Patent Description:
The present disclosure relates generally to materials and 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 barrier materials. 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.

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 and high pressure. 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.

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.

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.

In many 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.

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 <NUM><NUM>/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.

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 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.

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

In certain aspects of the present disclosure, pre-hydrolyzed TEOS, such as Silbond H-<NUM> (SBH5, Silbond Corp), which is hydrolyzed with a water/silica ratio of about <NUM>-<NUM>, 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 <NUM>) or 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 arylsilanes. Hydrophobic gel precursors may be used as primary precursor materials to form the framework of a gel material. However, hydrophobic gel precursors are more commonly used as co-precursors in combination with simple metal alkoxides in the formation of amalgam aerogels. Hydrophobic inorganic precursor materials for silica based aerogel synthesis include, but are not limited to trimethyl methoxysilane (TMS), dimethyl dimethoxysilane (DMS), methyl trimethoxysilane (MTMS), trimethyl ethoxysilane, dimethyl diethoxysilane (DMDS), methyl triethoxysilane (MTES), ethyl triethoxysilane (ETES), diethyl diethoxysilane, dimethyl diethoxysilane (DMDES), ethyl triethoxysilane, propyl trimethoxysilane, propyl triethoxysilane, phenyl trimethoxysilane, phenyl triethoxysilane (PhTES), hexamethyldisilazane and hexaethyldisilazane, and the like. Any derivatives of any of the above precursors may be used and specifically certain polymeric of other chemical groups may be added or cross-linked to one or more of the above precursors.

Organic aerogels are generally formed from carbon-based polymeric precursors. Such polymeric materials include, but are not limited to resorcinol formaldehydes (RF), polyimide, polyacrylate, polymethyl methacrylate, acrylate oligomers, polyoxyalkylene, polyurethane, polyphenol, polybutadiane, trialkoxysilyl-terminated polydimethylsiloxane, polystyrene, polyacrylonitrile, polyfurfural, melamine-formaldehyde, cresol formaldehyde, phenol-furfural, polyether, polyol, polyisocyanate, polyhydroxybenze, polyvinyl alcohol dialdehyde, polycyanurates, polyacrylamides, various epoxies, agar, agarose, chitosan, and combinations thereof. As one example, 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)<NUM>, with traditional alkoxide precursors, Y(OX)<NUM>. In these formulas, X may represent, for example, CH<NUM>, C<NUM>H<NUM>, C<NUM>H<NUM>, C<NUM>H<NUM>; 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.

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

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

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 a reinforcement material. 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 nonwovens, 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. In some examples, the reinforcement material can include a reinforcement including a plurality of layers of material.

In some aspects, structures described herein provide numerous benefits to the assembly and operation of battery packs. In some aspects, 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 modem manufacturing techniques and also enables precision in the dimensions of the battery pack and its components. In some aspects, the carrier frame itself, a central separator therein, and/or other structures improve the operation and safety of battery backs by providing effective thermal management. As used herein, thermal management may include one or more of cooling (e.g., via conductive, convection, forced or passive cooling) and insulation.

In some aspects, in addition to thermal insulating layers, 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 or layers 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, graphite, silicon carbide, metals including but not limited to copper, stainless steel, aluminum, and the like, as well as combinations thereof.

To aid in the distribution and removal of heat by, in at least one aspect 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 of the multilayer materials disclosed herein 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 of the multilayer materials and heat sink elements within the battery system can allow for removal of excess heat from the cell or cells adjacent to the multilayer material to the heat sink, thereby reducing the effect, severity, or propagation of a thermal event that may generate excess heat.

<FIG> shows one example of a battery system <NUM>. The system <NUM> includes one or more battery modules <NUM>. In the example of <FIG>, each module includes a carrier frame and two batteries as indicated by the dashed square <NUM>. A heat sink <NUM> is shown located on a side of the system <NUM>, and in thermal communication with the battery modules <NUM>.

<FIG> shows a cross section of a portion of a battery module <NUM> similar to battery module <NUM> in the dashed square <NUM> of <FIG>. The battery module <NUM> includes a carrier frame <NUM>, a central separator <NUM>, a first battery <NUM>, a second battery <NUM> are shown.

In some aspects, the carrier frame <NUM> 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 <NUM> may also provide additional benefits, such as managing the thermal conditions within a battery pack. These include preventing one cell from heating other cells in a module, and also providing conduction pathways to remove excess heat generated by the batteries, among other benefits described below.

In some aspects, the carrier frame <NUM> includes a first cavity <NUM> and a second cavity <NUM>. The first cavity <NUM> and the second cavity <NUM> may be disposed on opposite sides of the central separator <NUM> in some aspects. In this way, the first cavity <NUM> and the second cavity <NUM> may be configured and dimensioned (e.g., based on the dimensions of the central separator <NUM> and other features of the carrier frame <NUM>) to receive the first battery <NUM> and the second battery <NUM>.

In some aspects, the first battery <NUM> and the second battery <NUM> are shown located at least partially within the a first cavity <NUM> and the second cavity <NUM>. In one example, the batteries <NUM>, <NUM> are lithium ion pouch cells, although the invention is not so limited. While lithium ion pouch cells are frequently used in electric vehicle battery modules, other examples of batteries that may be held by the carrier frame <NUM> (e.g., via dimensioning and configuring the structure defining first cavity <NUM> and the second cavity <NUM>) include prismatic cells, cylindrical cells, among others.

<FIG> shows a battery module <NUM> similar to similar to battery module <NUM> from <FIG>. The module <NUM> includes a carrier frame <NUM>, a first cell <NUM> in corresponding first cavity, a second cell <NUM> in a corresponding second cavity, a central separator <NUM>, a thermal insulation layer <NUM>, a first metal plate <NUM>, a second metal plate <NUM>, a first heat sink <NUM>, and a second heat sink <NUM>.

At a high level, the battery module <NUM> employs conductive materials (e.g., metals, graphite) as the carrier frame <NUM>. Conductive materials may also be used within some components of the central separator <NUM>, and heat sinks <NUM>, <NUM> to conduct heat away from cells <NUM>, <NUM> and into the heat sinks <NUM>, <NUM>. The inclusion of the thermal insulation layer <NUM> provides a level of safety in the event of a thermal runaway in one or more of the cells <NUM>, <NUM> by reducing heat transfer between adjacent cells. At the same time, thermal conduction from the opposing metal plates <NUM> and <NUM> and the carrier frame <NUM> help to cool the cells <NUM>, <NUM>. In this way, the central separator <NUM> provides both cooling to improve battery performance, and safety from the thermal insulation layer <NUM>.

As described above, the carrier frame <NUM> and the central separator <NUM> are dimensioned and configured to define the first cavity and the second cavity, both of which are occupied by corresponding first and second cells <NUM>, <NUM> in <FIG>. 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 <NUM>.

In some aspects, the first cell <NUM> and the second cell <NUM> are disposed within the first cavity and the second cavity, respectively, as described above.

In some aspects, the central separator <NUM> 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 <NUM> prevents thermal events from spreading from one cell to another cell. In some aspects, the central separator <NUM> may have sufficient mechanical integrity to resist (for <NUM> seconds, for <NUM> minute, for <NUM> minutes) the degrading effects of ejecta from a cell (e.g., cell <NUM>, <NUM>) in thermal runaway, thereby preventing the ejecta from damaging and/or igniting an adjacent cell.

In one aspect, the central separator <NUM> of the module <NUM> is a multi-component structure. Aspects in which a central separator <NUM> are fabricated from multiple layers may accomplish multiple design goals more efficiently than single-layer configurations. For example, because the central separator <NUM> includes a thermal insulation layer <NUM> disposed between opposing metal plates <NUM> and <NUM>, the central separator <NUM> 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.

In some aspects, the thermal insulation layer <NUM> has a low thermal conductivity (e.g., on the order of <NUM> milliWatts/meter-Kelvin) to prevent undesired heat transfer between adjacent cells. In some aspects, the thermal insulation layer <NUM> may be fabricated from an aerogel material and/or a reinforced aerogel material. Other thermal insulation materials are also within the scope of the invention including, but not limited to ceramic (woven and/or non-woven) fiber materials, polymeric materials (e.g., oxidized polyacrylonitrile (O-PAN), (woven and/or non-woven) glass fibers, among others.

In some aspects, the opposing metal plates <NUM> and <NUM> may be fabricated from a known thermal conductor. In some aspects, the opposing metal plates <NUM>, <NUM> may have a thermal conductivity of at least <NUM> Watts/meter-Kelvin. In some aspects, the opposing metal plates <NUM>, <NUM> may be fabricated from metals, including but not aluminum, copper, steel, or any other known thermal conductor. In some aspects, the opposing metal plates <NUM> and <NUM> 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.

As indicated above, one aspect of the metal plates <NUM>, <NUM> is to conduct heat from the cells. In some aspects, the first heat sink <NUM> and the second heat sink <NUM> are shown in thermal contact with the carrier frame <NUM>, and more specifically, metal plates <NUM>, <NUM> of the central separator <NUM>. In this way, the heat generated within the cells <NUM>, <NUM> may be transferred to one or more heat sinks <NUM>, <NUM>, thereby reducing the likelihood of thermal runaway within one or more of the cells <NUM>, <NUM>.

<FIG> shows a battery system <NUM> similar to battery system <NUM> of <FIG> and similar to battery module <NUM> of <FIG>. As with one or both of these previously described examples, the system <NUM> includes a first cell <NUM>, a second cell <NUM>, a carrier frame <NUM>, and a central separator <NUM>, and a heat sink <NUM>.

Analogous to the previously described example, the system <NUM> includes a first cavity and a second opposing cavity similar to aspects described above. As with <FIG>, both of these cavities are occupied by corresponding cells <NUM>, <NUM> and are not visible in the view presented by <FIG>.

In some aspects, any of the modules described herein may include a single heat sink, as is illustrated in <FIG>. The single heat sink <NUM> is in thermal communication with an "L" shaped metal plates <NUM>, <NUM> that provide a conduction pathway that removes heat generated by cells <NUM>, <NUM>.

In some aspects, any of the modules described herein may alter the insulative characteristics of the central separator <NUM> by including one or more air gaps <NUM>, <NUM> adjacent to the thermal insulation layer <NUM>, as is shown in <FIG>. In this configuration (any one or more aspects of which may be combined with any other module described herein), the central separator <NUM> thus includes an insulation layer <NUM>, with opposing major surfaces at least partially exposed by a corresponding air gap <NUM>, <NUM>. The air gaps <NUM>, <NUM> are at least partially defined by the insulation layer <NUM> on one side and a portion of the "L-shaped" metal plates <NUM>, <NUM> on another side.

In one aspect, the central separator <NUM> is part of (i.e., integral with, attached to, mounted on) the carrier frame <NUM>. The carrier frame <NUM> may be an assembly of the metal plate <NUM>, <NUM> and optionally the central separator <NUM>. The central separator <NUM> in <FIG> includes a thermal insulation layer <NUM> included between opposing metal plates <NUM> and <NUM>. 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 <FIG>.

The central separator <NUM> further includes one or more air gaps <NUM>, <NUM> between the thermal insulation layer <NUM> and the opposing metal plates <NUM> and <NUM>. The inclusion of one or more air gaps <NUM>, <NUM> provides increased thermal isolation between the first cell <NUM> and the second cell <NUM>, while still providing thermal conduction through the opposing metal plates <NUM> and <NUM> and the carrier frame <NUM> to a heat sink <NUM>. In this way, the configuration of the central separator <NUM> shown in <FIG> (and therefore the system <NUM> as a whole) may provide added thermal isolation between adjacent cells, thereby reducing heat transfer between adjacent cells and therefore reducing the risk of thermal runaway from one cell causing thermal runaway in an adjacent cell.

<FIG> shows a side view of a portion of a battery module <NUM> similar to the previously described battery modules. The module <NUM> includes a battery <NUM>, and a central separator <NUM>, first fins <NUM>, second fins <NUM>. The central separator <NUM> is composed of (at least in part) a thermal insulator <NUM>, and a conductor plate <NUM>.

One of ordinary skill in the art, having the benefit of the present disclosure, will recognize that the central separator <NUM> may be included between two batteries in a module as shown in <FIG> and <FIG>, although the invention is not so limited. In one example, the thermal insulation <NUM> includes an aerogel material. Other thermal insulation materials are also within the scope of the invention.

In one example, one or more fins <NUM> are included with the conductor plate <NUM>. In some aspects, the one or more fins <NUM> are integral with the conductor plate <NUM>, whether formed from the conductor plate itself <NUM> or formed separately and later mounted on the conductor plate <NUM>. Regardless of the continuity and/or connection between the conductor plate <NUM> and the one or more fins <NUM>, these two components are associated with one another so that thermal energy ("heat") may be transferred from the from one to the other.

In one example, the fins <NUM> are part of a regular textured pattern. In one example, the fins <NUM> are part of an irregular textured pattern. For example, as illustrated in <FIG>, a second fin <NUM> is a different size and shape from fin <NUM>, as indicated by respective dimensions (e.g., fin height) β and α. In one aspect, β is greater than α. In one aspect, each of β and α are less than a thickness γ of the conductor plate <NUM>.

<FIG> further shows a top view <NUM> of the conductor plate <NUM> and fins <NUM>, <NUM>. In the example of <FIG>, the textured pattern includes a lengthwise orientation indicated by arrows <NUM> that preferentially conducts heat towards a heat sink such as the heat sinks described in <FIG> and <FIG> when in operation. In one example, the lengthwise orientation is perpendicular to the largest surface of the heat sink. In one example, coolant as a liquid or gas such as air may be used to flow through the fins <NUM> to provide additional cooling capacity. In one example, the conductor plate <NUM> and textured pattern are concentrated or only located over known hot spots on batteries in a module. In one example, the textured pattern is anisotropic, and concentrates heat removal from known hot spots on batteries in a module. In other examples, the conductor plate <NUM> and textured pattern cover an entire surface adjacent to a battery in a module.

<FIG> shows a side view of a portion of a battery module <NUM>. The module <NUM> includes a battery <NUM> and a central separator <NUM>. One of ordinary skill in the art, having the benefit of the present disclosure, will recognize that the central separator <NUM> may be included between two batteries in a module as shown in <FIG>, <FIG>, and <FIG> although the invention is not so limited. The central separator <NUM> includes a conductor plate <NUM> having textured pattern. In the example of <FIG>, the textured pattern includes fins <NUM> and gaps <NUM>.

<FIG> further shows a plan view <NUM> of the conductor plate <NUM> and fins <NUM>. The conductor plate <NUM> is shown in thermal communication with a heat sink <NUM>. In the example of <FIG>, the textured pattern includes a lengthwise orientation indicated by arrows <NUM> that preferentially conducts heat towards the heat sink <NUM> when in operation.

<FIG> shows a battery module <NUM> similar to similar to battery module <NUM> from <FIG>. The module <NUM> includes a first battery <NUM> and a second battery <NUM>. A central separator <NUM> is shown between the first battery <NUM> and the second battery <NUM>. In one example, the central separator <NUM> may be used as part of a carrier frame similar to other examples described. The central separator <NUM> includes opposing metal plates <NUM>, <NUM> with a thermal insulation layer <NUM> between the opposing metal plates <NUM>, <NUM>. In one example, the thermal insulation <NUM> includes an aerogel material. Other thermal insulation materials are also within the scope of the invention. A number of fins <NUM> are shows as part of a textured pattern on the opposing metal plates <NUM>, <NUM>. The fins <NUM> may be oriented as described in examples above to preferentially conducts heat towards a heat sink such as the heat sinks described in <FIG> and <FIG> when in operation.

The fins <NUM> in <FIG> are offset with one another to provide greater compression range of the thermal insulation layer without contact between the textured patterns. In operation, batteries <NUM>, <NUM> may expand, and require space to expand into. In one example, the thermal insulation layer <NUM> is resilient and can compress and expand as needed while the opposing metal plates <NUM>, <NUM> 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.

<FIG> shows a battery module <NUM> similar to similar to battery module <NUM> from <FIG>. The module <NUM> includes a first battery <NUM> and a second battery <NUM>. A central separator <NUM> is shown between the first battery <NUM> and the second battery <NUM>. In one example, the central separator <NUM> may be used as part of a carrier frame similar to other examples described.

In the Example of <FIG>, opposing metal plates are omitted and only a number of fins <NUM> are used to conduct heat towards a heat sink when in operation. A thermal insulation <NUM> is shown between the textured pattern of the fins <NUM>. In one example, the thermal insulation <NUM> includes an aerogel material. Other thermal insulation materials are also within the scope of the invention. As shown in <FIG> and <FIG>, in selected examples, a thermal insulation conforms to the textured pattern. Similar to the example of <FIG>, in <FIG>, the fins <NUM> are offset with one another to provide greater compression range of the thermal insulation layer without contact between the textured patterns.

<FIG> shows a side view of a portion of a battery module <NUM> similar to battery module <NUM> from <FIG>. The module <NUM> includes a battery <NUM> and a central separator <NUM>. One of ordinary skill in the art, having the benefit of the present disclosure, will recognize that the central separator <NUM> may be included between two batteries in a module as shown in other examples, although the invention is not so limited. The central separator <NUM> includes a conductor plate <NUM> having textured pattern. In the example of <FIG>, the textured pattern includes fins <NUM> and gaps <NUM>. In the example of <FIG>, a thermal insulation <NUM> is shown between the textured pattern of the fins <NUM>. In one example, the thermal insulation <NUM> includes an aerogel material. Other thermal insulation materials are also within the scope of the invention. The thermal insulation <NUM> conforms to the textured pattern.

<FIG> further shows a top view <NUM> of the conductor plate <NUM> and fins <NUM>. The conductor plate <NUM> is shown in thermal communication with a heat sink <NUM>. In the example of <FIG>, the textured pattern includes a lengthwise orientation similar to orientations described in other examples that preferentially conducts heat towards the heat sink <NUM> when in operation.

<FIG> and <FIG> show other examples of textured patterns that may be used as components of central separators described. <FIG> shows a side view of a portion of a battery module <NUM>. <FIG> further shows a top view <NUM> of a conductor plate <NUM> with a number of fins <NUM>. In the example of <FIG>, the number of fins <NUM> include rounded tops. <FIG> shows a side view of a portion of a battery module <NUM>. <FIG> further shows a top view <NUM> of a conductor plate <NUM> with a number of cavities <NUM>. In <FIG>, a conductor plate <NUM> is shown with a number of cavities <NUM> that form a textured pattern. In one example, 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. <FIG> illustrates an example electronic device <NUM> that includes a battery module <NUM>. The battery module <NUM> is coupled to functional electronics <NUM> by circuitry <NUM>. In the example shown, the battery module <NUM> and circuitry <NUM> are contained in a housing <NUM>. A charge port <NUM> is shown coupled to the battery module <NUM> to facilitate recharging of the battery module <NUM> when needed.

In one example, the functional electronics <NUM> 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..

<FIG> illustrates another electronic system that utilizes battery modules that include multilayer thermal barriers as described above. An electric vehicle <NUM> is illustrated in <FIG>. The electric vehicle <NUM> includes a chassis <NUM> and wheels <NUM>. In the example shown, each wheel <NUM> is coupled to a drive motor <NUM>. A battery module <NUM> is shown coupled to the drive motors <NUM> by circuitry <NUM>. A charge port <NUM> is shown coupled to the battery module <NUM> to facilitate recharging of the battery module <NUM> when needed.

Examples of electric vehicle <NUM> 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.

To better illustrate the method and apparatuses disclosed herein, a non-limiting list of aspects is provided here:.

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. Other aspects can be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it 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 aspect. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate aspect. The scope of the invention should be determined with reference to the appended claims.

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

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

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

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

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. 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 aspects. 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.

Claim 1:
A battery module (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>), comprising:
a carrier frame (<NUM>, <NUM>, <NUM>) having a pair of opposing cavities (<NUM>, <NUM>) to house batteries (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>);
a central separator (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) region between the pair of opposing cavities (<NUM>, <NUM>); and
a thermal insulation layer (<NUM>, <NUM>, <NUM>, <NUM>) included within the central separator (<NUM>, <NUM>) region.