US 2025/0343301 A1Published application

Electric Vehicle Battery With Thermal Failure Protection

AssigneeAmple, Inc.

InventorsRaymond Tsang, Albert Liu, Caleb Tseng-Tham, Shahrul Song, Henry Smith, Erid Pineda, Saideep Vollala

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Abstract

A battery module includes multiple battery-cell stacks of battery cells. The respective battery cells in the battery-cell stacks are spatially aligned with each other along respective longitudinal axes. The battery cells are oriented such that a positive terminal of a battery cell in one of the battery-cell stacks is spatially aligned with a negative terminal of a battery cell in a neighboring battery-cell stack. The battery-cell stacks are spaced apart to form respective air gaps between neighboring battery-cell stacks. A respective electrical connection layer is disposed on each side of a battery-cell stack to electrically connect the respective battery cells. A respective thermal protection shield is disposed on the respective electrical connection layer. The thermal protection shield includes channels that are spatially aligned with the positive terminals to allow gas and/or thermal energy to escape from a positive terminal in the event of battery-cell damage or breakdown.

Claims20

Dependent claims

A battery module comprising:

a plurality of battery-cell stacks, each battery-cell stack including a plurality of battery cells, the battery cells arranged such that at least some positive terminals of the battery cells are disposed on a respective first side of a respective battery-cell stack and at least some negative terminals of the battery cells are disposed on a respective second side of the respective battery-cell stack, the respective first and second sides on opposing sides of the respective battery-cell stack;
a plurality of first thermal-protection shields, each first thermal-protection shield disposed on the respective first side of the respective battery-cell stack;
and
a plurality of second thermal-protection shields, each second thermal-protection shield disposed on the respective second side of the respective battery-cell stack,
wherein:
the battery-cell stacks include at least one neighboring battery-cell stack pair,
a respective air gap is defined between (a) a respective first thermal-protection shield on the respective first side of a first battery-cell stack in a respective battery-cell stack pair and (b) a respective second thermal-protection shield on the respective second side of a second battery-cell stack in the respective battery-cell stack pair,
a plurality of holes are defined in each first thermal-protection shield, the holes spatially aligned with the at least some positive terminals on the respective first side of the first battery-cell stack in each battery-cell stack pair such that each positive terminal on the respective first side of each first battery-cell stack is at least partially fluidly coupled to the respective air gap, and
the respective second thermal-protection shield covers the at least some negative terminals side on the respective second side of the second battery-cell stack in each battery-cell stack pair such that each negative terminal on the respective second side of each second battery-cell stack is shielded from a thermal event occurring at any of the at least some positive terminals on the respective first side of each first battery-cell stack.

6 more elements

A battery module comprising:

a plurality of battery-cell stacks, each battery-cell stack including battery cells, the battery cells in the battery-cell stacks spatially aligned along longitudinal axes, each longitudinal axis passing through respective terminals of a respective battery cell in each battery-cell stack, the longitudinal axes parallel to one another;
a plurality of first electrical wiring layers, each first electrical wiring layer disposed on a first side of a respective battery-cell stack and in electrical contact with each battery cell in the respective battery-cell stack;
a plurality of second electrical wiring layers, each second electrical wiring layer disposed on a second side of the respective battery-cell stack and in electrical contact with each battery cell in the respective battery-cell stack;
a plurality of first thermal-protection shields, each first thermal-protection shield disposed on a respective first electrical wiring layer;
and
a plurality of second thermal-protection shields, each second thermal-protection shield disposed on a respective second electrical wiring layer,
wherein:
the battery-cell stacks include at least one neighboring battery-cell stack pair,
a respective air gap is defined between (a) a respective first thermal-protection shield on the first side of a first battery-cell stack in a respective battery-cell stack pair and (b) a respective second thermal-protection shield on the second side of a second battery-cell stack in the respective battery-cell stack pair,
a plurality of first channels are defined in the respective first thermal-protection shield, each first channel fluidly coupling a respective positive terminal of each battery cell that has the respective positive terminal on the first side of the first battery-cell stack in the respective battery-cell stack pair to the respective air gap, and
a plurality of second channels are defined in the respective second thermal-protection shield, each second channel fluidly coupling the respective positive terminal of each battery cell that has the respective positive terminal on the second side of the second battery-cell stack in the respective battery-cell stack pair to the respective air gap.

8 more elements

A battery module comprising:

a plurality of support frames, each support frame defining a plurality of battery-cell cavities;
a plurality of battery cells, each battery cell disposed in a respective battery-cell cavity of a respective support frame to form a plurality of battery-cell stacks, the support frames configured such that each battery cell is oriented such that a respective axis pass through the respective terminals of a respective battery cell, the respective axes parallel to one another;
a plurality of first electrical wiring layers, each first electrical wiring layer disposed on a first side of a respective battery-cell stack and in electrical contact with each battery cell in the respective battery-cell stack;
a plurality of second electrical wiring layers, each second electrical wiring layer disposed on a second side of the respective battery-cell stack and in electrical contact with each battery cell in the respective battery-cell stack;
a plurality of first thermal-protection shields, each first thermal-protection shield disposed on a respective first electrical wiring layer;
and
a plurality of second thermal-protection shields, each second thermal-protection shield disposed on a respective second electrical wiring layer,
wherein:
a respective air gap is defined between (a) a respective first thermal-protection shield on the first side of a first battery-cell stack in a respective neighboring battery-cell stack pair and (b) a respective second thermal-protection shield on the second side of a second battery-cell stack in the respective neighboring battery-cell stack pair,
the battery cells in each battery-cell stack includes one or more first battery cells, each first battery cell oriented such that a respective positive terminal of a respective first battery cell is on the first side of the respective battery-cell stack and a respective negative terminal of the respective first battery cell is on the second side of the respective battery-cell stack,
the battery cells in each battery-cell stack includes one or more second battery cells, each second battery cell oriented such that the respective positive terminal of a respective second battery cell is on the second side of the respective battery-cell stack and the respective negative terminal of the respective second battery cell is on the first side of the respective battery-cell stack,
each negative terminal on the second side of the second battery-cell stack is spatially aligned with the respective positive terminal on the first side of the second battery-cell stack,
one or more first holes is/are defined in each first electrical wiring layer, each first hole spatially aligned with the respective positive terminal of the respective first battery cell, and
one or more second holes is/are defined in each second electrical wiring layer, each second hole spatially aligned with the respective positive terminal of the respective second battery cell.

11 more elements

Dependencies are inferred from the claim text.

Facts

Application: 19/197,403Filed 2 May 2025
Priority: 2 May 2024
Published: 6 Nov 2025
Term ends: Not estimatedThe source records don’t support an estimate.

Classification15 codes

H01M 10/658
Means for temperature control structurally associated with the cells: by thermal insulation or shielding
B60K 1/04
Arrangement or mounting of electrical propulsion units: of the electric storage means for propulsion
B60L 50/64
Using power supplied by batteries: constructional details of batteries specially adapted for electric vehicles
H01M 10/659
Means for temperature control structurally associated with the cells: by heat storage or buffering, e.g. heat capacity or liquid-solid phase…