US 12,266,813 B2
Hybrid composite materials systems for battery housings having improved thermal performance
Venkateshwar R. Aitharaju, Troy, MI (US); Xiaosong Huang, Novi, MI (US); Bhavesh Shah, Troy, MI (US); Gustavo Cibrian Salazar, Belle River (CA); and Su Jung Han, West Bloomfield, MI (US)
Assigned to GM GLOBAL TECHNOLOGY OPERATIONS LLC, Detroit, MI (US)
Filed by GM GLOBAL TECHNOLOGY OPERATIONS LLC, Detroit, MI (US)
Filed on Sep. 10, 2021, as Appl. No. 17/472,210.
Prior Publication US 2023/0142691 A1, May 11, 2023
Int. Cl. H01M 50/231 (2021.01); H01M 50/209 (2021.01); H01M 50/224 (2021.01); H01M 50/227 (2021.01); H01M 50/233 (2021.01)
CPC H01M 50/231 (2021.01) [H01M 50/209 (2021.01); H01M 50/224 (2021.01); H01M 50/227 (2021.01); H01M 50/233 (2021.01)] 20 Claims
OG exemplary drawing
 
1. A hybrid material housing for a battery pack for reducing or minimizing thermal runaway propagation, the housing comprising:
an interior compartment;
a battery disposed in the interior compartment;
a composite structure defining an exterior surface and an opposite interior surface that faces the interior compartment and the battery, wherein the composite structure comprises a polymeric matrix and a reinforcing material distributed therein, the interior surface of the composite structure being an innermost surface of the housing adjacent the interior compartment and the battery;
a metal layer disposed along the exterior surface of the composite structure, wherein in a first operational mode the metal layer contacts the composite structure and in a second operational mode after the composite structure is exposed to a thermal load originating in the interior compartment 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 that define a thermal barrier between the exterior surface of the composite structure and the metal layer; and
a coating on the metal layer along an interface between the exterior surface of the composite structure and the metal layer, the coating comprising an intumescent material that further separates the metal layer from the composite structure in the second operational mode, wherein the intumescent material comprises expandable graphite.