The present invention provides a fiber-reinforced aerogel material which can be used as insulation in thermal battery applications. The fiber-reinforced aerogel material is highly durable, flexible, and has a thermal performance that exceeds the insulation materials currently used in thermal battery applications. The fiber-reinforced aerogel insulation material can be as thin as 1 mm less, and can have a thickness variation as low as 2% or less. Also provided is a method for improving the performance of a thermal battery by incorporating a reinforced aerogel material into the thermal battery. Further provided is a casting method for producing thin fiber-reinforced aerogel materials.

The present invention provides a fiber-reinforced aerogel material which can be used as insulation in thermal battery applications. The fiber-reinforced aerogel material is highly durable, flexible, and has a thermal performance that exceeds the insulation materials currently used in thermal battery applications. The fiber-reinforced aerogel insulation material can be as thin as 1 mm less, and can have a thickness variation as low as 2% or less. Also provided is a method for improving the performance of a thermal battery by incorporating a reinforced aerogel material into the thermal battery. Further provided is a casting method for producing thin fiber-reinforced aerogel materials.

An electrochemical cell comprises at least the following layers stacked in the following order: a first electrode layer, an electrolyte layer, a second electrode layer, a current collector layer, and a protective cover; the protective cover comprising an electrically-insulating material. The cell further comprises an electrically-conductive contact pad that is configured to enable connection of the cell to external devices, the contact pad being provided on an external side of the protective cover that is opposed to the current collector layer, and comprising an exposed surface that is bounded about its perimeter by the electrically-insulting material. An electrically-conductive pathway is provided between the contact pad and the current collector layer, the electrically-conducive pathway extending through the protective cover and contacting a face of the current collector layer at a connection site.

An electrochemical cell comprises at least the following layers stacked in the following order: a first electrode layer, an electrolyte layer, a second electrode layer, a current collector layer, and a protective cover; the protective cover comprising an electrically-insulating material. The cell further comprises an electrically-conductive contact pad that is configured to enable connection of the cell to external devices, the contact pad being provided on an external side of the protective cover that is opposed to the current collector layer, and comprising an exposed surface that is bounded about its perimeter by the electrically-insulting material. An electrically-conductive pathway is provided between the contact pad and the current collector layer, the electrically-conducive pathway extending through the protective cover and contacting a face of the current collector layer at a connection site.

Systems and methods are provided for a battery module. A battery module includes a module housing configured to hold a cell stack comprising a plurality of battery cells. A busbar assembly having an electrically conductive busbar is configured for electrical connection to electrode leads of the battery cells. The busbar assembly includes a gas outlet configured for discharging gas generated within the plurality of battery cells in a direction away from the cell stack, and the module housing includes a venting member configured to vent the gas discharged from the gas outlet to an outside of the module housing.

Systems and methods are provided for a battery module. A battery module includes a module housing configured to hold a cell stack comprising a plurality of battery cells. A busbar assembly having an electrically conductive busbar is configured for electrical connection to electrode leads of the battery cells. The busbar assembly includes a gas outlet configured for discharging gas generated within the plurality of battery cells in a direction away from the cell stack, and the module housing includes a venting member configured to vent the gas discharged from the gas outlet to an outside of the module housing.

Provided are a secondary battery, a battery module, and a battery pack, which have improved safety. Particularly, since a bulletproof material is disposed on the inside and/or the outside of an exterior part, even when a conductive needle-shaped member penetrates a secondary battery, heating, burning, discharge of evaporated electrolyte, and electrical contact between the needle-shaped member and an electrode can be prevented, thereby improving safety of the secondary battery, the battery module, and the battery pack.

Approaches herein provide a device, such as a battery protection device, including a cathode current collector and an anode current collector provided atop a substrate, a cathode provided atop the cathode current collector, and an electrolyte layer provided over the cathode. An interlayer, such as one or more layers of silicon, antimony, magnesium, titanium, magnesium lithium, and/or silver lithium, is formed over the electrolyte layer. An anode contact layer, such as an anode or anode current collector, is then provided over the interlayer. By providing the interlayer atop the electrolyte layer prior to anode contact layer deposition, lithium from the cathode side alloys with the interlayer, thus providing a more isotropic or uniaxial detachment of the anode contact layer.

An electrochemical battery can include electrodes (a cathode and an electrode) arranged on respective surfaces of an electrolyte. The electrodes and electrolyte can each be solid state films that can be layered on top of one another to create a stacked structure disposed on a substrate. A polymeric sealant material can be applied over and around the battery stack and a moisture barrier can be formed over the sealant material to thereby prevent moisture from reaching the battery. Conductive terminals electrically coupled to the cathode and anode, respectively, can be formed on a second side of the substrate. As such, the battery can be flip-chip mounted to corresponding mounting pads and thereby connected to other electronics that can receive power from the battery.

An electrochemical device is claimed and disclosed, including a method of manufacturing the same, comprising an environmentally sensitive material, such as, for example, a lithium anode; and a plurality of alternating thin metallic and ceramic, blocking sub-layers. The multiple metallic and ceramic, blocking sub-layers encapsulate the environmentally sensitive material. The device may include a stress modulating layer, such as for example, a Lipon layer between the environmentally sensitive material and the encapsulation layer.