Abstract: A method for constructing a cell support assembly with thermal runaway mitigation for a multi-cell rechargeable energy storage system (RESS) include forming a cell holder configured to support the RESS battery cells. The cell holder has a holder body defining a plurality of apertures arranged in rows, such that each aperture is configured to align and be in fluid communication with a cell vent of one of the RESS battery cells. Individual embodiments of the method also include various techniques of arranging a plurality of thermal-barrier strips and potting elements to align with apertures of the cell holder body and adhering the thermal-barrier strips to the potting elements and to the cell holder. The resultant cell support assembly operates to channel thermal runaway energy away from the affected battery cell(s) and out of the RESS enclosure without triggering thermal runaway in adjacent cells.

Abstract: A battery module includes a housing including a sidewall structure, a top shear plate and a bottom shear plate. A vent tray assembly is disposed within the housing and includes a plurality of cell trays and a plurality of vent trays that combine to define a plurality of vent channels therebetween. The cell trays include a base plate having a plurality of vent openings in communication with one of the plurality of vent channels, the vent tray assembly including an air vent through a seam between the base plates of the cell trays. A plurality of battery cells each include an end with a vent that is aligned with one of the vent openings in the base plate in the cell tray. A potting foam is dispersed within the housing and between the batteries.

Abstract: A battery module includes a housing including a sidewall structure, a top shear plate and a bottom shear plate. A vent tray assembly is disposed within the housing and including a cell tray and a vent tray that combine to define a plurality of vent channels therebetween. The cell tray includes a base plate having a plurality of vent openings in communication with one of the plurality of vent channels. The vent tray assembly includes a plurality of air vents therethrough that are isolated from the plurality of vent channels. A plurality of battery cells each have an end with a vent that is aligned with one of the vent openings in the base plate in the cell tray. A potting foam is dispersed within the housing and between the batteries.

Abstract: A rechargeable energy storage system (RESS) includes battery cells, each having a respective gas vent. The RESS also includes a cell support assembly with thermal runaway mitigation and has a cell holder for supporting the battery cells. The cell holder defines apertures arranged in rows and each aperture fluidly communicates with one cell vent. The assembly also includes multiple thermal-barrier strips adhered to the holder. Each thermal-barrier strip extends parallel to a respective aperture row to thermally insulate each corresponding cell from gases expelled by neighboring cells during a thermal runaway. The assembly additionally includes multiple potting elements. Each potting element is arranged in one of the apertures between a respective cell and a corresponding thermal-barrier strip to thereby adhere to the cell and to the corresponding thermal-barrier strip and maintain position of the cell on the holder. A motor vehicle may employ such a RESS.

Abstract: A method for constructing a cell support assembly with thermal runaway mitigation for a multi-cell rechargeable energy storage system (RESS) include forming a cell holder configured to support the RESS battery cells. The cell holder has a holder body defining a plurality of apertures arranged in rows, such that each aperture is configured to align and be in fluid communication with a cell vent of one of the RESS battery cells. Individual embodiments of the method also include various techniques of arranging a plurality of thermal-barrier strips and potting elements to align with apertures of the cell holder body and adhering the thermal-barrier strips to the potting elements and to the cell holder. The resultant cell support assembly operates to channel thermal runaway energy away from the affected battery cell(s) and out of the RESS enclosure without triggering thermal runaway in adjacent cells.