Thermal management systems for energy storage cells having high charge/discharge currents and methods of making and using thereof

• US 9,614,263 B2
• Filed: 02/17/2015
• Issued: 04/04/2017
• Est. Priority Date: 02/14/2014
• Status: Active Grant

• Current Assignee: IntraMicron, Inc.
• Original Assignee: IntraMicron, Inc.
• Inventors: Yang, Hongyun, Tatarchuk, Bruce J., Barron, Troy J., Dimick, Paul S.
• Primary Examiner(s): Ryan, Patrick
• Assistant Examiner(s): MCCONNELL, WYATT P
• Application Number:
  US14/624,349
• Publication Number:
  US 20150236386A1
• Time in Patent Office: 777 Days
• Field of Search: None
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/613 Cooling or keeping cold
• CPC Class Codes: H01M 10/625 Vehicles
• CPC Class Codes: H01M 10/653 characterised by electrically insulating or thermally conductive materials
• CPC Class Codes: H01M 10/6557 arranged between the cells
• CPC Class Codes: H01M 10/6567 Liquids
• CPC Class Codes: H01M 10/658 by thermal insulation or shielding
• 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 50/213 adapted for cells having curved cross-section, e.g. round or elliptic H01M50/209, H01M50/216 take precedence
• CPC Class Codes: H01M 50/222 Inorganic material
• CPC Class Codes: H01M 50/224 Metals
• CPC Class Codes: H01M 50/227 Organic material
• CPC Class Codes: H01M 50/229 Composite material consisting of a mixture of organic and inorganic materials
• CPC Class Codes: H01M 50/233 characterised by physical properties of casings or racks, e.g. dimensions
• CPC Class Codes: H01M 50/24 adapted for protecting batteries from their environment, e.g. from corrosion thermal insulation H01M10/658
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

Thermal management systems for high energy density batteries, particularly arrays of such batteries, and methods of making and using thereof are described herein. The system includes one or more thermal conductive microfibrous media with one or more phase change materials dispersed within the microfibrous media and one or more active cooling structures. Energy storage packs or arrays which contain a plurality of energy storage cells and the thermal management system are also described. Further described are thermal or infrared shielding blankets or barriers comprising one or more thermal conductive microfibrous media comprising one or more phase change materials dispersed within the microfibrous media.

Claims

1. An energy storage pack or array comprising a plurality of energy storage cells and a thermal management system

wherein the thermal management system comprises one or more thermal conductive microfibrous media and one or more active cooling structures,

wherein the microfibrous media are porous networks comprising sintered micron-size fibers, wherein one or more phase change materials are dispersed within the microfibrous media, and

wherein the microfibrous media is machined and/or deformed to match one or more surfaces of the cells and the one or more active cooling structures.

2. The pack or array of claim 1, wherein the cells comprise batteries.

3. The pack or array of claim 2, wherein the batteries comprise lithium-ion batteries.

4. The pack or array of claim 1, wherein the cells are characterized with a C-rate of greater than 1 C.

5. The pack or array claim 1, wherein the one or more cells comprise one or more electrically insulating, thermally conductive films that encapsulate the cells.

6. The system of claim 1, wherein the one or more active cooling structures comprises tubes or channels that pass through the microfibrous media.

7. The system of claim 6, wherein the tubes or channels are formed from a material selected from the group consisting of metal, ceramics, and glass, and combinations thereof.

8. The pack or array of claim 5, wherein the electrically insulating films comprise one or more thermally conductive polymers.

9. The pack or array of claim 5, wherein the electrically insulating films comprise one or more thermally conductive ceramics.

10. The pack or array of claim 9, wherein the thermally conductive ceramic is selected from the group consisting of alumina, boron nitride, aluminum nitride, and combinations thereof.

11. The pack or array of claim 5, wherein the electrically insulating films comprise glass or enamel.

12. The pack or array of claim 5, wherein the thickness of the film is from about 50 microns to about 1000 microns.

13. The pack or array of claim 1, wherein the energy storage cells are cylindrical.

14. The pack or array of claim 13, wherein the microfibrous media comprises openings in the shape of cylinders into which the cells are inserted.

15. The pack or array of claim 1, wherein the sintered fibers are sintered metal fibers selected from the group consisting of copper, nickel, aluminum, steel, stainless steel, silver, gold, and alloys, and combinations thereof.

16. The pack or array of claim 1, wherein the microfibrous media further comprise carbon fibers, graphite fibers, single wall or multi-wall carbon nanotubes, or a combination thereof.

17. The pack or array of claim 16, wherein the microfibrous media further comprise carbon fibers, and wherein the diameter of the carbon fibers is from about 1 nanometer to about 250 microns.

18. The pack or array of claim 1, wherein the volumetric loading of fibers in the microfibrous media ranges from about 1 to about 40 vol. %.

19. The pack or array of claim 1, wherein the one or more phase change materials are selected from the group consisting of paraffin waxes, polyethylene glycols, fatty acids, metal salts, and combinations thereof.

20. The pack or array of claim 19, wherein the phase change material is immobilized inside the microfibrous media or encapsulated within a higher melting point material that is immobilized inside the microfibrous media.

21. The pack or array of claim 15, wherein the one or more phase change materials and/or phase change material encapsulating materials are chemically inert to the metal fibers.

22. The pack or array of claim 1, wherein the one or more phase change materials and/or phase change material encapsulating materials are electrically insulating.

23. The pack or array of claim 1, wherein the one or more phase change materials have heats of fusion larger than 100 J/g.

24. The pack or array of claim 1, wherein the one or more phase change materials have a melting temperature range of less than 5°

C.

25. The pack or array of claim 1, wherein the one or more phase change materials have a solidifying temperature range of less than 5°

C.

26. The pack or array of claim 1, wherein the one or more phase change materials have a melting temperature range and a solidifying temperature range which overlap with a maximum difference of 2°

C.

27. The pack or array of claim 1, wherein cooling water passes through the active cooling structures.

28. The pack or array of claim 1 in the form of a rechargeable battery, capacitor, supercapacitor, or other electronic device.