between the thermal insulation layer 422 and the opposing metal plates 424 and 426. The inclusion of one or more air gaps 428, 429 provides increased thermal isolation between the first cell 410 and the second cell 412, while still providing thermal conduction through the opposing metal plates 424 and 426 and the carrier frame 402 to a heat sink 430.
  • Figure 5A shows a side view of a portion of a battery module 520 similar to the previously described battery modules.
  • the module 520 includes a battery 522, and a central separator 521, first fins 526, second fins 527.
  • the central separator 521 is composed of (at least in part) a thermal insulator 524, and a conductor plate 530.
  • the central separator 521 may be included between two batteries in a module as shown in Figures 3 and 4, although the invention is not so limited.
  • the thermal insulation 422 includes an aerogel material. Other thermal insulation materials are also within the scope of the invention.
  • one or more fins 526 are included with the conductor plate 530. In some aspects, the one or more fins 526 are integral with the conductor plate 530, whether formed from the conductor plate itself 530 or formed separately and later mounted on the conductor plate 530. Regardless of the continuity and/or connection between the conductor plate 530 and the one or Atty. Dkt.
  • the fins 526 are part of a regular textured pattern. In one example, the fins 526 are part of an irregular textured pattern.
  • a second fin 527 is a different size and shape from fin 526, as indicated by respective dimensions (e.g., fin height) E and D ⁇ In one aspect, E is greater than D.
  • Figure 5C further shows a top view 500 of the conductor plate 530 and fins 526, 527.
  • the textured pattern includes a lengthwise orientation indicated by arrows 504 that preferentially conducts heat towards a heat sink such as the heat sinks described in Figures 3 and 4 when in operation.
  • the lengthwise orientation is perpendicular to the largest surface of the heat sink.
  • coolant as a liquid or gas such as air may be used to flow through the fins 526 to provide additional cooling capacity.
  • the conductor plate 530 and textured pattern are concentrated or only located over known hot spots on batteries in a module.
  • the textured pattern is anisotropic, and concentrates heat removal from known hot spots on batteries in a module.
  • the conductor plate 530 and textured pattern cover an entire surface adjacent to a battery in a module.
  • Figure 6 shows a side view of a portion of a battery module 620.
  • the module 620 includes a battery 622 and a central separator 621.
  • the central separator 621 may be included between two batteries in a module as shown in Figures 3, 4, and 5A although the invention is not so limited.
  • the central separator 621 includes a conductor plate 630 having textured pattern.
  • the textured pattern includes fins 626 and gaps 624.
  • Figure 6 further shows a plan view 600 of the conductor plate 630 and fins 626.
  • the conductor plate 630 is shown in thermal communication with a heat sink 602.
  • the textured pattern includes a lengthwise orientation indicated by arrows 604 that preferentially conducts heat towards the heat sink 602 when in operation. Atty. Dkt. No.6089.004WO1 / Client Ref. No.1162-WO01
  • Figure 7A shows a battery module 700 similar to similar to battery module 102 from Figure 1.
  • the module 700 includes a first battery 710 and a second battery 712.
  • a central separator 711 is shown between the first battery 710 and the second battery 712.
  • the central separator 711 may be used as part of a carrier frame similar to other examples described.
  • the central separator 711 includes opposing metal plates 702, 704 with a thermal insulation layer 708 between the opposing metal plates 702, 704.
  • the thermal insulation 708 includes an aerogel material.
  • Other thermal insulation materials are also within the scope of the invention.
  • a number of fins 706 are shows as part of a textured pattern on the opposing metal plates 702, 704. The fins 706 may be oriented as described in examples above to preferentially conducts heat towards a heat sink such as the heat sinks described in Figures 3 and 4 when in operation.
  • the fins 706 in Figure 7A are offset with one another to provide greater compression range of the thermal insulation layer without contact between the textured patterns.
  • batteries 712, 712 may expand, and require space to expand into.
  • the thermal insulation layer 708 is resilient and can compress and expand as needed while the opposing metal plates 702, 704 flex to accommodate the expansion and contraction.
  • the offset of the fins allows added expansion and contraction while still providing conducts heat towards a heat sink as described.
  • Figure 7B shows a battery module 720 similar to similar to battery module 102 from Figure 1.
  • the module 720 includes a first battery 722 and a second battery 724.
  • a central separator 721 is shown between the first battery 722 and the second battery 724.
  • the central separator 721 may be used as part of a carrier frame similar to other examples described.
  • opposing metal plates are omitted and only a number of fins 726 are used to conduct heat towards a heat sink when in operation.
  • a thermal insulation 728 is shown between the textured pattern of the fins 726.
  • the thermal insulation 708 includes an aerogel material. Other thermal insulation materials are also within the scope of the invention.
  • a thermal insulation conforms to the textured pattern. Similar to the example of Figure7A, in Figure 7B, the fins 726 are offset with one another to provide Atty. Dkt.
  • FIG. 8 shows a side view of a portion of a battery module 820 similar to battery module 102 from Figure 1.
  • the module 820 includes a battery 822 and a central separator 821.
  • the central separator 821 may be included between two batteries in a module as shown in other examples, although the invention is not so limited.
  • the central separator 821 includes a conductor plate 830 having textured pattern.
  • the textured pattern includes fins 826 and gaps 824.
  • a thermal insulation 825 is shown between the textured pattern of the fins 826.
  • the thermal insulation 825 includes an aerogel material. Other thermal insulation materials are also within the scope of the invention.
  • the thermal insulation 825 conforms to the textured pattern.
  • Figure 8 further shows a top view 800 of the conductor plate 830 and fins 826.
  • the conductor plate 830 is shown in thermal communication with a heat sink 802.
  • the textured pattern includes a lengthwise orientation similar to orientations described in other examples that preferentially conducts heat towards the heat sink 802 when in operation.
  • Figures 9 and 10 show other examples of textured patterns that may be used as components of central separators described.
  • Figure 9 shows a side view of a portion of a battery module 920.
  • Figure 9 further shows a top view 900 of a conductor plate 902 with a number of fins 904.
  • the number of fins 904 include rounded tops.
  • Figure 10 shows a side view of a portion of a battery module 1020.
  • Figure 10 further shows a top view 1000 of a conductor plate 1002 with a number of cavities 1004.
  • a conductor plate 1002 is shown with a number of cavities 1004 that form a textured pattern.
  • textured patterns as described provide added expansion and contraction with a central separator to allow for battery expansion and contraction.
  • Battery modules 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.
  • the battery Atty. Dkt. No.6089.004WO1 / Client Ref. No.1162-WO01 module 1110 and circuitry 1112 are contained in a housing 1102.
  • a charge port 1114 is shown coupled to the battery module 1110 to facilitate recharging of the battery module 1110 when needed.
  • 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, navigation systems, etc.
  • Figure 12 illustrates another electronic system that utilizes battery modules that include multilayer thermal barriers as described above.
  • the electric vehicle 1200 includes a chassis 1202 and wheels 1232. In the example shown, each wheel 1232 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.
  • 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 is not so limited. For example, two wheeled vehicles such as motorcycles and scooters are also within the scope of the invention.
  • Example 1 includes a battery module.
  • the module includes a carrier frame having a pair of opposing cavities to house batteries, a central separator region between the pair of opposing cavities, and a thermal insulation layer included within the central separator region.
  • Example 2 includes the battery module of Example 1, wherein the thermal insulation layer includes an aerogel material.
  • Example 3 includes the battery module of any one of Examples 1- 2, wherein the central separator includes opposing metal plates with the thermal insulation layer between the opposing metal plates. Atty. Dkt. No.6089.004WO1 / Client Ref.
  • Example 4 includes the battery module of any one of Examples 1- 3, wherein the thermal insulation layer is resilient, and wherein the opposing metal plates are flexible.
  • Example 5 includes the battery module of any one of Examples 1- 4, further including an air gap between the thermal insulation layer and the central separator region.
  • Example 6 includes the battery module of any one of Examples 1- 5, wherein the carrier frame and central separator region include metal.
  • Example 7 includes the battery module of any one of Examples 1- 6, wherein the carrier frame and central separator region are an integral metal casting.
  • Example 8 includes battery module.
  • the module includes a carrier frame having a pair of opposing cavities, a pair of pouch batteries in the pair of opposing cavities, a central separator between the pair of opposing cavities, wherein the central separator includes a textured pattern in one or more opposing major surfaces of the central separator, and a thermal insulation layer included between the pair of opposing cavities.
  • Example 9 includes the battery module of Example 8, wherein the textured pattern includes fins.
  • Example 10 includes the battery module of any one of Examples 8-9, wherein the fins include rounded tops.
  • Example 11 includes the battery module of any one of Examples 8-10, wherein the textured pattern includes an array of circular cavities.
  • Example 12 includes the battery module of any one of Examples 8-11, wherein the thermal insulation layer conforms to the textured pattern.
  • Example 13 includes the battery module of any one of Examples 8-12, further including a heat sink in thermal communication with a side of the carrier frame, and wherein the textured pattern includes a lengthwise orientation that preferentially conducts heat towards the heat sink when in operation.
  • Example 14 includes the battery module of any one of Examples 8-13, wherein the thermal insulation layer includes an aerogel material.
  • Example 15 includes the battery module of any one of Examples 8-14, wherein the central separator includes opposing metal plates with the thermal insulation layer between the opposing metal plates. Atty. Dkt. No.6089.004WO1 / Client Ref.
  • Example 16 includes the battery module of any one of Examples 8-15, wherein the textured pattern is included on interior surfaces of each of the opposing metal plates.
  • Example 17 includes the battery module of any one of Examples 8-16, wherein the textured pattern on each of the opposing metal plates are offset with one another to provide greater compression range of the thermal insulation layer without contact between the textured patterns.
  • Example 18 includes the battery module of any one of Examples 8-17, wherein the thermal insulation layer conforms to the textured pattern on each of the opposing metal plates.
  • 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 in combination with each other.
  • first contact could be termed a second contact
  • second contact could be termed a first contact
  • the first contact and the second contact are both contacts, but they are not the same contact.
  • the terminology used in the description of the example aspects herein is for the purpose of describing particular example aspects only and is not intended to be limiting. As used in the description of the example aspects 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.
  • phrase “if it is determined” or “if [a stated condition or event] is detected” may be construed to mean “upon determining” or “in response to determining” or “upon detecting [the stated condition or event]” or “in response to detecting [the stated condition or event],” depending on the context.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Inorganic Chemistry (AREA)
  • Battery Mounting, Suspending (AREA)

Abstract

L'invention concerne un module de batterie et des procédés associés. Dans un exemple, un module de batterie comprend un cadre de support et un séparateur central. Les modules de batterie sont représentés avec un séparateur central qui comprend un motif texturé dans une ou plusieurs surfaces principales opposées. Les modules de batterie sont représentés avec un séparateur central qui comprend une couche d'isolation thermique en tant que partie d'un séparateur central. Des modules de batterie sont représentés avec une couche d'isolation thermique d'aérogel.
PCT/US2023/036006 2022-11-17 2023-10-26 Structure et procédé d'isolation et de conduction thermique WO2024107321A1 (fr)

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US202263426306P 2022-11-17 2022-11-17
US63/426,306 2022-11-17

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN106025126A (zh) * 2016-05-27 2016-10-12 苏州太浦新能源科技有限公司 一种高效热管理汽车动力电池包
DE102020101018A1 (de) * 2020-01-17 2021-07-22 Audi Aktiengesellschaft Batteriegehäuse mit einer Kühlfluidführungsvorrichtung für ein Batteriesystem sowie ein Kühlsystem und ein Kraftfahrzeug hierzu
CN115295946A (zh) * 2022-08-16 2022-11-04 小米汽车科技有限公司 电池包和热失控防护设计方法

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN106025126A (zh) * 2016-05-27 2016-10-12 苏州太浦新能源科技有限公司 一种高效热管理汽车动力电池包
DE102020101018A1 (de) * 2020-01-17 2021-07-22 Audi Aktiengesellschaft Batteriegehäuse mit einer Kühlfluidführungsvorrichtung für ein Batteriesystem sowie ein Kühlsystem und ein Kraftfahrzeug hierzu
CN115295946A (zh) * 2022-08-16 2022-11-04 小米汽车科技有限公司 电池包和热失控防护设计方法

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