Aerogel-based components and systems for electric vehicle thermal management

Abstract

Aerogel-based components and systems for electric vehicle thermal management are provided. Exemplary embodiments include a heat control member. The heat control member can include reinforced aerogel compositions that are durable and easy to handle, have favorable performance for use as heat control members and thermal barriers for batteries, have favorable insulation properties, and have favorable reaction to fire, combustion and flame-resistance properties. Also provided are methods of preparing or manufacturing such reinforced aerogel compositions. In certain embodiments, the composition has a silica-based aerogel framework reinforced with a fiber and including one or more opacifying additives.

1 . A battery module comprising:
 a first battery cell and a second battery cell;   a heat control member between the first battery cell and the second battery cell, the heat control member comprising;   multiple layers of reinforced aerogel, including;
 a first layer of reinforced aerogel; 
 a second layer of reinforced aerogel; and 
   a thermally conductive material layer between the first layer of reinforced aerogel and the second layer of reinforced aerogel.   
     
     
         2 . The battery module of  claim 1 , wherein the lofty aerogel composition provides compressibility of at least 50% of an uncompressed thickness. 
     
     
         3 . The battery module of  claim 1 , wherein the lofty aerogel composition provides compressibility of at least 80% of an uncompressed thickness. 
     
     
         4 . The battery module of  claim 1 , wherein the lofty aerogel composition provides resilient recovery to at least 70% of an uncompressed thickness after compression. 
     
     
         5 . The battery module of  claim 1 , wherein the lofty aerogel composition provides resilient recovery to at least 80% of an uncompressed thickness after compression. 
     
     
         6 . The battery module of  claim 1 , wherein the lofty aerogel composition provides a thermal conductivity at 10° C. of about 40 mW/mK or less while under compression. 
     
     
         7 . The battery module of  claim 1 , wherein the first layer of reinforced aerogel includes a different resilience than the second layer of reinforced aerogel. 
     
     
         8 . The battery module of  claim 1 , wherein the thermally conductive material layer includes metallic foil. 
     
     
         9 . The battery module of  claim 1 , wherein the thermally conductive material layer includes carbon. 
     
     
         10 . The battery module of  claim 1 , wherein the first layer of reinforced aerogel and the second layer of reinforced aerogel further include a reinforcement fiber comprising oxidized polyacrylonitrile (OPAN). 
     
     
         11 . The battery module of  claim 1 , wherein the first layer of reinforced aerogel and the second layer of reinforced aerogel further include a reinforcement fiber comprising glass fiber. 
     
     
         12 . The battery module of  claim 1 , wherein the thermally conductive material layer forms a direct interface with both the first layer of reinforced aerogel and the second layer of reinforced aerogel. 
     
     
         13 . A battery module comprising:
 a first battery cell and a second battery cell;   a heat control member comprising:   multiple layers of reinforced aerogel between the first battery cell and the second battery cell, the multiple layers of reinforced aerogel including;
 a first layer of reinforced aerogel; 
 a second layer of reinforced aerogel; and 
   a thermally conductive material layer between the first layer of reinforced aerogel and the second layer of reinforced aerogel;   wherein one or more of the multiple layers of reinforced aerogel include a porous structure to provide resilience.   
     
     
         14 . The battery module of  claim 13 , wherein the porous structure includes macropores. 
     
     
         15 . The battery module of  claim 14 , wherein the porous structure includes mesopores. 
     
     
         16 . The battery module of  claim 13 , wherein the reinforced aerogel including the porous structure provides compressibility of at least 50% of an uncompressed thickness. 
     
     
         17 . The battery module of  claim 13 , wherein the reinforced aerogel including the porous structure provides a thermal conductivity at 10° C. of about 40 mW/mK or less while under compression. 
     
     
         18 . A battery module comprising:
 a first battery cell and a second battery cell;   a heat control member comprising:   multiple layers of fiber reinforced aerogel between the first battery cell and the second battery cell, the multiple layers of reinforced aerogel including;
 a first layer of reinforced aerogel; 
 a second layer of reinforced aerogel; and 
   a thermally conductive material layer between the first layer of reinforced aerogel and the second layer of reinforced aerogel;   wherein one or more of the multiple layers of reinforced aerogel include a resilient reinforcing material.   
     
     
         19 . The battery module of  claim 18 , wherein the resilient reinforcing material includes pores with both open cell portions and closed cell portions. 
     
     
         20 . The battery module of  claim 19 , wherein the pores in the resilient reinforcing material include macropores. 
     
     
         21 . The battery module of  claim 19 , wherein the pores in the resilient reinforcing material include mesopores.