Systems, structures and materials for electrochemical device thermal management

• US 10,003,053 B2
• Filed: 02/04/2015
• Issued: 06/19/2018
• Est. Priority Date: 02/04/2015
• Status: Active Grant

• Current Assignee: Latent Heat Solutions, LLC
• Original Assignee: Global Web Horizons, LLC
• Inventors: Hartmann, Mark, Kelly, Joseph
• Primary Examiner(s): Slifka, Sarah A.
• Assistant Examiner(s): Ohara, Brian R
• Application Number:
  US14/614,223
• Publication Number:
  US 20160226042A1
• Time in Patent Office: 1,231 Days
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: H01G 11/18 against thermal overloads, e.g. heating, cooling or ventilating
• CPC Class Codes: H01G 11/78 Cases; Housings; Encapsulations; Mountings
• CPC Class Codes: H01G 11/82 Fixing or assembling a capacitive element in a housing, e.g. mounting electrodes, current collectors or terminals in containers or encapsulations
• CPC Class Codes: H01G 2/08 Cooling arrangements; Heating arrangements; Ventilating arrangements
• CPC Class Codes: H01M 10/643 Cylindrical cells
• CPC Class Codes: H01M 10/647 Prismatic or flat cells, e.g. pouch cells
• CPC Class Codes: H01M 10/659 by heat storage or buffering, e.g. heat capacity or liquid-solid phase changes or transition
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 2220/30 Batteries in portable systems, e.g. mobile phone, laptop
• CPC Class Codes: H01M 50/103 prismatic or rectangular H01M50/109, H01M50/11 take precedence
• CPC Class Codes: H01M 50/107 having curved cross-section, e.g. round or elliptic H01M50/103, H01M50/109, H01M50/11 take precedence
• CPC Class Codes: H01M 50/202 Casings or frames around the primary casing of a single cell or a single battery
• CPC Class Codes: H01M 50/209 adapted for prismatic or rectangular cells H01M50/216 takes precedence
• CPC Class Codes: H01M 50/213 adapted for cells having curved cross-section, e.g. round or elliptic H01M50/209, H01M50/216 take precedence
• CPC Class Codes: H01M 50/227 Organic material
• CPC Class Codes: H01M 50/236 Hardness
• CPC Class Codes: H01M 50/238 Flexibility or foldability
• CPC Class Codes: H01M 50/24 adapted for protecting batteries from their environment, e.g. from corrosion thermal insulation H01M10/658
• CPC Class Codes: H01M 50/249 specially adapted for aircraft or vehicles, e.g. cars or trains constructional details of batteries specially adapted for electric vehicles B60L50/64
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02E 60/13 : Energy storage using capacitors
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries

Abstract

This disclosure provides a casing for the thermal management and protection of an electrochemical cell. The casing may comprise an inner surface configured to be in physical contact with at least a portion of an outer surface of an electrochemical cell. The inner surface may be substantially solid at room temperature. The casing may also comprise a polymer matrix which itself comprises two or more temperature management materials. At least one of the two or more temperature management materials may comprise a microencapsulated phase change material having a latent heat of at least 5 Joules per gram and a transition temperature between 0° C. and 100° C., and at least one other of the two or more temperature management materials may comprise an elastomeric material. The polymer matrix may be substantially homogeneous.

Claims

1. A wrapping material for the thermal management and protection of an electrochemical cell, the wrapping material comprising:

a polymer matrix comprising two or more temperature management materials, at least one of the two or more temperature management materials comprising,

a microencapsulated phase change material, and

at least one other of the two or more temperature management materials comprising,

a polymer elastomer comprising block copolymers with crosslinked hard or soft segments, wherein the crosslinks are non-covalent;

wherein the polymer elastomer surrounds the microencapsulated phase change material and the polymer matrix is homogeneous and solid at room temperature, and

wherein the wrapping material forms an individual sheet having a uniform thickness, has a latent heat of at least 5 Joules per gram and a transition temperature between 0°

C. and 100°

C., and is configured to be wrapped one or more times around an outer surface of an electrochemical cell.

2. The wrapping material of claim 1, wherein the microencapsulated phase change material is a polymeric phase change material.

3. The wrapping material of claim 2, wherein the phase change material is a functional polymeric phase change material.

4. The wrapping material of claim 1, wherein the wrapping material comprises an adhesive configured to adhere to the outer surface of a commercially available electrochemical cell, and the polymer elastomer has properties of thermal elasticity and rebound such that engagement is maintained between the wrapping material and the outer surface of the electrochemical cell after a plurality of charge and discharge cycles of the electrochemical cell.

5. The wrapping material of claim 1, further comprising;

a second polymer matrix comprising one or more temperature management materials, wherein the second polymer matrix forms a layer upon on the polymer matrix comprising two or more temperature management materials.

6. The wrapping material of claim 1, wherein the wrapping material is configurable to form a cylindrical sleeve.

7. The wrapping material of claim 1, wherein the wrapping material has tacky properties such that it adheres to itself.

8. The wrapping material of claim 1, wherein the wrapping material has a Shore A hardness of greater than 85 and a Shore D hardness of greater than 25 (per ASTM D2240).

9. The wrapping material of claim 1, wherein the wrapping material has a flex modulus of greater than 15 pounds per square inch and a break elongation of greater than 20%.

10. The wrapping material of claim 1, further comprising a gel disposed on at least a portion of the wrapping material.

11. The wrapping material of claim 1, wherein the wrapping material is configured to be wrapped around a plurality of electrochemical cells.

12. The wrapping material of claim 1, wherein the crosslinked hard and soft segments are cross-linked with an average of between 0.05 to 1.0 crosslinks per polymeric chain.

13. The wrapping material of claim 1, wherein the phase change material has a latent heat content of greater than 10 Joules per gram and less than 60 Joules per gram.

14. The wrapping material of claim 1, wherein the casing is further comprised of one or more additives selected from the group comprising:

a fire-retardant additive, an energy conductivity additive, a thermal conductivity additive, a waterproofing additive, a nucleating agent, and an antioxidant.

15. The wrapping material of claim 1, wherein the wrapping material further comprises a conductive substrate.

16. A wrapping material for the thermal management and protection of the electrochemical cell, the wrapping material comprising:

a polymer matrix comprising two or more temperature management materials, at least one of the two or more temperature management materials comprising,

a polymeric phase change material, and

at least one other of the two or more temperature management materials comprising,

a polymer elastomer comprising block copolymers with crosslinked hard or soft segments, wherein the crosslinks are non-covalent,

wherein the polymer elastomer surrounds the microencapsulated phase change material and the polymer matrix is homogeneous and solid at room temperature, and

wherein the wrapping material forms an individual sheet having a uniform thickness, has a latent heat of at least 5 Joules per gram and a transition temperature between 0°

C. and 100°

C., and is configured to be wrapped one or more times around an outer surface of an electrochemical cell.

17. The wrapping material of claim 16, wherein the polymeric phase change material is a functional polymeric phase change material.

18. The wrapping material of claim 16, wherein the wrapping material comprises an adhesive configured to adhere to the outer surface of a commercially available electrochemical cell, and the polymer elastomer has properties of thermal elasticity and rebound such that engagement is maintained between the wrapping material and the outer surface of the electrochemical cell after a plurality of charge and discharge cycles of the electrochemical cell.

19. The wrapping material of claim 16, further comprising;

a second polymer matrix comprising one or more temperature management materials, wherein the second polymer matrix forms a layer upon on the polymer matrix comprising two or more temperature management materials.

20. The wrapping material of claim 16, wherein the wrapping material is configurable to form a cylindrical sleeve.

21. The wrapping material of claim 16, wherein the wrapping material has tacky properties such that it adheres to itself.

22. The wrapping material of claim 16, wherein the wrapping material has a Shore A hardness of greater than 85 and a Shore D hardness of greater than 25 (per ASTM D2240).

23. The wrapping material of claim 16, wherein the wrapping material has a flex modulus of greater than 15 pounds per square inch and a break elongation of greater than 20%.

24. The wrapping material of claim 16, further comprising a gel disposed on at least a portion of the wrapping material.

25. The wrapping material of claim 16, wherein the wrapping material is configured to be wrapped around a plurality of electrochemical cells.

26. The wrapping material of claim 16, wherein the crosslinked hard and soft segments are cross-linked with an average of between 0.05 to 1.0 crosslinks per polymeric chain.

27. The wrapping material of claim 16, wherein the phase change material has a latent heat content of greater than 10 Joules per gram and less than 60 Joules per gram.

28. The wrapping material of claim 16, wherein the wrapping material is further comprised of one or more additives selected from the group comprising:

a fire-retardant additive, an energy conductivity additive, a thermal conductivity additive, a waterproofing additive, a nucleating agent, and an antioxidant.

29. The wrapping material of claim 16, wherein the wrapping material further comprises a conductive substrate.

30. A container for the thermal management and protection of an electrochemical cell pack configured to be in physical contact with a plurality of electrochemical cells, the container comprising:

a polymer matrix comprising two or more temperature management materials,

at least one of the two or more temperature management materials comprising;

a microencapsulated phase change material, and

at least one other of the two or more temperature management materials comprising;

a polymer elastomer comprising block copolymers with crosslinked hard or soft segments, wherein the crosslinks are non-covalent;

wherein the polymer elastomer surrounds the microencapsulated phase change material and the polymer matrix is homogeneous and solid at room temperature, and

wherein the container has a latent heat of at least 5 Joules per gram and a transition temperature between 0°

C. and 100°

C. is configured to be in physical contact with at least a portion of an outer surface of at least one of the plurality of electrochemical cells.

31. The container of claim 30, wherein the container comprises a plurality of interconnected sleeves.

32. The container of claim 30, wherein the microencapsulated phase change material is a polymeric phase change material.

33. The container of claim 32, wherein the polymeric phase change material is a functional polymeric phase change material.

34. The container of claim 30 further comprising a gel disposed on at least a portion of an inner surface of the polymer matrix of the container.

35. The container of claim 30, wherein the container comprises a wrapping material forming an individual sheet having a uniform thickness.

36. The container of claim 30, further comprising one or more additives selected from the group comprising:

a fire-retardant additive, an energy conductivity additive, a thermal conductivity additive, a waterproofing additive, a nucleating agent, and an antioxidant.

37. A portable electrochemical-cell-powered device, comprising:

one or more electrochemical cells;

a casing for the one or more electrochemical cells comprising;

a polymer matrix comprising two or more temperature management materials,

at least one of the two or more temperature management materials comprising,

a microencapsulated phase change material, and

at least one other of the two or more temperature management materials comprising,

a polymer elastomer comprising block copolymers with crosslinked hard or soft segments, wherein the crosslinks are non-covalent,

wherein the polymer elastomer surrounds the microencapsulated phase change material and the polymer matrix is homogeneous and solid at room temperature, and

wherein the wrapping material forms an individual sheet having a uniform thickness, has a latent heat of at least 5 Joules per gram and a transition temperature between 0°

C. and 100°

C., and is configured to be wrapped one or more times around an outer surface of an electrochemical cell.

38. The electrochemical-cell-powered device of claim 37, wherein the device is a power tool.

39. A vehicle, comprising;

at least one component powered by an electrochemical cell pack and,

a container configured to be in physical contact with a plurality of electrochemical cells, the container comprising;

a polymer matrix comprising two or more temperature management materials,

at least one of the two or more temperature management materials comprising;

a microencapsulated phase change material, and

at least one other of the two or more temperature management materials comprising;

a polymer elastomer comprising block copolymers with crosslinked hard or soft segments, wherein the crosslinks are non-covalent;

wherein the polymer elastomer surrounds the microencapsulated phase change material and the polymer matrix is homogeneous and solid at room temperature, and

wherein the container has a latent heat of at least 5 Joules per gram and a transition temperature between 0°

C. and 100°

C. is configured to be in physical contact with at least a portion of an outer surface of at least one of the plurality of electrochemical cells.