Granted Patent B2

US 12,401,077 · App. 17/791,519 · Granted Aug 26, 2025

Inventors: Owen Evans (Chelmsford, MA); George Gould (Mendon, MA); Kathryn Dekrafft (Marlborough, MA); David Mihalcik (Northborough, MA); David Baur (Ashland, MA)

Assignee: Aspen Aerogels Inc.

H01M10/658B32B5/18C04B38/0048H01M10/625H01M50/204H01M50/249B32B2250/03H01M2220/20

Abstract

Claims (19)

1. A battery thermal management member comprising:

a first heat protection layer comprising an aerogel composition;

a second heat protection layer comprising the aerogel composition;

wherein the aerogel composition includes a fiber reinforcement material,

wherein each of the first heat protection layer and the second heat protection layer is completely encapsulated with a first encapsulation member and a second encapsulation member, respectively, and

at least one compressible resilient layer including one or more organic materials with a temperature of chemical decomposition greater than 280° C.,

wherein each of the first and second heat protection layers has a thermal conductivity less than about 65 mW/mK,

wherein the first and second heat protection layers maintain at least a surface of the compressible resilient layer below a chemical decomposition temperature of at least one of the one of the more organic materials,

wherein the first encapsulation member of the first heat protection layer is in direct contact with a first side of the at least one compressible layer and the second encapsulation member of the second heat protection layer is in direct contact with a second side of the least one compressible layer, wherein the first side is opposite the second side, and

wherein portions of the first encapsulation member and the second encapsulation member are the outermost layers of the battery thermal management member.

2. The battery thermal management member of claim 1 , wherein the temperature of chemical decomposition of the one or more organic materials is greater than about 300° C.

3. The battery thermal management member of claim 1 , wherein the temperature of chemical decomposition of the one or more organic materials is greater than about 350° C.

4. The battery thermal management member of claim 1 , wherein the temperature of chemical decomposition of the one or more organic materials is in the range of about 300° C. to about 400° C.

5. The battery thermal management member of claim 1 , wherein the at least one compressible resilient layer consists of the one or more organic materials, and the one or more organic materials is selected from the group consisting of siloxanes, polyolefins, polyurethanes, phenolics, melamine, cellulose acetate, and polystyrene.

6. The battery thermal management member of claim 1 , wherein the fiber is selected from the group consisting of discrete fibers, woven materials, non-woven materials, needled nonwovens, battings, webs, mats, felts, and combinations thereof.

7. The battery thermal management member of claim 1 , wherein the aerogel of the aerogel composition comprises inorganic, organic, or inorganic/organic hybrid materials.

8. The battery thermal management member of claim 1 , wherein the aerogel composition is a silica aerogel composition.

9. The battery thermal management member of claim 1 , wherein the first heat protection layer, the second heat protection layer, or both further includes a material selected from the group consisting of mica, microporous silica, ceramic fiber, mineral wool, and combinations thereof.

10. The battery thermal management member of claim 1 , wherein the battery thermal management member exhibits a compressibility of: less than about 25% in a range of about 25 kPa to about 35 kPa, less than about 50% at about 50 kPa, and less than about 80% at about 245 kPa.

Assignments (2)

Continuity (5)

References Cited (205)