Hybrid composite materials systems for battery housings having improved thermal performance

A hybrid material housing for a battery pack for reducing or minimizing thermal runaway propagation, the housing comprising:

• a composite structure defining an interior surface and an exterior surface, wherein the composite structure comprises a polymeric matrix selected from the group consisting of:
• epoxy, phenolic resin, polyester, vinyl ester, and combinations thereof and a reinforcing material selected from the group consisting of:
• glass fibers, carbon fibers, basalt fibers, aromatic polyamide fibers, and combinations thereof distributed in the polymeric matrix;
• and
• a metal layer disposed along the exterior surface of the composite structure, wherein the metal layer is selected from the group consisting of:
• aluminum, steel, stainless steel, alloys, and combinations thereof, wherein in a first operational mode the metal layer contacts the composite structure and in a second operational mode after exposure to a thermal load of greater than or equal to about 500° C., the metal layer at least partially delaminates from the exterior surface and forms insulating air gaps to define a thermal barrier and the composite structure remains intact free of any openings.

A method of forming a hybrid material housing for a battery for reducing or minimizing thermal runaway propagation, the method comprising:

• disposing a metal layer into a cavity of a mold;
• disposing a reinforcing material and a polymer or precursor of a polymer into the cavity of the mold adjacent to the metal layer;
• solidifying the polymer or precursor of the polymer to form a composite material comprising a polymeric matrix having the reinforcing material disposed therein;
• and
• opening the mold to remove a hybrid material housing for a battery pack comprising a composite structure formed of the composite material and having an integrally formed metal layer adjacent thereto.