Modules and packs for solid-state rechargeable batteries

Patent metadata

Field	Value
Publication number	US-2026011817-A1
Application number	US-202519325228-A
Country	US
Kind code	A1
Filing date	Sep 10, 2025
Priority date	Mar 28, 2023
Publication date	Jan 8, 2026
Grant date	—

Abstract

Provided herein is a module with at least two electrochemical stack assemblies (ESA), wherein each ESA individually, in each instance, includes one or more electrochemical cells, each electrochemical cell including a solid-state electrolyte; a frame surrounding the one or more electrochemical cells; and a laminated pouch surrounding the frame and the one or more electrochemical. Also set forth herein are methods of making and using the same.

First claim

What is claimed is:

1 . A module comprising at least two electrochemical stack assemblies (ESA), wherein each ESA comprises:
one or more electrochemical cells, each electrochemical cell comprising a solid-state electrolyte; a frame surrounding the one or more electrochemical cells; and a laminated pouch surrounding the frame and the one or more electrochemical cells; the module further comprising a compliant cooling plate or compressible cooling pouch between adjacent laminated pouches.

2 . The module of claim 1 , comprising an alignment segment which interfaces with side or bottom edges of the laminated pouches.

3 . The module of claim 1 or claim 2 , wherein the frame is a structural support for the module.

4 . The module of claim 3 , wherein the structural support is selected from the group consisting of an airplane wing strut, a motorcycle body, and a motor vehicle body.

5 . The module of claim 3 , wherein the structural support is a component of a honeycomb structure.

6 . The module of any of claims 1-5 , wherein the frame has three sides, the module further comprising a header closing off a fourth side of the frame.

7 . The module of any one of claims 1-6 , wherein one of the at least two ESAs in the module has a thickness that is larger than the thickness of another one of the at least two ESAs in the module.

8 . The module of any one of claims 1-7 , wherein the laminated pouches are disposed in close-packed arrangement to minimize vacant space between adjacent laminated pouches.

9 . The module of any of claims 1-8 , wherein the laminated pouches provide dimensional stability to the module.

10 . The module of any of claims 1-9 , wherein the laminated pouches are vertically stacked in the module.

11 . The module of any one of claims 1-9 , wherein the laminated pouches are horizontally arrayed in the module.

12 . The module of claim 11 , wherein the compliant cooling plate comprises a metal.

13 . The module of any one of claims 1-10 , wherein the compressible cooling pouch contains a cooling fluid.

14 . The module of any one of claims 1-13 , comprising from about 10 to about 1000 ESAs.

15 . The module of any one of claims 1-14 , wherein the module has a capacity of about 100 kWh.

16 . The module of any one of claims 1-15 , wherein the laminated pouches are pressurized to an internal pressure of 300 Pascals (Pa).

17 . The module of any one of claims 1-16 , comprising laminated pouches positioned flat with respect to the ground.

18 . The module of any one of claims 1-16 , comprising laminated pouches oriented in a skateboard pack design.

19 . The module of any one of claims 1-18 , comprising at least two laminated pouches of different sizes.

20 . The module of claim 1 , wherein the frame comprises a center wall or center plate.

21 . The module of claim 20 , wherein the one or more electrochemical cells are disposed within the frame comprising a center wall or center plate.

22 . The module of claim 20 or 21 , wherein the frame comprising a center wall or center plate is adjacent to at least a portion of the laminated pouch.

23 . The module of claim 20 or 21 , wherein the frame comprising a center wall or center plate is adjacent to a major face of the laminated pouch.

24 . The module of claim 1 , wherein the frame does not comprise a center wall or center plate.

25 . A method of determining state-of-charge (SOC), comprising,
measuring the thickness of a laminated pouch in a module of any one of claims 1 - 24 , wherein the thickness is proportional to the SOC; and determining SOC based on the measured thickness.

26 . The method of claim 25 , wherein the measuring comprises using a strain gauge.

27 . The method of claim 25 or claim 26 , further comprising acquiring historical displacement data regarding cycles of charging and discharging of electrochemical cells in the module and determining state-of-health (SOH) based on the historical displacement data.

28 . A method of pumping a coolant, comprising
providing a compressible cooling pouch or pocket containing cooling fluid and coupled to a cooling system, the compressible cooling pouch or pocket being disposed between adjacent laminated pouches in a module of any one of claims 1-24 ; expanding and contracting the laminated pouches by charging and discharging the electrochemical cells therein; and using mechanical force created by the expansion and contraction of the laminated pouches to pump the cooling fluid.

29 . A method of cooling a module of any one of claims 1-24 , comprising drawing heat from the ESAs through the tabs.

30 . The method of claim 28 , wherein the cooling is concurrent with a fast charge event.

31 . A method of cooling a module of any one of claims 1-24 , comprising drawing heat from the ESA through side or bottom edges of the laminated pouches.

32 . The method of claim 31 , wherein the cooling is concurrent with a fast charge.

33 . A method of cooling a module of any one of claims 1-24 , comprising drawing heat from the electrochemical cells through side or bottom edges of the laminated pouches.

34 . The method of claim 33 , wherein the sides are faces of the laminated pouch.

35 . The method of claim 28 or 29 , wherein the cooling is concurrent with a fast charge event.

Assignees

• Quantumscape Battery Inc

Inventors

• Gardner William
• Holme Timothy
• Hudson William
• Mikolajczak Celina
• Slagle Richard Anthony
• Daroczi Shandor

Classifications

• H01M50/211

  adapted for pouch cells · CPC title

• H01M50/242

  adapted for protecting batteries against vibrations, collision impact or swelling · CPC title

• H01M50/249

  specially adapted for aircraft or vehicles, e.g. cars or trains (constructional details of batteries specially adapted for electric vehicles B60L50/64) · CPC title

• G01R31/392

  Determining battery ageing or deterioration, e.g. state of health · CPC title

• G01R31/387

  Determining ampere-hour charge capacity or SoC · CPC title