Battery thermal release layer

Patent metadata

Field	Value
Publication number	US-12431597-B2
Application number	US-202217708538-A
Country	US
Kind code	B2
Filing date	Mar 30, 2022
Priority date	Mar 30, 2022
Publication date	Sep 30, 2025
Grant date	Sep 30, 2025

Abstract

A thermal release layer for electrode materials in a battery cell is provided. The battery cell can include a terminal and an electrode, in contact with the terminal. The battery cell can include a first material that conducts electricity to establish electrical continuity with the terminal. The battery call can include a second material that, in response to a temperature of the electrode reaching or exceeding a temperature threshold, expands to reduce the electrical continuity with the terminal.

First claim

What is claimed is:

1. A battery cell, comprising:
a terminal; and
an electrode, in contact with the terminal, comprising:
a first material that conducts electricity to establish electrical continuity with the terminal, and
a second material that, in response to a temperature of the electrode exceeding a temperature threshold, expands to reduce the electrical continuity with the terminal, wherein at least a portion of a layer in electrical contact with the terminal comprises an adhesive material to couple the terminal and the electrode, and responsive to the temperature of the second material exceeding the temperature threshold, the second material expands to decouple the electrode from the terminal by generating foam to cause a reduction in the electrical continuity via the terminal.

2. The battery cell of claim 1 , comprising:
an adhesive configured to bind the electrode to a current collector in electrical contact with the terminal, wherein the second material expands at a greater rate than the adhesive at the temperature threshold.

3. The battery cell of claim 1 , comprising:
a component that couples the terminal and the electrode via adhesion to establish the electrical continuity.

4. The battery cell of claim 3 , wherein the electrode comprises the layer in contact with the component, the layer comprising the second material and configured to decouple the electrode from the component at the temperature threshold.

5. The battery cell of claim 1 , wherein the electrode comprises the layer in electrical contact with the terminal, the layer comprising the second material that expands at a greater rate than the first material.

6. The battery cell of claim 1 , wherein the terminal comprises a current collector of the battery cell and the electrode comprises a cathode comprising nickel.

7. The battery cell of claim 1 , comprising:
a plurality of electrodes each comprising the second material and in electrical contact with the terminal, wherein electrical continuity of a first electrode of the plurality of electrodes is reduced responsive to the temperature of the second material at the first electrode exceeding the temperature threshold, and electrical continuity of a second electrode of the plurality of electrodes is maintained based on the temperature of the second material at the second electrode being less than the temperature threshold.

8. The battery cell of claim 1 , wherein:
the temperature threshold is greater than or equal to 200 degrees Celsius;
the electrical continuity, prior to the temperature of the second material exceeding the temperature threshold, corresponds to electrical resistance less than or equal to 0.1 ohms; and
the reduction in the electrical continuity subsequent to the temperature of the second material exceeding the temperature threshold corresponds to an open circuit.

9. The battery cell of claim 1 , comprising:
the battery cell comprising the terminal and the electrode, wherein the battery cell is included in a battery pack of a vehicle.

10. The battery cell of claim 1 , wherein the second material comprises:
a plurality of particles formed from plastic having a shape that is spheroidal and encapsulates a gas.

11. The battery cell of claim 10 , wherein the gas expands at the temperature threshold to cause an increase in volume of each of the plurality of particles by at least a factor of 5.

12. A method, comprising:
providing a terminal for a battery; and
forming, for the battery, an electrode in contact with the terminal from:
a first material that conducts electricity to establish electrical continuity with the terminal, and
a second material that, in response to a temperature of the electrode exceeding a temperature threshold, expands to reduce the electrical continuity with the terminal, wherein at least a portion of a layer in electrical contact with the terminal comprises an adhesive material to couple the terminal and the electrode, and responsive to the temperature of the second material exceeding the temperature threshold, the second material expands to decouple the electrode from the terminal by generating foam to cause a reduction in the electrical continuity via the terminal.

13. The method of claim 12 , comprising:
binding the electrode with the terminal using an adhesive, wherein the second material expands at a greater rate than the adhesive at the temperature threshold.

14. The method of claim 12 , comprising:
electrically coupling, via adhesion, the terminal and the electrode using a component to establish the electrical continuity; and
providing the layer for the electrode, the layer in contact with the component and comprising the second material configured to decouple the electrode from the component at the temperature threshold.

15. The method of claim 12 , wherein:
the terminal comprises a current collector of the battery and the electrode comprises a cathode comprising nickel;
the second material comprises a plurality of particles formed from plastic having a spherical shape that encapsulates a gas;
the temperature threshold is greater than or equal to 200 degrees Celsius;
the electrical continuity, prior to the temperature of the second material exceeding the temperature threshold, corresponds to electrical resistance less than or equal to 0.1 ohms; and
the reduction in the electrical continuity subsequent to the temperature of the second material exceeding the temperature threshold corresponds to an open circuit.

16. The method of claim 12 , comprising:
providing a battery cell comprising the terminal and the electrode, wherein the battery cell is included in a battery pack of a vehicle.

17. An electric vehicle, comprising:
a battery cell comprising:
a current collector connected to a positive terminal; and
a cathode, in contact with the current collector, comprising:
a first material that conducts electricity to establish electrical continuity with the current collector, and
a second material that, in response to a temperature of the cathode exceeding a temperature threshold, expands at a greater rate than the first material to decouple the cathode from the current collector and results in an increase of a resistance of the battery cell, wherein at least a portion of a layer in electrical contact with the positive terminal comprises an adhesive material to couple the positive terminal and the cathode, and responsive to the temperature of the second material exceeding the temperature threshold, the second material expands to decouple the cathode from the positive terminal by generating foam to cause a reduction in the electrical continuity via the positive terminal; and

a battery management system, executed by one or more processors, to:
determine, based on the increase of the resistance of the battery cell, an occurrence of a decoupling event at the battery cell.

18. The electric vehicle of claim 17 , comprising:
a battery pack comprising a plurality of battery cells, the plurality of battery cells comprising the battery cell and a second battery cell; and
the battery management system to manage an amount of current provided via the second battery cell responsive to determination of the occurrence of the decoupling event at the battery cell.

Assignees

• Rivian Ip Holdings Llc

Inventors

• Kim Soo
• Park Ki Tae

Classifications

• H01M10/425

  Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing (printed circuits H05K1/00) · CPC title

• B60L50/64

  Constructional details of batteries specially adapted for electric vehicles · CPC title

• H01M10/4235 Primary

  Safety or regulating additives or arrangements in electrodes, separators or electrolyte (H01M10/4242 takes precedence) · CPC title

• H01M4/62

  Selection of inactive substances as ingredients for active masses, e.g. binders, fillers · CPC title

• H01M10/48

  Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte (constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569) · CPC title