Improved EV Battery Packaging Density for Reduced Thermal Propagation

High performance heat control members for separating battery cells or insulating battery components that have favorable resistance to heat propagation and fire propagation while minimizing thickness and weight of materials used. The members include reinforced aerogel composites with durability, compressibility, and thermal insulation properties for battery applications. The aerogel composites have a reinforcing phase like fibers or open-cell macroporous materials to enhance mechanical properties compared to pure aerogels. The reinforced aerogel composites have compressibility less than 25% at 25 kPa, density less than 0.3 g/cm3, and thermal conductivity less than 25 mW/mK.

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A thermal barrier assembly for traction battery packs that mitigates thermal runaway propagation between battery cells. The assembly has a heat spreader fin inside the cell stack that directs thermal energy from a cell into the pack enclosure instead of through the barrier. The fin extends between the cell and enclosure or between the insulation layers. This prevents thermal energy from spreading through the barrier to adjacent cells during a cell failure.

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Wrapped thermal barrier assembly for traction battery packs that both mitigates heat transfer and provides a sealed interface between the battery and the pack enclosure. The barrier has a structural component surrounded by a wrapping material. The wrapping is wrapped around edges of the barrier to seal against the pack enclosure and internal components like cross-members. This prevents thermal conduction and convection between the battery and pack while creating a sealed barrier to prevent coolant leakage.

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Battery design incorporating a thermal management component that regulates cell temperature through a novel spatial arrangement of components. The battery comprises a stack of cells arranged in a perpendicular stack orientation, with a thermal management component positioned between adjacent cells. This configuration enables the thermal management component to maintain optimal temperature across the cell stack while the cells themselves maintain their original orientation, thereby preventing thermal diffusion and runaway.

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A flexible multilayer thermal insulator for electric vehicle battery packs that inhibits flame propagation. The insulator comprises a multilayer wall with an outer layer, intermediate layer, and inner layer, each formed from interlaced mineral yarns. The layers are bonded with flame-resistant coatings and a pressure-sensitive adhesive, and are fixed together with filaments. The insulator provides a high level of thermal protection against flame propagation, meeting or exceeding industry standards for thermal runaway protection.

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Thermal management of battery packs in electrified vehicles to reduce heat propagation between battery compartments and facilitate venting. The technique involves using a thicker thermal barrier between adjacent battery cells than the cell height. This prevents direct cell-to-cell thermal conduction. A slot in the cover above the cells allows the barrier to project through. This allows venting while sealing the cells. The barrier can have features like a deflectable flap to contact the cover.

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A multi-layer insulation element for thermal and electrical insulation of rechargeable batteries, particularly lithium-ion batteries, comprising a first electrically insulating material, a second electrically insulating material, and an intermediate material, wherein the intermediate material is a textile and/or thermally insulating material. The insulation element is designed to provide thermal runaway protection, electrical insulation, and arc protection for battery cells and modules, while also enabling simple battery assembly.

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A battery pack for electric tools with improved thermal management to prevent overheating and fires. The pack features a heat management apparatus comprising thermal isolation plates between cells and the control board, and thermally conductive plates to dissipate heat to the outside. The isolation plates prevent heat transfer between adjacent cells and the control board, while the conductive plates enable controlled heat dissipation. The design enables effective thermal isolation and fire prevention while maintaining normal heat dissipation functionality.

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A protection element for preventing thermal runaway propagation in lithium-ion batteries, comprising a fiber layer with a flame-retardant finish, and a heat-reflecting coating that accumulates heat during thermal runaway and forms a localized hole to allow hot gases to escape while protecting adjacent cells. The protection element is designed to cover battery cells and their vents, preventing thermal runaway from spreading between cells.

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A battery module and pack with enhanced thermal management and safety features. The module includes a cell assembly, collection assembly, heat insulation member, and cushion assembly. The cushion assembly is positioned between adjacent cells and comprises a heat insulating member and two cushion members that absorb cell deformation and prevent electrolyte migration. The heat insulation member is located on the collection assembly side and includes grooves that match the cell explosion ports. The module design prevents thermal runaway propagation between cells and maintains module performance.

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A thermal barrier article for electric vehicle batteries that combines a thin, flexible multilayer material with blast and thermal resistance. The article comprises alternating layers of inorganic fabric and ceramic-based binder, with an adhesive layer on the fabric side. The material withstands both flexure conditioning and pyrotechnic blast tests, providing a safe thermal barrier for battery compartments in electric vehicles.

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A battery module with improved fire resistance and thermal diffusivity, comprising a plurality of battery cells and an insulating pad having a multi-layer structure disposed between the cells. The insulating pad includes a swelling pressure absorption layer, an insulating fire-resistant layer, and a thermal diffusion layer, which work together to prevent heat transfer and cell swelling while maintaining electrical insulation.

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A battery pack design that prevents thermal runaway between adjacent cells by asymmetrically arranging cooling plates and insulation sheets. The cooling plate is positioned closer to the cell's main surface, while the insulation sheet is positioned closer to the adjacent cell, thereby blocking heat transfer between cells and preventing chain reactions. This design enables effective cooling of individual cells while maintaining a balanced cooling load across the pack.

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Battery pack with improved thermal safety, comprising a plurality of single cells arranged in a staggered configuration to prevent direct thermal conduction between adjacent cells, thereby reducing the risk of thermal runaway propagation.

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A heat absorber for battery applications that achieves high thermal absorption efficiency while maintaining flame retardancy and mechanical integrity. The heat absorber comprises a bag filled with a hydrogel material, which is a three-dimensional network structure formed through a polymerization reaction. The hydrogel material exhibits excellent thermal absorption capacity, with a low onset temperature and high heat absorption coefficient. The heat absorber is designed to be molded at elevated temperatures, allowing it to provide effective thermal management without compromising its structural integrity. The heat absorber is particularly suitable for battery applications where thermal management is critical, particularly in high-speed charging scenarios where thermal runaway is a significant concern.

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A battery design that improves energy density by optimizing thermal management components. The battery features a unique arrangement of thermal management components, with thinner end components that match the reduced expansion forces of the battery cells at the edges. This design enables a more compact thermal management system that maintains performance while reducing overall battery size.

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A multilayer protective element for battery assemblies comprising at least two battery cells, the element comprising an elastic buffer layer made of a foamed or woven polymeric material and a heat-insulating barrier layer made of a ceramic material, arranged between the battery cells to compensate for dimensional changes and prevent heat propagation during thermal runaway.

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A battery with improved energy density and thermal management, comprising a plurality of thermal management components arranged along a first direction, with at least one battery cell group disposed between two adjacent components. Each battery cell group includes multiple battery cells arranged along a second direction perpendicular to the first direction, and a heat exchange cavity is provided within each thermal management component to regulate battery cell temperature.

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Thermal barrier system for managing heat transfer between battery cells in high-voltage traction battery packs. The system includes a thermal barrier structure positioned between adjacent battery cells, comprising an insulation layer sandwiched between foam layers, to prevent heat transfer and electrical shorts during thermal events. The insulation layer can be made of refractory ceramic fibers, mica, sheet moulding compound, or phenolic. The system can be applied to individual cell pairs or to entire cell banks, and can be integrated into the battery pack's end plates.

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Thermal management barrier for battery cells that enables effective cooling while preventing thermal runaway between cells. The barrier comprises a main body with a thermally insulating material and a thermally conductive layer coating on the first side. The barrier prevents heat transfer from the first side to the second side through the main body, while maintaining sufficient thermal conductivity for cooling. This design enables precise control over thermal distribution between battery cells while maintaining safety.

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